Operating Instructions
Translation of the original Operating Instructions
for machine operator and maintenance staff
always keep by the machine
Motar machine
SP11 LMR
Machine no.
Rev. 00--0412
PMM_365375026
Putzmeister
Mörtelmaschinen
GmbH
Max–Eyth–Str. 10
D–72631 Aichtal
Postfach 2152
D–72629 Aichtal
07127 / 599–0
Hotline:
(07127) 599--699
07127 / 599 743
Internet:
www.putzmeister.de
e--mail:
pmm@pmw.de
Contents
1
About these Operating Instructions
1.1
1.2
Foreword . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 —
Icons and symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 —
2
Safety Regulations
2.1
Principle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Onwards sale . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Designated use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Use contrary to the designated use . . . . . . . . . . . . . . . . . . . . .
Extending delivery line . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Modifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Liability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exclusion of liability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Personnel selection and qualifications . . . . . . . . . . . . . . . . . .
Training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Qualified electrician . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hydraulics technician . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Sources of danger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hot machine components . . . . . . . . . . . . . . . . . . . . . . . . . . .
Delivery line and coupling system . . . . . . . . . . . . . . . . . . . .
Safety equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Personal protective clothing . . . . . . . . . . . . . . . . . . . . . . . . . . .
Risk of injury -- residual risk . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Risk of crushing and bumping . . . . . . . . . . . . . . . . . . . . . . . . .
Transporting the machine . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly of the auger pump . . . . . . . . . . . . . . . . . . . . . . . .
Electrical contact . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Risk of burns and scalding . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hydraulic fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Starting up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Blockage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.2
2.3
2.4
2.5
2.6
2.7
2.8
2.9
2.10
2.11
2.12
2.13
2.14
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I
Contents
2.15
2.16
2.17
2.18
2.19
2.20
2.21
2.22
2.23
2.24
2.25
2.26
2.27
2.28
2.29
2.30
2.31
II
Hydraulic and pneumatic equipment . . . . . . . . . . . . . . . . . . . .
Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Dumping pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bleeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Place of work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Working area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Conduct in emergencies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Noise pollution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Environmental protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Storing the machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Sound emissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Place of work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Machine operator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
High-pressure gun operator . . . . . . . . . . . . . . . . . . . . . . . . .
Working area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Conduct in an emergency . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Storing the machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Injuries through unauthorised starting or use of the machine
Safety-related parts (SRP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Labelling of safety-related parts in the spare parts sheets
Spare delivery of safety-related parts . . . . . . . . . . . . . . . . .
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Contents
3
General Technical Description
3.1
3.2
3.3
3.4
3.5
Machine versions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Machine designation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Machine model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Machine number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tyres . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Performance data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fluid capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rating plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Sound power level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
EMERGENCY STOP button . . . . . . . . . . . . . . . . . . . . . . . . .
Hood safety device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Protective grilles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Functional description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General set-up of the machine . . . . . . . . . . . . . . . . . . . . . .
Control cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Auger pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hydraulic control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hydraulic control block SP11 . . . . . . . . . . . . . . . . . . . . . . . .
Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Air valve fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Spray gun . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Dust extraction (option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
High-pressure cleaner (option) . . . . . . . . . . . . . . . . . . . . . . . . .
3.6
3.7
3.8
3.9
3.10
3.11
3.12
3.13
3.14
3.15
3.16
3.17
3.18
3.19
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Contents
4
Transport, Set-up and Connection
4.1
4.2
4.3
4.4
Transport and driving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Transporting the machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Machine transport position . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Before a journey . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ground clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Towing gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Transport position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Adjusting the towing gear . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ball hitch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Coupling the ball hitch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disconnecting the ball hitch . . . . . . . . . . . . . . . . . . . . . . . . .
Permitted slewing circle of the ball hitch . . . . . . . . . . . . . .
Permitted drawbar load . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lighting equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Selecting the set-up site . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Set-up site requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Supporting ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Setting up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inclination angles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Aligning the machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Water connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.5
4.6
4.7
4.8
4.9
IV
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Contents
5
Starting up
5.1
Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Visual checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operating materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Compressor oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hydraulic fluid level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Coolant level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking cooling fins on the radiator . . . . . . . . . . . . . . . . .
Refuelling the machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Test run . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Starting the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Function checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking the function of the safety equipment . . . . . . . .
Function check of EMERGENCY STOP button . . . . . . . . .
Function check of hood safety device . . . . . . . . . . . . . . . .
Function check of the protective grille cut-out . . . . . . . . .
Pump functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mixer functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
The delivery line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Shutting down machine after initial operation . . . . . . . . . . . . .
5.2
5.3
5.4
5.5
5.6
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Contents
6
Operation
6.1
6.2
6.13
Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Emergency shut-down procedures . . . . . . . . . . . . . . . . . . . . .
EMERGENCY STOP button . . . . . . . . . . . . . . . . . . . . . . . . .
Initial pumping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Adjusting the auger pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Raising / lowering the lifting mixer unit . . . . . . . . . . . . . . . . . .
Pumping operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pumping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Output regulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Breaks in pumping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Blockages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rectifying blockages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Using the spray gun . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Adjusting the air nozzle tube . . . . . . . . . . . . . . . . . . . . . . . .
Practical tip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cleaning the machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Information on cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Delivery line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Spray gun . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
High-pressure cleaner (optional) . . . . . . . . . . . . . . . . . . . . . . .
7
Faults, Cause and Remedy
7.1
7.2
7.3
Machine, general . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 — 2
Electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 — 12
Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 — 14
6.3
6.4
6.5
6.6
6.7
6.8
6.9
6.10
6.11
6.12
VI
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19
22
23
Contents
8
Maintenance
8.1
8.2
Maintenance intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Other risks during maintenance work . . . . . . . . . . . . . . . . . . .
Personal protective clothing . . . . . . . . . . . . . . . . . . . . . . . . .
Personnel requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Other risks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operating materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hydraulic oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Compressor oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mixer bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Axle and wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
High-pressure cleaner (option) . . . . . . . . . . . . . . . . . . . . . .
Maintenance work in the engine compartment . . . . . . . . . . .
8.3
8.4
8
8
8
8
8
8
8
8
8
8
8
8
8
8
8
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
2
12
12
12
13
15
16
17
17
18
18
19
19
19
20
8
8
8
8
8
8
8
8
8
8
8
8
8
8
8
8
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
25
27
30
32
35
39
44
47
52
56
58
61
64
66
71
76
Maintenance Chart
40--066
41--003
41--011
44--019
44--059
44--062
44--090
44--092
44--093
44--095
44--096
44--137
44--138
44--140
46--027
46--028
Lubrication diagram . . . . . . . . . . . . . . . . . . . . . . . . .
Cleaning the solenoids . . . . . . . . . . . . . . . . . . . . . . .
Checking acid level in the battery . . . . . . . . . . . . .
Changing the oil in the compressor . . . . . . . . . . . .
Changing the engine oil and engine oil filter . . . .
Checking and replacing hydraulic hoses . . . . . . .
Changing the coolant . . . . . . . . . . . . . . . . . . . . . . . .
Changing the hydraulic fluid . . . . . . . . . . . . . . . . . .
Changing the hydraulic filter . . . . . . . . . . . . . . . . . .
Antifreeze protection for the radiator . . . . . . . . . . .
Cleaning and changing the dry air filter . . . . . . . .
Cleaning the radiator . . . . . . . . . . . . . . . . . . . . . . . .
Checking the V-belt . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembly and assembly of the auger pump .
Adjusting the auger pump . . . . . . . . . . . . . . . . . . . .
VII
Contents
46--030
52--008
52--010
52--026
Replacing the screw conveyor . . . . . . . . . . . . . . . .
High-pressure cleaner . . . . . . . . . . . . . . . . . . . . . . .
Water supply fitting antifreeze protection . . . . . . .
High-pressure cleaner antifreeze
protection measures . . . . . . . . . . . . . . . . . . . . . . . . .
9
Decommissioning
9.1
Temporary decommissioning . . . . . . . . . . . . . . . . . . . . . . . . . .
Shutting the machine down . . . . . . . . . . . . . . . . . . . . . . . . .
Filling up the fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Frost protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Final decommissioning, disposal . . . . . . . . . . . . . . . . . . . . . . .
Material used . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Parts requiring separate disposal . . . . . . . . . . . . . . . . . . . .
9.2
10
Appendix
10.1
10.2
10.3
10.4
General tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lubricant recommendation . . . . . . . . . . . . . . . . . . . . . . . . . . . .
The correct mortar mixture . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Template for EC declaration of conformity . . . . . . . . . . . . . . .
Index of Key Words
VIII
8 — 79
8 — 81
8 — 83
8 — 86
9
9
9
9
9
9
9
—
—
—
—
—
—
—
1
2
2
2
3
4
4
10— 1
10— 3
10— 6
10— 10
About these Operating Instructions
1
About these Operating Instructions
In this chapter you will find notes and information that will help you
use these Operating Instructions. Do not hesitate to contact us if you
have any queries:
Putzmeister Mörtelmaschinen GmbH
Postfach 2152
D-72629 Aichtal, Germany
Tel: +49 (0)7127 599-0
Fax: +49 (0)7127 599-743
Internet: http://www.moertelmaschinen.de
E-mail: pmm@pmw.de
or the branch or services agent responsible for you.
Address:
Telephone:
Fax:
E-mail:
01_0001_0505GB
1—1
About these Operating Instructions
1.1 Foreword
These Operating Instructions are intended to familiarise the user with
the machine and to assist him in using the machine properly in various possible applications.
The Operating Instructions contain important information on how to
operate the machine safely, properly and economically. Taking these
instructions into consideration will help
-- to avoid dangers,
-- to reduce repair costs and downtimes,
-- to increase the reliability and service life of the machine.
The Operating Instructions must be supplemented by the relevant
national rules and regulations for accident prevention and environmental protection.
The Operating Instructions must always be available wherever the
machine is in use.
The machine owner must make the location of these Operating Instructions known to all personnel charged with performing jobs on
the machine and ensure they are accessible. These operating instructions must be read and applied by any person who carries out
work with or on the machine, e.g.
-- operation, including setting up, fault rectification in the course of
work, removal of production waste, care and disposal of fuels and
consumables,
-- service (maintenance, inspection, repair), and/or
-- transport.
The generally recognised 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 and
environmental protection in the country and place of use of the machine.
Continuation next side
1—2
01_0001_0505GB
About these Operating Instructions
The Branch or Agent serving you, or the Aichtal Works, will be happy
to give you more information, should you have any questions following your study of the Operating Instructions.
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.
These operating instructions do not include a description of the drive
motor; please refer to the operating instructions provided by the motor manufacturer.
Modifications are made from time to time in the interests of constant
improvement and it could be possible that we were unable to take
these into consideration when these Operating Instructions were
printed.
These operating instructions are not covered by the Amendment Service of Putzmeister Mörtelmaschinen GmbH. Alterations may be
made to these operating instructions without prior notification.
The contents of this document may not be reproduced, even in part,
without our written permission. All technical data, drawings, etc. are
protected by copyright law.
The pages are divided into chapters where they are numbered consecutively.
Example:
Page 3--2
Chapter 3
Page 2
 Copyright by
01_0001_0505GB
1—3
About these Operating Instructions
1.2 Icons and symbols
"
The following icons and symbols are used in the Operating Instructions:
Action symbol
Text following this symbol describes tasks which you are required to
work through, generally in the sequence shown from top to bottom.
⇒ Text after this icon describes the result or the effect of an
activity.
Refer also to the maintenance charts:
This symbol is used to refer to the maintenance charts required, possibly as a supplement to the maintenance charts you are currently
reading.
The following special tool is required:
This icon identifies the special tools necessary to carry out the work.
Normal tools, i. e. standard tools or tools carried in the vehicle are
not listed additionally.
Environmental protection
This symbol is used to identify tasks during which particular attention
is to be paid to environmental protection. The associated text is written in italics and is closed off with a line.
Notes
Particular specifications with regard to the economic use of the machine are introduced with the word ”Note” and the pictogram illustrated. The associated text is written in italics and is closed off with
a line.
Caution
Particular specifications or instructions and prohibitions with regard
to the prevention of damage are introduced with the word ”Caution”
in bold and the pictogram illustrated. The associated text is written in
italics and is closed off with a line.
Continuation next side
1—4
01_0001_0505GB
About these Operating Instructions
Danger
Particular specifications or instructions and prohibitions with regard
to the prevention of personal injury or significant damage are introduced with the pictogram illustrated, the word ”Danger” written in bold
and a line. The associated text is written in italics and is closed off
with a line.
The appropriate symbol will be used if it is possible to identify the
source of the danger precisely.
Suspended Load
This symbol is used to identify tasks in which suspended loads may
fall down.
Danger of crushing
This symbol is used to identify tasks during which there is the danger
of being crushed.
Heavy current
This symbol is used to identify tasks in which there is the danger of
electrocution, possibly with lethal consequences.
01_0001_0505GB
1—5
Safety Regulations
2
Safety Regulations
This chapter summarises the most important safety regulations. This
Chapter must be read and understood by all persons who handle
the machine. The various regulations are also repeated once more at
the appropriate points in the Operating Instructions.
Notes
Special safety regulations may be necessary for some tasks. These
special safety regulations will only be found in the description of the
particular task.
The following safety instructions should be regarded as a supplement to already existing valid national accident prevention regulations and laws.
Existing accident prevention regulations and laws must be observed
in all cases.
03_0001_0505GB
2—1
Safety Regulations
2.1 Principle
Use only machines in a technically perfect condition, as designated
and being conscious of safety and the dangers, taking account of
the Operating Instructions. Any faults, especially those affecting the
safety of the machine, must, therefore, be rectified immediately.
Make sure that
-- no safety equipment is removed, rendered inoperable or modified,
-- safety equipment removed for the purposes of maintenance work
is refitted immediately after the work is completed.
Check operational safety every time you start work. Any defects
found or suspected must be eliminated immediately. If necessary,
inform the project supervisor.
If defects or faults are found or suspected during operation, operation must cease immediately. Eliminate the defect or fault before restarting.
Onwards sale
The following should be noted if you sell the machine on:
Pass on to the new operator all the accompanying documentation
(Operating Instructions, Maintenance Instructions, diagrams, inspection certificates etc.) you received with your machine. If necessary,
you may have to order the papers from us, quoting the machine
number. The machine may not be sold on without the accompanying
documentation under any circumstances.
Reporting an onwards sale or acquisition to Putzmeister ensures
that you will be sent any information relating to modifications or innovations relevant to safety, and you will also be eligible for technical
consultancy from our works.
2—2
03_0018_0809GB
Safety Regulations
2.2 Designated use
The machine has been built in accordance with the state of the art
and recognised safety rules. Nevertheless, its use may constitute a
risk to life and limb of the operator or of third parties, or cause damage to the machine and to other property.
The machine must only be used as specified in the Operating Instructions and the enclosed documentation. All information and safety regulations in the Operating Instructions must be observed.
The auger pump SP 11 is designed exclusively to mix and pump
premixed dry mortar and site mixes of up to 6 mm grain size through
hose lines with 50 mm maximum diameter.
Performance must be restricted to pumping operations on building
sites. The maximum delivery pressure must not be higher than that
specified on the rating plate or in Technical Data.
The delivery line through which the pump is to deliver must be designed for the delivery pressure and installed and secured correctly
in accordance with recognised technical regulations.
Filling of the auger pump is carried out in the reservoir / hopper.
Any protective covers belonging to the machine should be attached
before operation.
The machine must be operated only with the safety equipment fitted.
Specified inspection work should be carried out at regular intervals.
Any work on the electric or hydraulic unit of the machine must be
carried out only by trained and qualified hydraulic and electrotechnical specialists.
Never make any modifications, additions or conversions to the machine without first obtaining the manufacturer’s approval.
The machine must be inspected for operational safety by a technical
expert at least once a year. The operator is responsible for commissioning the inspection.
03_0058_0511GB
2—3
Safety Regulations
2.3 Use contrary to the
designated use
Extending delivery line
Use of the machine other than described in the section ”Designated
use”, or which goes beyond such use, is considered contrary to the
designated use. Putzmeister Mörtelmaschinen GmbH accepts no
liability for damage resulting from such use. The risk of such misuse
lies entirely with the machine operator.
Extending the delivery line beyond the length specified in the technical data is prohibited.
A new delivery line is only suitable for pressures entered on the rating plate.
Modifications
Never make any modifications, additions or conversions to the machine which might affect safety without first obtaining the manufacturer’s approval. This also applies to the installation and adjustment of
safety devices and valves as well as to welding work on load--bearing elements.
The values quoted on the rating plate and in the technical data are
the maximum permissible values.
The control and safety settings made at Putzmeister Mörtelmaschinen GmbH must not be changed.
The machine must not be operated with deactivated, modified or defective safety devices.
Safety devices must only be repaired, adjusted or replaced by technically qualified experts.
All devices of relevance for safety must be in place and fully functional.
2—4
03_0123_0808GB
Safety Regulations
2.4 Liability
The operator is obliged to act in accordance with the Operating Instructions.
The safety and accident prevention regulations from the following
institutions must be observed:
-- Industrial Employers’ Liability Insurance Association,
-- the responsible corporate liability insurance company.
-- the legal authorities in your country.
The following persons are liable under the law for accidents which
can be ascribed to the failure to comply with safety regulations and
accident prevention regulations:
-- the operating personnel or (unless not liable due to lack of training
or basic knowledge)
-- their supervisors.
under the law.
Please therefore ensure that the necessary caution prevails.
Exclusion of liability
03_0021_0508GB
We state here expressly that Putzmeister Mörtelmaschinen 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 machine which may compromise
safety. The guarantee will no longer be valid in such cases.
2—5
Safety Regulations
2.5 Personnel selection
and qualifications
Training
The machine may only be operated or serviced independently by
persons who
-- have reached the legally required age;
-- are physically capable (rested and not under the influence of alcohol, drugs or medication);
-- have been instructed in the operation and maintenance of the machine;
-- can be expected reliably to execute the tasks they are charged
with.
The machine must only be operated, serviced or maintained by persons who are trained to carry out such tasks and have been commissioned to do so.
The staff areas of responsibility must be clearly defined.
The following personnel must only work on the machine under the
permanent supervision of an experienced person:
-- persons who have not yet completed training or instruction,
-- persons taking a general training course.
Qualified electrician
Work on the electrical system and equipment of the machine must
be carried out by a qualified electrician or by instructed persons under the supervision and guidance of a qualified electrician and in
accordance with electrical engineering rules and regulations.
Hydraulics technician
Only persons having special knowledge and experience in hydraulic
systems may work on hydraulic equipment.
2—6
03_0010_0702GB
Safety Regulations
2.6 Sources of danger
Never reach into moving machine components, whether the machine
is running or switched off. Always switch off the main switch first.
Take note of the warning plate.
In the event of malfunctions, stop the machine immediately and secure it. Have any faults rectified immediately.
Secure the machine at the set-up site against rolling away by means
of wedges.
Make sure that nobody is placed at risk by the running machine before starting up the machine.
Never release or tighten threaded unions that are under pressure.
Hot machine components
During and after completion of work, there is a risk of burns from hot
parts on the drive motor.
Delivery line and coupling system
The delivery line and coupling system is designed for a max. operating pressure of 40 bar.
The max. operating pressure must not exceed 40 bar.
03_0048_0511GB
2—7
Safety Regulations
2.7 Safety equipment
Never remove or modify safety devices on the machine.
Any safety devices removed for set-up, maintenance or repair purposes must be refitted and checked immediately upon completion of
the maintenance and repair work.
Safety devices must only be repaired, adjusted or replaced by technically qualified experts.
All equipment required for safety and accident prevention (warning
signs and information plates, cover grilles, guards, etc.) must be in
place. Such equipment must not be removed, modified or damaged.
2—8
03_0014_0603GB
Safety Regulations
2.8 Personal protective
clothing
To reduce the risk to life and limb, the following personal protective
clothing must be worn whenever necessary or required by regulations.
Protective helmet, protective gloves and safety boots are always
specified for all persons working at or with the machine.
Personal protective clothing must at least comply with the specified
standards.
Protective helmet
The protective helmet protects your head, e.g. against falling concrete or parts of the delivery line if the lines burst.
(EN ISO 397; Industrial safety helmet)
Safety boots
Safety boots protect your feet against falling objects and against
penetration by projecting nails.
(EN ISO 345; Safety boots for industrial purposes; classification S2)
Ear defenders
Ear defenders protect you against the noise generated by the machine when you are standing close to it.
(EN ISO 352-1; Hearing protectors -- General specifications -- Part 1:
Ear muffs
or
EN ISO 352-3; Hearing protectors -- General specifications -- Part 3:
Ear muffs fitted to industrial safety helmets)
Protective gloves
Protective gloves protect your hands from harsh or chemical substances, from mechanical factors (e.g. impacts) and from cuts.
(EN ISO 388; Protective gloves against mechanical risks; classification 111)
Fortsetzung nächste Seite
03_0057_0911GB
2—9
Safety Regulations
Protective goggles
Protective goggles protect your eyes against injuries from concrete
spatters or other particles.
(EN ISO 166; Personal eye protection -- Specifications)
Safety harness
A safety harness protects you against falling when you are working
on scaffolding, bridges or in similar areas.
(EN ISO 361; Personal protective clothing against falls -- safety harnesses; classification III)
Face-mask and respiratory protector
A face-mask and respirator protector prevent particles of dust from
entering your body through your respiratory passages (particles
such as concrete additives).
(EN ISO 149; Respiratory protection devices -- Filtering half-masks
to protect against particles -- Specifications, test, type; classification
FFP1)
2 — 10
03_0057_0911GB
Safety Regulations
2.9
Risk of injury -- residual risk
The machine has been built in accordance with state of the art technology and recognised safety rules. Nevertheless, its use may constitute a risk to life and limb of the operator or of third parties,
or cause damage to the machine and to other property.
Some of the injuries that may be caused by improper use of the machine are listed below:
-- Danger of crushing and bumping when moving and setting up the
machine.
-- Electric contact (in some circumstances with fatal consequences)
with the electrical equipment. If the connection has not been made
correctly or electric subassemblies are damaged.
-- Risk of burns from hot machine components. This includes engine,
exhaust system and frame.
-- Injuries through unauthorised starting or use of the machine.
-- Noise pollution is a danger for persons working continuously in the
vicinity of the machine without ear defenders.
-- Eye and skin injuries from escaping hydraulic fluid if threaded
unions are opened without first dumping the pressure in the entire
system.Injuries caused by sprayed material, dust particles or other
chemical substances.
-- Eye and skin injuries from escaping hydraulic fluid if threaded
unions are opened without first dumping the pressure in the entire
system.
-- Eye and skin injuries caused by dust particles, concrete spatter,
water glass or other chemical substances.
-- Damage to health through inhalation of dust particles or cleaning
agents, solvents or preserving agents.
-- Risk of scalding by hot hydraulic fluid or other hot functional fluids
escaping under pressure.
-- Injuries caused by the machine rolling away as a result of support
feet or wedges under the wheels releasing themselves.
-- Injuries caused by opening pressurised delivery lines (e.g. after
blockages).
-- Injuries caused by tripping over cables, hoses or reinforcing steel.
03_0049_1201GB
2 — 11
Safety Regulations
2.10 Risk of crushing and
bumping
Transporting the
machine
During the following machine operating modes:
-- Set-up
-- Starting up
-- Operation
-- Cleaning, Troubleshooting, Maintenance
-- Decommissioning
there is a risk of injury through crushing or bumping.
When loading the machine with a crane onto a transport vehicle, the
machine must only be suspended on the lifting eyes provided. Only
in this way can you be sure that the machine is suspended horizontally and securely in the hook and will not be able to tip over.
Danger of crushing
The machine may only be loaded by crane if fitted with suitable attachment points.
Use only suitable lifting equipment for lifting components.
Lifting equipment, lifting tackle, support trestles and other auxiliary
equipment must be reliable and safe in operation.
Make sure that the loadbearing capacity is sufficient.
When lifting with the crane, determine the centre of gravity of the machine by lifting carefully. All cables or chains on the lifting gear must
be tensioned evenly and the machine must be raised evenly at all
support points.
The machine must only be loaded onto a suitable transport vehicle
and must be secured against rolling, sliding and overturning during
transport.
Suspended Load
Hoisted loads may fall if they are not loaded properly or if the auxiliary loading equipment is damaged.
Make sure personnel do not walk under suspended loads.
Only use an auxiliary loading device with a loadbearing capacity designed to support the gross weight of the machine!
Continuation next side
2 — 12
03_0050_0605GB
Safety Regulations
Assembly of the auger
pump
There is a risk of crushing when installing the auger pump.
Depending on the mounting position of the stator or auger barrel,
these may turn until they rests against the stop when the machine is
switched on.
Never place hands into the auger pump when switching the machine
on.
Risk of crushing in the end stop area of the auger pump
03_0050_0605GB
2 — 13
Safety Regulations
2.11 Electrical contact
The control cabinet, electrical wiring and drive motor pose a risk of
fatal injury from electrical contact during the following:
-- Setting up
-- Operation
-- Cleaning, Troubleshooting, Maintenance
-- Decommissioning
All electrical assemblies are protected as standard, as per
IEC 60204 Part1 or DIN 40050 IEC 144 in accordance with protection category IP 54.
Use only original fuses with the specified amperage! The electrical
system can be destroyed by overrated fuses or overriding.
Heavy current
Work on the electrical system and equipment of the machine must
be carried out by a qualified electrician or by instructed persons under the supervision and guidance of a qualified electrician and in
accordance with the electrical engineering rules and regulations.
2 — 14
03_0016_0505GB
Safety Regulations
2.12 Risk of burns and
scalding
The drive motor and the frame pose a risk of burns during the following:
-- Starting up
-- Operation
-- Cleaning, Troubleshooting, Maintenance
-- Decommissioning
Risk of burns.
Danger
The control cabinet switches off the drive motor in the event of overheating. However, the drive motor and frame can still become very
hot during operation.
Allow the machine to cool before starting any maintenance work.
Work with protective gloves.
Hydraulic fluid
Particular care must be taken when working with the hydraulic system. Serious scalding including eye and skin injuries can result from
escaping hydraulic fluid if threaded unions are opened.
Danger
Risk of scalding when hot hydraulic fluid shoots out.
Allow the machine to cool and relieve pressure in the entire hydraulic
system before starting any maintenance work.
Work with protective gloves and face mask.
Continuation next side
03_0051_0511GB
2 — 15
Safety Regulations
Coolant
Particular care must be taken when handling the end cover of the
water cooler. The end cover must be sealed and closed firmly.
Danger
Never remove the cooler end cover if the drive motor is running or is
still hot.
Hot water may spray out and scald bystanders.
After switching off the drive motor, wait at least 10 minutes before
removing the cover.
Work with protective gloves and face mask.
2 — 16
03_0051_0511GB
Safety Regulations
2.13 Starting up
When starting the machine at temperatures below +10 _C, a vacuum may develop in the hydraulic hoses due to the increased oil
viscosity. Under unfavourable conditions, this may damage the hydraulic fluid circuit in the machine.
Danger
The hydraulic fluid circuit may be blocked!
To avoid damage at temperatures below +10 _C, the machine
must only be started at half throttle and warmed up in this position
for at least 2 minutes.
The hydraulic fluid can heat up.
The machine can then be operated at full throttle.
03_0055_1203GB
2 — 17
Safety Regulations
2.14 Blockage
Avoid blockages. A well cleaned and leak-tight delivery line is the
best assurance against formation of a blockage! Blockages considerably increase the risk of accident.
Always use cement grout for initial pumping.
Danger
Never attempt to blow out a blockage with compressed air. There is
a risk of fatal injury because the delivery line can burst!
Injury through the force of bursting couplings, pipelines or blockages
flying out of delivery lines.
Always attempt to remove the blockage by reverse pumping followed by normal pumping.
Relieve pressure in the delivery pipe by briefly reverse pumping.
Then uncouple the delivery line and clear the blockages in the line
by shaking and tapping it.
If the obstruction is not released, the affected delivery section must
be disassembled.
When you start the drive motor up again, add a cement grout to the
delivery line.
2 — 18
03_0052_0512GB
Safety Regulations
2.15 Hydraulic and pneumatic equipment
Work on hydraulic equipment may be carried out only by persons
having special knowledge and experience in hydraulic systems, who
can demonstrate to us appropriate certification of competence (certificates of training).
Couplings must be fitted to hoses by persons who possess the necessary experience and equipment required for this task.
Wear a face mask and gloves whenever you work on the hydraulic
system. Escaping fluid is toxic and can penetrate the skin.
Never work without protective equipment
Check
Check all lines, hoses and threaded unions regularly for leaks and
obvious damage. Repair damage immediately. Splashed fluid may
cause injury and fire.
Check hydraulic hoses
Continuation next side
03_0044_0511GB
2 — 19
Safety Regulations
Regular inspections are specified as part of the safety inspections of
the machine. Bursting lines present a risk of injury. The manufacturer
accepts no responsibility for damage resulting from the use of worn
or defective components.
Do not repair damaged hydraulic lines, but replace them. Replace
damaged or saturated hydraulic hoses immediately.
Even if no external damage is detected, hydraulic hoses must be replaced every six years (including a storage time of no more than two
years). For this purpose, the period must be calculated from the marking on the fitting (date of manufacture of the hose).
Dumping pressure
Depressurise, in accordance with the specific instructions for the unit
concerned, all system sections and pressure lines (hydraulic and
pneumatic systems) to be removed before carrying out any repair
work!
Bleeding
Carefully bleed the hydraulic system after any maintenance or repair
work.
2 — 20
03_0044_0511GB
Safety Regulations
2.16 Place of work
The workplace is the area in which people must remain in order to
carry out the work.
Operator
The place of work of the operator during use of the machine is at the
operating panel of the machine.
2.17 Working area
The working area is the area where work is carried out with the delivery line, or the machine is filled with material. Parts of the working
area can become danger areas, depending on the job that is being
performed with the delivery line or machine filling.
The working area and the working environment around the machine
must be cordoned off against unauthorised access by other personnel when work is carried out. If necessary, install warning plates and
barricades.
The operator is responsible for safety in the working area when the
machine is in use.
2.18 Conduct in emergencies
Switch off the machine at the EMERGENCY STOP button in an emergency situation.
Caution
In the event of malfunctions, stop the machine immediately and secure it. Have any faults rectified immediately.
2.19 Noise pollution
During the following operating modes at the machine:
-- Starting up
-- Operation
-- Cleaning, Troubleshooting, Maintenance
-- Decommissioning
there is a risk of noise pollution.
In the vicinity of the machine, a sound level of up to 85 dB(A) is possible.
Wear the specified ear defenders.
Wear your personal ear defenders.
Operator
03_0053_0512GB
Instruct your personnel always to wear their personal ear defenders.
As the operator, you are responsible for ensuring that your personnel
comply with this regulation.
2 — 21
Safety Regulations
2.20 Environmental protection
Have old operating materials such as oils, filters, batteries, replacement parts etc. disposed of in line with regulations. Used cleaning
cloths must also be disposed of properly.
14000700
Environmental protection
2.21 Spare parts
Spare parts must comply with the technical requirements specified
by the manufacturer. Spare parts from original equipment manufacturers guarantee this.
Use only original spare parts.
Putzmeister Mörtelmaschinen GmbH accepts no liability for damage
caused as a result of using non-original spare parts.
2.22 Storing the machine
The machine should only be stored in a dry, clean and well ventilated
area.
If there is a risk of freezing in the storage area, you must check the
anti-freeze content of the cooling water once it has cooled off and, if
necessary, top it up.
Caution
If there is inadequate frost-protection, the engine, cooler and/or lines
can burst in frosty conditions.
For further details, refer to the chapter: “Decommissioning”.
2 — 22
03_0053_0512GB
Safety Regulations
2.23 Sound emissions
Sound emissions are generated during the following operating modes at the machine:
-- Starting up
-- Operation
-- Cleaning, Troubleshooting, Maintenance
-- Decommissioning
Refer to the technical data for the sound pressure level value in the
vicinity of the machine.
We recommend wearing ear defenders for noises louder than
85 dB (A); the employer should provide personnel with ear defenders although this is not compulsory.
Wearing ear defenders for noises louder than 90 dB (A) is compulsory.
Wear your personal ear defenders.
Operator
Instruct your personnel always to wear their personal ear defenders.
As the operator, you are responsible for ensuring that your personnel
comply with this regulation.
All soundproofing equipment must be present and in perfect condition. This equipment must be set to protective position during operation. High sound levels can cause permanent hearing damage.
03_0112_0702GB
2 — 23
Safety Regulations
2.24 Place of work
The place of work is the area in which people must remain in order to
carry out the work.
Machine operator
The place of work of the machine operator during operation is at the
operating panel on the machine.
High-pressure gun operator
The place of work of the high-pressure gun operator is within the
danger zone of the high-pressure gun. Proceed with extreme caution
here. The high-pressure gun operator and the machine operator
must have visual contact.
Danger
Removed material may spray back and cause serious injury. Never
work alone.
If an operator falls unconsciousness or suffers serious injuries, you
are advised to call for help as you will not be able to secure the machine alone.
2.25 Working area
The working area is the area in which work is carried out with and at
the machine. Parts of the working area can become danger areas,
depending on the job being performed.
The working area is also the area in which work is carried out with
and on the high-pressure gun.
Any persons other than the operator of the high-pressure gun must
keep a distance of at least 10 metres from operating area around the
high-pressure gun while work is being performed.
Secure the working area and affix signs clearly indicating the dangers. Suitable protective equipment is compulsory within the working
area. The operator is responsible for safety in the working area when
the machine is in use.
2.26 Conduct in an emergency
Switch off the machine immediately in an emergency situation.
Refer also to chapter: ”Operation” -- section: ”Emergency shutdown
procedures” for further details
Caution
In the event of malfunctions, stop the machine immediately and secure it. Have any faults rectified immediately.
2 — 24
03_0120_0702GB
Safety Regulations
2.27 Accessories
Accessories must meet the requirements specified by Putzmeister
Mörtelmaschinen GmbH and be compatible with one another. Using
accessories from original equipment manufacturers guarantee this.
Notes
Accessories that are not included in the scope of supply delivered
with the machine are supplied by Putzmeister and can be purchased
through Parts Sales.
Please refer to the delivery note for a list of accessories supplied.
The operating company is responsible for ensuring that the correct
accessories are used.
Putzmeister Mörtelmaschinen GmbH declines all responsibility and
liability for damage caused as a result of using non-original accessories or using correct accessories inappropriately.
2.28 Storing the machine
The machine should be stored only in a dry, frost-free location.
If there is a danger of freezing at the storage location, take appropriate antifreeze protection measures.
For further details, refer also to chapter: ”Decommissioning”.
03_0122_1011GB
2 — 25
Safety Regulations
2.29 Injuries through unau- During the following operating modes at the machine:
-- Starting up
thorised starting or
-- Operation
use of the machine
-- Cleaning, Troubleshooting, Maintenance
-- Decommissioning
there is a risk due to unauthorised starting or use of the machine.
Always secure the machine against unauthorised starting before leaving the work area. This means:
-- Switch off the pump drive and motor.
-- Switch the main switch to OFF.
-- Secure the control cabinet against opening with a lock.
-- Close the hoods.
The operator must always have a clear view of the machine. If necessary, the operator will have to appoint a person to monitor the
machine.
If unauthorised persons approach the machine, the operator must
stop work immediately.
2 — 26
03_0009_0505GB
Safety Regulations
2.30 Safety-related parts
(SRP)
Safety-related parts (SRP) are parts used to ensure the machine’s
functional safety.
Safety-related parts are parts that
-- are used to ensure safety functions and
-- which, if they fail or are missing, endanger personal safety.
Unauthorised interference with safety-related parts (SRP), adjustable
equipment, machine data or removal of seals by the operator or the
operator’s authorised maintenance and repair staff is prohibited.
The manufacturer accepts no liability for damages caused by unauthorised interference.
Danger
Increased risk of injuries (including fatal injuries) resulting from the
absence and/or malfunction of safety functions.
Safety-related parts (SRP) much only be maintained, repaired and
replaced by authorised Putzmeister specialists.
If a safety-related part (SRP) is incorrectly maintained, repaired or
replaced, this can result in safety functions not operating correctly.
03_0174_1011GB
2 — 27
Safety Regulations
2.31 Spare parts
Spare parts must comply with the technical requirements specified
by the manufacturer. Spare parts from original equipment manufacturers guarantee this.
Use only original spare parts. Putzmeister Mörtelmaschinen GmbH
accepts no liability for damage caused as a result of using non-original spare parts.
Labelling of safety-related parts in the spare
parts sheets
Safety-related parts (SRP) are specially labelled on the spare parts
sheets.
3
Labelling of SRP in spare parts sheets
Spare delivery of safetyrelated parts
If you order a safety-related part (SRP), it is delivered in its own separate, labelled package.
Labelling of SRP as spare parts
2 — 28
03_0174_1011GB
General Technical Description
3
General Technical Description
This chapter describes the components and assemblies on this machine and describes how they function. Please note that available
options are also described.
3.1 Machine versions
You will make it much easier for us to answer any questions or respond to orders if you can give us the details of the machine model
and the machine number.
The following data can be found on the rating plate:
-- Machine model
-- Machine number
Notes
The machine number is allocated by Putzmeister Mörtelmaschinen
GmbH. Each machine number is only allocated once. This means
that the machine number identifies each individual machine.
02_0615_0905GB
3—1
General Technical Description
3.2 Machine designation
Your machine is an SP11 auger pump from
Putzmeister Mörtelmaschinen GmbH.
3.3 Machine model
The machine model designation is printed on the cover sheet of
the operating instructions and on the rating plate of your machine.
3.4 Machine number
3—2
Machine model
Models with
SP11 LMR
Lifting mixer
The machine number is located on the rating plate and stamped
and marked in red on the front right of the machine viewed in the direction of travel.
02_0693_1202GB
General Technical Description
3.5 Summary
Below you will find a summary of the most important components,
which are described on the following pages.
Machine
6
5
4
3
2
7
1
8
9
10
13
02_0694_1202GB
12
11
Item
Designation
1
Towing gear
2
Socket
3
Air valve fitting
4
Rating plate
5
Hopper
6
Hood
7
Control cabinet
8
Operating elements
9
Axle and wheels
10
Lifting mixer unit
11
Support foot
12
Auger pump
13
Pressure connection
3—3
General Technical Description
Engine compartment
2
1
3
4
5
12
11
10
9
6
8
7
Item
3—4
Designation
1
Engine
2
Return line suction filter
3
Hydraulic fluid reservoir
4
Radiator
5
Expansion tank for coolant
6
Dry air filter
7
Battery
8
Compressor
9
Fuel tank filler neck
10
Fuel filter
11
Hydraulic pump
12
Hydraulic control block
02_0694_1202GB
General Technical Description
3.6 Technical data
The following technical data and characteristics relate to the SP11.
SP 11 LMR
Dimensions
Length:
3480 mm
Width:
1420 mm
Height:
1162 mm
Fill height:
750 mm
Weight
Permitted gross weight:
750 kg
Permitted drawbar load:
max. 75 kg
Chassis
Permitted driving speed:
In accordance with regulations
in the country of use.
Caution
Observe the maximum speed regulations in force in the country
of use.
SP 11 LMR
Tyres
Tyre size:
165 SR 13
Rim size:
4 1/2JX13H2 ET 30
Inflation pressure:
2.4 bar
Tightening torque of wheel nuts:
90 Nm
Danger
When assembling the wheels, retighten the wheels to 90 Nm after
driving 50 km.
02_0695_1202GB
3—5
General Technical Description
SP 11 LMR
Performance data
Engine:
Compressor:
Auger pump:
(depending on model)
Delivery rate:
3-cylinder diesel engine
16.3 kW at 2600 rpm
2 cylinders; 3.5 bar; 400 l/min.
2L6
0 - 55 l/min.
Delivery pressure:
25 bar
Max. delivery pressure:
40 bar
Max. hydraulic pressure
210 bar
Delivery distance:
120 m distance, 60 m high
Max. grain size of conveyed
medium:
6 mm
Control voltage:
12 V
Temperature range:
Installation height (without reduction in performance):
--5 ˚C to +45 ˚C
up to 1000 m above sea level
Notes
The delivery rate specifications are only guide values!
The maximum delivery rate and the maximum delivery pressure cannot be reached simultaneously.
The actual rates depend on the properties and consistency of the
material being delivered.
3—6
02_0695_1202GB
General Technical Description
SP 11 LMR
Fluid capacities
Engine oil:
Engine oil volume 5.3 l
with filter change
Refer also to the documentation provided by the engine manufacturer.
Fuel:
Diesel fuel
capacity approx. 25 l
Compressor oil:
Compressor fluid
volume approx. 1.0 l
Hydraulic fluid reservoir:
Capacity approx. 14 l
Coolant tank:
Coolant
capacity approx. 0.5 l
Caution
The capacities are only approximate values and may vary depending on the model and quantity of oil remaining.
The upper marking on the oil dipstick always takes precedence.
02_0695_1202GB
3—7
General Technical Description
3.7 Rating plate
The most important machine data is shown on the rating plate.
1
2
3
8
9
4
10
5
6
11
7
13
Item
3—8
12
Designation
1
Model (machine model)
2
Year of manufacture
3
Maximum delivery pressure [bar]
4
Hydraulic pressure [bar]
(maximum fluid pressure in the hydraulic system)
5
Voltage [V]
6
Frequency [Hz]
7
Power [kW]
8
Licence number
9
Chassis number no.
10
Permitted gross weight [kg]
11
Permitted axle load [kg]
12
Maximum permitted drawbar load [kg]
13
Identification number for certification and monitoring
office
02_0335_0911GB
General Technical Description
3.8 Sound power level
In accordance with Directive 2000/14/EC the sound power level emitted by the machine is given below.
Next to the rating plate on the machine there is the plate shown in
the picture below which gives the machine’s sound power level measurement.
XXX
Item
02_0174_0603GB
Designation
LWA
Sound power level
dB
Decibel value
3—9
General Technical Description
3.9 Safety equipment
The following is a list of installed safety equipment on the machine.
Danger
Only operate the machine with the safety equipment fitted and fully
functional.
EMERGENCY STOP button
The control cabinet of the machine accommodates an EMERGENCY
STOP button.
Danger
Should situations arise during operation which may endanger the
operator, third parties or the machine, the machine must be stopped
immediately by pressing the EMERGENCY STOP button. After an
EMERGENCY STOP, eliminate the danger before restarting the machine.
Caution
Familiarise yourself with the position of the EMERGENCY STOP buttons on your machine.
Pressing the EMERGENCY STOP button triggers the following activities:
-- The machine stops immediately.
-- The compressor is switched off.
-- The drive motor is switched off.
-- The mixing mechanism stops.
-- The hydraulic system is deactivated (if fitted).
Notes
To cancel the EMERGENCY STOP status, unlock the depressed
EMERGENCY STOP button by turning it.
3 — 10
02_0240_0711GB
General Technical Description
Hood safety device
The machine is fitted with a hood safety device. If the hood is opened during operation, a safety switch is actuated and the drive motor
switches off immediately.
Notes
You must close the hood after carrying out the check and test operations.
The machine may be operated only with the hood closed.
Protective grilles
Protective grilles are fitted to the machine.
The mesh size is such that material can fall unobstructed into the
drum, yet guarantees protection for the operator.
Danger
The protective grille must be installed in every operating mode and
after every repair.
The machine may be operated only with the protective grille closed.
The grille on the machine is protected by a safety switch that switches off the mixer shaft automatically when the mixer grille is opened.
Safety switch
The safety device on the protective grille is fitted with a safety switch
that shuts down the mixing mechanism when the protective grille is
raised.
Danger
The protective grille must be installed in every operating mode and
after every repair.
The machine may be operated only with the protective grille closed.
02_0240_0711GB
3 — 11
General Technical Description
3.10 Functional description
General set-up of the
machine
The following chapter is intended to help you understand the functions of the machine so that you can limit the field of the machine’s
applications to suitable areas and avoid errors in operation.
Putzmeister machines are easy to assemble and operate. In spite of
this, certain precautionary measures must be taken when operating
the machine to ensure that the wear parts have as high a life limit as
possible.
The SP11 mortar spray pump is designed to process premixed dry
mortar and site mixes. It mixes, pumps and sprays continuously.
Dry mortar, water and concrete admixtures are mixed in the mixer
and poured into the hopper. The mixed material is conveyed from the
hopper by an auger pump.
A spray gun can be attached to the end of the delivery hose. Air is
introduced from the compressor and the mortar applied at the desired coat thickness.
3 — 12
02_0087_0511GB
General Technical Description
3.11 Control cabinet
The machine is operated and controlled from the control cabinet.
Heavy current
Work on the machine’s electrical system and equipment may only be
carried out by a qualified electrician or by instructed persons under
the supervision and guidance of a qualified electrician in accordance with electrotechnical rules and regulations.
The wiring, earthing and connections on the control cabinet comply
with VDE codes of practice.
Only use original fuses with the specified amperage! Fitting over-rated fuses or bypassing fuses may destroy the electrical system.
02_0696_1202GB
3 — 13
General Technical Description
9
8
10
7
6
1
11
5
4
3
2
Item
3 — 14
Operating / control
elements
Function / display
1
Master switch
(under hood)
Power supply OFF / ON
2
Ignition switch
Starts the engine
3
Rocker switch
High-pressure cleaner ON / OFF
4
Toggle switch
Mixer unit
BACKWARDS -- 0 -- FORWARDS
5
Toggle switch
Auger pump
BACKWARDS -- 0 -- FORWARDS
6
Indicator lamp
High-pressure cleaner (optional)
ready
7
Indicator lamp
Preheat
8
Indicator lamp
Engine oil pressure
9
Indicator lamp
Charge monitor
10
Rocker switch
Acknowledge engine start
Acknowledge after EMERGENCY
STOP
11
EMERGENCY STOP
button
Switch off the machine in an
emergency (mixer unit, high-pressure cleaner and auger pump
come to a halt)
02_0696_1202GB
General Technical Description
3.12 Engine
The machine is powered by a 3-cylinder diesel engine.
1
2
3
4
Different models available
Item
Designation
1
Oil dipstick
2
Oil filler
3
Engine oil filter
4
Oil drain plug (obscured)
The engine has different performance data, depending on the model. Please refer to the rating plate or “Technical data” section of the
chapter “General Technical Description” for information on machine
values.
Notes
For further information on the engine, refer also to the documentation
provided by the engine manufacturer.
02_0698_1202GB
3 — 15
General Technical Description
3.13 Auger pump
The auger pump built into the machine is called a displacement
pump. An auger (rotor) rotates inside a fixed auger barrel (stator).
The auger consists of a highly wear-resistant, very hard metal alloy
and the auger barrel of a multi-notched steel sleeve with vulcanised
elastic rubber core.
2
1
Item
Designation
1
Auger
2
Auger barrel
The auger pump may be fitted with a clamping sheath for tightening,
depending on the model.
4
3
1
Item
3 — 16
2
Designation
1
Auger
2
Auger barrel
3
Clamping sheath
4
Tensioning screws
02_0057_0611GB
General Technical Description
3.14 Hydraulic control
The machine is equipped with a hydraulic constant-displacement
pump.
The hydraulic fluid supply is sufficient to power several functions simultaneously.
The variable output auger pump, the mixing mechanism, the mixer
lifting device (depending on model) and the high-pressure cleaner
(optional) are driven via 2 separate hydraulic circuits, depending on
the model of the machine.
02_0241_0606GB
3 — 17
General Technical Description
Hydraulic control block
SP11
The SP11 has an electromagnetic hydraulic control block with valves
for the auger pump and the mixer. Output can be regulated using the
output controller under the control cabinet.
Notes
Reducing the output with the output controller will not reduce the engine’s power.
The engine output can only be reduced by modifying the consistence and quality of the material or by fitting an auger pump
with output volumes.
1
2
3
Item
3 — 18
Designation
1
Hydraulic control block
2
Rotary output regulator switch
3
Control lever for the lifting mixer unit
02_0699_1203GB
General Technical Description
3.15 Compressor
A 2-cylinder compressor has been integrated into the SP11 to generate the air required to spray the mortar. This is driven by V-belts
from the diesel engine.
2-cylinder compressor
The air generated is transported through the air battery and an air
hose to the spray gun. The spray air is also used to control the mortar pump pneumatically.
Caution
Check the oil level on the inspection glass of the compressor daily.
Do not overfill the compressor with oil. Place horizontally when filling.
02_0080_0511GB
3 — 19
General Technical Description
3.16 Air valve fitting
The air valve fitting is located on the front of the machine, viewed in
the direction of travel.
1
2
3
Item
Designation
1
Valve for spray air
2
Air hose connector
3
Air valve for controlling the pump
Air is channelled from the compressor into the air valve fitting for
spray gun operation. This fitting comprises two air valves and an air
hose connector.
A spray gun is fitted to the end of the hose and a coat of mortar applied with the desired thickness.
3 — 20
02_0242_0606GB
General Technical Description
3.17 Spray gun
The spray gun can be attached to the end of the delivery line.
1
7
3
2
2
4
2
5
6
Different models available
Item
Designation
1
Rubber finishing nozzle
2
Delivery line connection
3
Material lever (depending on model)
4
Remote control valve
5
Air supply coupling
6
Stop cock (depending on model)
7
Air-regulation cock (depending on model)
If your machine is not fitted with these components, consult your
dealer or local Putzmeister Mörtelmaschinen GmbH representative
as to how and whether you should upgrade your machine.
02_0570_0808GB
3 — 21
General Technical Description
3.18 Dust extraction
(option)
As an option, the machine can be fitted with a dust extraction system.
1
2
Item
Designation
1
Mixer cover
2
Dust extraction
Dust is extracted above the filling opening on the mixer.
Caution
Only regular cleaning will guarantee that the dust extraction system
functions correctly.
Observe the maintenance intervals.
"
Clean the mixer cover on a daily basis.
Maintenance chart: Cleaning the dust extractor
3 — 22
02_0223_0605GB
General Technical Description
3.19 High-pressure cleaner
(option)
A hydraulically driven high-pressure cleaner can be installed as an
option.
The high-pressure cleaner is used to clean the outside of the machine with pressurised water.
Caution
The high-pressure cleaner must never be operated without water.
Make sure that the water inlet is connected correctly.
Notes
The high-pressure cleaner is not a suction pump.
It must be connected to the mains water supply.
The available water pressure must be at least 0.5 bar.
3
2
4
5
1
Different models available
Item
Designation
1
High-pressure cleaner
2
Handwheel
3
Fan jet nozzle
4
Nozzle
5
High-pressure gun
Continuation next side
02_0403_0707GB
3 — 23
General Technical Description
Wear all the necessary personal protective equipment during operation. Refer also to chapter: ”Safety regulations” -- section: ”Protective
equipment”.
Danger
Waterproof protective equipment only provides protection from spray
water and splash particles. In the case of direct contact with the
high-pressure water jet, protective clothing does not provide sufficient protection from injury.
The control range of the high-pressure cleaner is from 5 to 140 bar
and depends on the number of engine revolutions. The pressure can
be regulated by turning the handwheel.
There is a trigger safety device on the high-pressure gun trigger that
prevents the high-pressure gun from triggering accidentally. and prevent personnel from actuating the gun trigger by mistake.
The red securing lever is folded in and locked.
Caution
The machine and lines must be drained fully of residual water if there
is a risk of freezing.
Only operate and store the machine in a frost-free location.
Maintenance chart: High-pressure cleaner anti- freeze protection
3 — 24
02_0403_0707GB
Transport, Set-up and Connection
4
Transport, Set-up and Connection
In this chapter you will find information concerning safe transport of
the machine. In addition this chapter describes operations that remain to be carried out to assemble and connect the machine. Starting up the machine will not be described until the chapter ”Starting
up”.
4.1 Transport and driving
Putzmeister trailer machines may only use public roads if properly
approved. They are subject to Road Traffic laws when being towed in
road traffic. This also stipulates the maximum permissible road
speed for trailer machines in Germany.
They must not be used for the transport of goods. The regulations
governing the operation of trailers, in particular the permissible trailer
loading of the tractor unit, must be observed.
Make sure that the trailer equipment, brakes and lighting equipment
are functioning correctly before starting a journey.
The machines are certified for roadworthiness in Germany. You will
receive operating permission on delivery; this must be carried with
the machine during transport at all times.
You may have to obtain an additional licence depending on the
country of use and the relevant regulations. The registration regulations applicable in the country of use shall always apply.
The trailer-mounted machine in Germany must display its own official
registration and is thus subject to the two-yearly roadworthiness test
according to § 29 StVZO. The registration can be obtained on production of the operating permission at the licensing office responsible.
04_0001_0607GB
4—1
Transport, Set-up and Connection
4.2 Transporting the machine
If you wish to load the machine onto a suitable transport vehicle, jack
rings must be fitted on the machine.
Use the slinging points provided on the machine when loading it by
crane. Only in this way can you be sure that the machine is suspended horizontally and securely in the hook and will not be able to tip
over.
Danger of crushing
When lifting with the crane, determine the centre of gravity of the machine by lifting carefully. All cables or chains on the lifting gear must
be tensioned evenly and the machine must be raised evenly at all
support points.
Suspended Load
Make sure personnel do not walk under suspended loads.
Only use an auxiliary loading device with a loadbearing capacity designed to support the gross weight of the machine!
Danger
The machine may only be loaded by crane if it is attached by the lifting eyes designed for this purpose. Lifting equipment, lifting tackle,
support trestles and other auxiliary equipment must be reliable and
safe in operation. Make sure that the load- bearing capacity is sufficient.
Additional loads on the machine are not permitted. Observe the maximum gross weight on the rating plate.
The machine must be properly secured on the transport vehicle to
prevent it rolling away, slipping or tipping over.
4—2
04_0023_0702GB
Transport, Set-up and Connection
4.3 Machine transport
position
Set the machine to transport position before towing on the open
road.
Machine lifting mixer
unit
Lifting mixer unit in transport position
Check that the machine is in transport position:
-- The lifting mixer unit is lowered.
-- The mixer cover is closed and secure.
-- The hood is closed properly and secure.
-- All protective grilles are closed.
-- The towing gear is at the same height as the trailer coupling on the
towing vehicle (truck = high, car = low).
-- The supporting foot is wound up after the trailer is attached.
04_0068_0605GB
4—3
Transport, Set-up and Connection
4.4 Before a journey
The following points must be observed before the machine can be
moved by a tractor unit on the open road:
-- The towing gear is fully functional.
-- The machine is in transport position.
-- The hood must be tightly closed.
-- The lighting equipment is fully functional and well secured.
-- The machine is correctly coupled.
Notes
Observe the permitted towed load for the tractor unit.
Additional loads on the machine are not permitted. Observe the maximum gross weight on the rating plate.
Ground clearance
The machine must have the maximum possible ground clearance
while it is being towed. It must be ensured that the machine is horizontal when it is attached ready for towing.
Caution
The machine must be kept horizontal when being towed by the tractor unit.
4—4
04_0056_0605GB
Transport, Set-up and Connection
Towing gear
The tractor unit must be equipped with a trailer coupling complying
with DIN specifications. The adjustable drawbar must be set up in
such a way that the trailer coupling ring may be inserted horizontally
into the trailer coupling.
"
Place the drawbar at the same height as the tractor unit’s trailer
coupling before attaching the machine to the tractor unit (truck
= high, car = low).
24001200
Attach the machine horizontally
Caution
Special high-strength bolts are used for the drawbar bracket connection. These may only be replaced with original spare parts. (tightening torque = 110 Nm +15 Nm)
Transport position
04_0056_0605GB
Before transportation, the machine must be placed in transport position:
"
Please ensure that the towing gear is functioning correctly.
"
Observe the permitted towed load for the tractor unit.
"
Additional loads on the machine are not permitted. Observe
the maximum gross weight on the rating plate.
"
The mixer must be in transport position before the machine is
transported.
"
Please ensure that the lighting equipment is functioning correctly and is secure.
4—5
Transport, Set-up and Connection
Adjusting the towing
gear
To adjust the towing gear, proceed as follows:
2
1
2
Symbolic illustration
Item
4—6
Designation
1
Spring pin
2
Locking toggle
"
Pull the spring pin(1) from the locking toggle(2).
"
Release the locking toggle and turn it as far as the stop.
⇒ The intermediate element can now be adjusted upwards
and downwards to the stops.
"
Tighten the locking toggle again and secure it by striking once
with a hammer (hard rubber mallet).
"
Insert the spring pin again firmly to secure.
"
Retighten the locking toggle after approx. 50 km.
04_0056_0605GB
Transport, Set-up and Connection
Ball hitch
The ball hitch is equipped with a safety control display. This consists
of clearly imprinted symbols, which are pasted over with a redgreen-red label with the same symbols, and a pointer.
Coupling the ball hitch
To couple, place the opened ball hitch (X-position) on the ball of the
tractor unit until it clearly audibly engages.
After correct engagement of the ball hitch, the pointer jumps to the
green area of the marking, which is identified by a “+” sign.
After connection, you absolutely must use the indicator to check
whether the ball hitch is correctly closed and locked, and the ball on
the towing vehicle still shows sufficient signs of wear reserves.
Notes
Only in this manner can a secure connection be set up between your
tractor unit and the trailer/combination be made roadworthy.
Continuation next side
04_0056_0605GB
4—7
Transport, Set-up and Connection
Caution
If the indicator is in the red “- ” area, then the ball hitch is not properly
closed and the trailer must under no circumstances be driven.
For further details, refer to the chapter: “Faults, Cause and Remedy”
-- Section: “Chassis”.
4—8
04_0056_0605GB
Transport, Set-up and Connection
Disconnecting the ball
hitch
To disconnect the trailer, proceed as follows.
2
1
"
Open hitch handle, pull up and then swivel forwards.
⇒ The ball hitch stays in the “open” position, in which the indicator points at the red area with the large “X”.
Danger
The trailer must never be driven in this condition.
Danger of crushing
Never reach into the opened ball hitch.
Even low pressure on the spherical cap can activate the spring-loaded closing mechanism and cause an injury.
04_0056_0605GB
4—9
Transport, Set-up and Connection
Permitted slewing circle
of the ball hitch
The swivel range of the ball hitch around the vehicle longitudinal axis
is max. +/-- 25˚. Horizontally, slewing angles within a range of +/-20˚ are possible.
A A
B B
A slewing circle 20˚
B slewing circle 25˚
Caution
If the slewing circles are exceeded, the components are overloaded
and operation of the ball hitch is no longer guaranteed.
Permitted drawbar load
The permitted drawbar load is imprinted in the handle of the ball
hitch.
Danger
Never drive with a negative drawbar load because this impairs the
driving stability of the trailer.
A negative drawbar load can result from residual material in the machine or loading with additional weight.
Caution
Loading the trailer with additional weight is not permitted!
4 — 10
04_0056_0605GB
Transport, Set-up and Connection
4.5 Lighting equipment
The machine is fitted with lighting equipment.
Notes
The lighting equipment is designed to run off 12 V as standard.
1
2
3
4
Item
Designation
1
Lighting equipment
2
Power cable
3
Connector
4
Socket
The vehicle registration plate is also located next to the lighting at the
lighting equipment(1). Plug the connector(3) on the power cable(2)
into the socket(4) on the machine and towing vehicle. In addition the
function of the lighting must be guaranteed prior to commencing
each journey.
Caution
Please ensure that the lighting equipment is functioning correctly
and is secured before every journey.
04_0057_0608GB
4 — 11
Transport, Set-up and Connection
4.6 Selecting the set-up
site
The set-up site of the machine is usually determined and appropriately prepared by the site management.
Notes
The responsibility for setting up the machine safely falls on the operator.
4.7 Set-up site requirements
Inspect the proposed site carefully and reject the set-up site if you
have any doubts in respect of safety.
The set-up site must:
-- be horizontal,
-- have level, firm supporting ground,
-- be large enough to allow you to open all flaps and hoods unhindered. You should therefore leave a clearance of at least 1 metre
around the entire machine,
-- such that the machine is accessible from all sides for servicing
and repairs.
Caution
The machine be situated outside the danger zone of elevated worksites, or protective roofing must be provided for the machine at its
operating sites.
Supporting ground
The support ground must be firm enough to absorb the forces passed on from the machine into the ground. There must be no hollow
spaces or ground unevenness under the machine.
If the machine is to remain at a set-up site for a long period, it is advisable to select a site with a concrete base.
In the case of machines which operate with at high pressure and
high delivery rate, it is advisable to anchor the machines to the
ground.
Lighting
4 — 12
Ensure that there is adequate lighting at the set-up site.
04_0003_0505GB
Transport, Set-up and Connection
4.8 Setting up
The machine must be set up so that it is absolutely stable and secured against rolling.
"
Secure the machine against rolling by placing chocks under
the wheels.
"
Apply the handbrake on machines with brake equipment.
"
Align the machine horizontally. Observe the permitted inclination angles.
On machines with detachable lighting equipment, fit this equipment
to the bracket provided before operating the machine.
Inclination angles
Observe the maximum inclination angles during machine set-up and
operation.
Refer also to chapter: ”General Technical Description” -- section:
”Technical data” for the maximum permitted inclination angles.
Danger
Lubrication is no longer guaranteed at excessive inclination angles.
These conditions will lead to increased wear or machine damage.
Do not operate the machine at inclination angles greater than those
specified!
04_0109_0703GB
4 — 13
Transport, Set-up and Connection
Aligning the machine
Align the machine horizontally.
1
2
Item
Designation
1
Support foot
2
Crank
"
Wind down the support foot (1) using the crank (2) until the machine is horizontal.
Caution
Wind the support foot back to its transport position before transporting the machine.
4 — 14
04_0082_0703GB
Transport, Set-up and Connection
4.9 Water connections
The following section describes how to connect the machine to the
water supply.
The water supply may only be connected as per DIN 1988 -- Technical Rules for Water Installations, i.e. using installation type 1 backflow preventers or an independent outlet (buffer tank with a booster
pump).
Please ensure that you check preconditions for connection to the water supply before beginning connection work.
-- The pipe must be at least 3/4” in diameter.
-- The available water pressure must be at least 0.5 bar.
Water pipes must be laid visibly, taking local conditions into consideration, and protected against damage. They must not be allowed to
obstruct operating personnel.
Caution
The water used must be clean and of drinking water quality.
Never use: salt water, sea water, completely desalted water or water
with added chemicals.
If there is a risk of freezing, the pipes must be laid so as to exclude
the possibility of the water freezing.
"
04_0067_0605GB
Attach the water hose to the water connection.
4 — 15
Starting up
5
Starting up
In this chapter you will find information on starting up the machine.
The work steps for initial operation of the machine are described as
well as how to prepare the machine for operation after a long break.
There is also a description on how to check the condition of your machine and how to carry out a test run with function checks.
Notes
The operating personnel should be trained on the machine during
initial operation.
Every time the machine is in operation, the operator accepts full responsibility for the safety of anyone located in the machine’s danger
zone. He is therefore obliged to ensure absolute operating safety of
the machine.
The operator must familiarise himself with the machine during machine handover.
This means:
-- He must have read and understood the Operating Instructions (especially the chapter on Safety Regulations).
-- He must be in a position to carry out the correct measures in case
of emergency and switch off and secure the machine.
The entire system must be observed during the initial hours of operation to identify possible malfunctions.
09_0001_0505GB
5—1
Starting up
5.1 Checks
Visual checks
Each time the machine is used, you should check the condition
of your machine and carry out a test run including function checks.
If you identify any defects during the checks, you must eliminate
these (or have these eliminated) immediately.
Some important visual checks should be carried out before starting
up the machine.
"
Always check the machine thoroughly for apparent defects before starting work.
"
Open up the hood to do this.
"
Move the safety lock which may be attached to the securing
bracket.
"
Check the fill levels of the operating materials.
"
Check that all closures are tightly sealed.
"
Inspect the main wear parts such as mixing unit, outlet connections, couplings etc.
"
Check that all lubrication points are lubricated as described in
the lubrication diagram.
Maintenance chart: Lubrication diagram
"
Check whether the machine has been correctly erected.
For further details, refer also to chapter: “Transport, Set-up and Connection”.
"
Check the delivery line for damage.
"
Check that all safety equipment is fitted and fully functional.
"
Observe the warning and information signs on the machine.
Notes
You must close the hood after carrying out the check and test operations.
The machine may be operated only with the hood closed.
5—2
09_0205_1203GB
Starting up
Operating materials
10000700
Water, oil and fuel levels
Danger
Oils and other operating materials can pose a threat to health if they
come into contact with the skin or similar.
You must, therefore, always wear personal protective clothing and
equipment when you are handling toxic, caustic or other operating
materials that are injurious to health and always take note of the manufacturer’s information.
Notes
The machine must be level when you check the operating materials.
"
Check all water, oil and fuel levels and top these up as necessary.
For fluid capacities, refer also to chapter: “General Technical Description” -- section: “Technical data”.
Caution
After checking and topping up (if necessary), all filler lids must again
be sealed tightly.
09_0205_1203GB
5—3
Starting up
Fuel level
The fuel level must be as close as possible to the “Max” marking.
"
Check the fuel level at the viewing window in the frame on the
left of the machine exterior.
"
Top up the fuel if necessary.
For further details, refer also to the chapter: “Starting up” -- section
“Filling the machine with fuel”.
Engine oil level
Check the engine oil level of the engine as follows:
"
Withdraw the oil dipstick from the engine, wipe the dipstick
with a lint-free cloth and insert it again.
"
Pull the oil dipstick out again for a further check. You can read
off the engine oil level at the dipstick marking.
"
Top up the engine oil if necessary.
Notes
The engine oil level is correct when it reaches the upper oil dipstick
marking.
Refer also to the documentation provided by the engine manufacturer.
"
5—4
Insert the oil dipstick again.
09_0205_1203GB
Starting up
Compressor oil level
You can check the compressor oil level at the level indicator on the
compressor.
"
Check the compressor oil level at the level indicator on the
compressor.
"
Top up the compressor oil if necessary.
Notes
Do not top up the beyond the “Max” marking. Too much oil causes
an increased oil consumption.
Hydraulic fluid level
You can check the hydraulic fluid level at the hydraulic fluid reservoir.
"
Check the hydraulic fluid level at the hydraulic fluid reservoir.
"
Note the Min. and Max. markings on the hydraulic fluid reservoir
"
Top up the hydraulic fluid if necessary.
For fluid capacities, refer also to chapter: “General Technical Description” -- section: “Technical data”.
Caution
The capacities are only approximate values and may vary depending on the model and quantity of oil remaining.
The upper mark on the fill level indicator is always decisive.
For types and grade of hydraulic fluid, refer also to chapter: “Maintenance” -- section: “Operating materials”.
09_0205_1203GB
5—5
Starting up
Coolant level
Check the coolant level at the expansion tank on the cooling system
as follows:
Notes
The coolant level must be as close as possible to the “Max” marking.
"
Checking cooling fins
on the radiator
Top up the coolant if necessary.
The air side of the radiator can become clogged if the unit is operating in dusty conditions.
"
Check the cooling fins on the radiator for contamination.
The cooling fins on the radiator must be cleaned if they are
contaminated.
Maintenance chart: Cleaning the cooling fins on the radiator
5—6
09_0205_1203GB
Starting up
5.2 Refuelling the
machine
Before starting up, check that there is sufficient fuel in the tank and, if
necessary, top up with fuel via the filler neck. The machine can be
filled with fuel via the filler neck when it has been shut down.
Notes
Always fill the tank in good time because otherwise you will have to
vent the fuel line to the diesel engine.
Use summer or winter diesel fuel depending on outside temperature!
Caution
Fill the fuel tank only with fuels available from regular commercial
outlets - otherwise the drive motor could be damaged.
When filling with fuel, pay particular attention to cleanness!
Danger
Fill the machine with fuel only when the drive motor is at a standstill!
No smoking is allowed when you are filling up!
Never fill the fuel tank near naked flames or ignitable sparks.
Ensure that no fuel spills onto hot machine parts while you are filling
up. There is a risk of the fuel igniting!
Avoid naked flames at the machine and lock the fuel tank after
refuelling - danger of fire!
Do not spill fuel!
Make sure that there are fire extinguishers in the vicinity of the machine.
09_0007_0703GB
5—7
Starting up
5.3 Test run
Carry out a test run before operating the machine.
Start the engine to perform a test run. Some functions must be chekked while the machine is running.
Notes
Any defects found during these tests must be rectified immediately.
A fresh inspection is necessary after every repair. The machine may
only be put into operation once all the inspections described below
have been concluded satisfactorily.
Starting the engine
The engine may only be started under no load, i.e. no consuming
devices should be switched on.
1
3
2
Item
5—8
Designation
1
Main switch (under hood)
“Power supply OFF / ON”
2
Toggle switch
“Mixer unit BACKWARDS -- 0 -- FORWARDS”
3
Toggle switch
“Auger pump BACKWARDS -- 0 -- FORWARDS”
"
Open the hood.
"
Switch on the power supply to the machine at the main switch
“Power supply OFF / ON” (1) (under hood).
09_0206_1203GB
Starting up
Close the hood again.
"
Danger
The machine must only be operated with the hood closed.
"
Switch off the auger pump at the “Auger pump BACKWARDS -0 -- FORWARDS” switch (2).
"
Switch off the mixer at the “Mixer unit BACKWARDS -- 0 -- FORWARDS” switch (3).
"
Set the output controller to “Max”.
3
2
1
Item
"
Designation
1
Ignition switch
2
“Preheat” indicator lamp
3
“Charge monitor” indicator lamp
Turn the ignition switch (1) clockwise until the “Charge monitor”
indicator lamp (3) lights up.
Notes
Preheating for approx. 10 seconds is necessary at temperatures below 5 ˚C.
"
09_0206_1203GB
Continue turning the ignition switch clockwise to the preheating
position.
⇒ The “Preheat” (2) indicator lamp lights up and the preheating process commences.
5—9
Starting up
Caution
Preheat the engine no longer than necessary (max. 20 s)!
Otherwise the spark plugs and starting solenoid could be damaged!
"
Then turn the ignition switch clockwise even further to start the
engine.
⇒ The engine starts.
⇒ All indicator lamps go out.
Caution
Attempt to start the engine for a maximum of 10 seconds.
Wait at least 30 seconds before attempting to start the machine
again.
If you are unable to start the engine during the second attempt, refer to the chapter “Faults, cause and remedy” to determine
the cause.
Caution
If there is a risk of freezing, allow the machine to run and warm up
for a minimum of 2 minutes with no load. Otherwise there is a risk
that the engine will be damaged.
5 — 10
09_0206_1203GB
Starting up
5.4 Function checks
Before using the machine, the following functions should be checked
with the machine running.
Notes
You must close the hood after carrying out the check and test operations.
The machine may be operated only with the hood closed.
Checking the function
of the safety equipment
Check whether all safety equipment are fitted and fully functional.
Check:
-- whether all protective grilles are fitted and secure,
-- the protective grilles are closed,
-- the function of the protective grille cut-outs,
-- the function of the EMERGENCY STOP button.
Danger
Defective safety devices could appear to be safe, but in reality pose
a danger. This may result in the machine continuing to run or, if there
is an imminent danger and the machine cannot be switched off
quickly enough, injury to personnel.
If the safety device does not respond during the check, the machine
must not be started up.
You must therefore check the operation of the safety device each
time you start work.
09_0060_0802GB
5 — 11
Starting up
Function check of
EMERGENCY STOP
button
Check the operability of the EMERGENCY STOP button.
Press:
lock EMERGENCY STOP
Rotate:
unlock EMERGENCY STOP
"
Start the drive motor. Refer also to the section: ”Starting the
drive motor”.
"
Press the EMERGENCY STOP button.
⇒ The machine switches off.
"
Unlock the EMERGENCY STOP button by turning it.
Caution
The machine is no longer safe to operate if the EMERGENCY STOP
button is defective, as you will no longer be able to switch off the machine quickly enough if danger threatens.
If the EMERGENCY STOP button does not respond during the
check, the machine must not be started up.
You must therefore check the functioning of the EMERGENCY STOP
button each time you start work.
5 — 12
09_0033_0712GB
Starting up
Function check of hood
safety device
The machine is fitted with a hood safety device. If the hood is opened while the drive motor is running, the hood switch triggers and
the machine switches off.
Danger
A defective hood switch could appear to be safe, but in reality poses
a danger. As a result, rotating drives will continue running when the
hood is opened and may cause personal injury.
There is an increased risk of accident when the hood is open due to
exposed operating drives.
If the safety device does not respond during the check, the machine
must not be started up.
You must therefore check the operation of the safety device each
time you start work.
Notes
The machine may only be operated when the hood is closed to prevent dust being drawn in directly, and, above all, to see that safety
and noise protection rules are observed.
Check that the hood safety device is fully functional.
"
Close the hood.
"
Start the drive motor. Refer also to the section: ”Starting the
drive motor”.
"
Open the hood.
⇒ The machine switches off.
For further details, refer to the chapter: “Faults, Cause and Remedy”.
09_0061_0605GB
5 — 13
Starting up
Function check of the
protective grille cut-out
Check that the protective grille cut-out is fully functional.
1
2
Item
Designation
1
Protective grille (different versions)
2
Safety switch
Notes
The safety device at the protective grille (1) is equipped with a safety switch (2) which switches off the mixing mechanism as soon as
the protective grille is raised.
5 — 14
09_0208_1203GB
Starting up
Protective grille
on the mixer
Protective grille
on the hopper
09_0208_1203GB
The auger pump is switched off by the protective grille cut-out on
the mixer.
"
Start the engine. Refer also to section “Starting the engine”.
"
Set the toggle switch “Auger pump BACKWARDS -- 0 -- FORWARDS” on the control cabinet to “FORWARDS”.
⇒ The auger pump runs forwards.
"
Raise the protective grille (1).
⇒ The auger pump switches off immediately.
"
Close the protective grille (1) again.
"
Press the “Acknowledge” rocker switch on the control cabinet
to acknowledge.
The mixer unit is switched off by the protective grille cut-out on the
hopper.
"
Start the engine. Refer also to section “Starting the engine”.
"
Set the “Mixer unit BACKWARDS -- 0 -- FORWARDS” toggle
switch to “FORWARDS”.
⇒ The mixer unit runs forwards.
"
Raise the protective grille (1).
⇒ The mixer unit switches off immediately.
"
Close the protective grille (1) again.
"
Press the “Acknowledge” rocker switch on the control cabinet
to acknowledge.
5 — 15
Starting up
Pump functions
The auger pump is controlled independently via the “Auger pump
BACKWARDS -- 0 -- FORWARDS” toggle switch.
The switch has a momentary contact function in a forwards direction
and maintained contact function in a backwards direction.
"
Start the engine. Refer also to section “Starting the engine”.
"
Turn the output controller towards “+”.
"
Set the “Auger pump BACKWARDS -- 0 -- FORWARDS” toggle
switch to “FORWARDS”.
⇒ The auger pump runs forwards.
Then switch the auger pump to “backwards” and check.
"
Mixer functions
Set the “Auger pump BACKWARDS -- 0 -- FORWARDS” toggle
switch to “BACKWARDS”.
⇒ The auger pump runs backwards.
The mixer unit is controlled independently via the “Mixer unit BACKWARDS -- 0 -- FORWARDS” toggle switch.
The switch makes momentary contact in both a forwards and backwards direction.
"
Start the engine. Refer also to section “Starting the engine”.
"
Turn the output controller towards “+”.
"
Set the “Mixer unit BACKWARDS -- 0 -- FORWARDS” toggle
switch to “FORWARDS”.
⇒ The mixer unit runs forwards.
Then switch the mixer unit to “backwards” and check.
"
5 — 16
Set the “Mixer unit BACKWARDS -- 0 -- FORWARDS” toggle
switch to “BACKWARDS”.
⇒ The mixer unit runs backwards.
09_0210_1204GB
Starting up
5.5 The delivery line
Only use original Putzmeister delivery lines which meet prescribed
operating and burst pressures.
Notes
Only Putzmeister couplings and fittings are guaranteed to comply
with the values specified in the German Accident Prevention Regulations.
You must secure delivery lines with threaded spouts by gluing. You
must ensure that you use a seal which is designed for the purpose to
secure any new coupling against being opened. You must screw the
coupling to the stop. After this, it should no longer be possible to
undo it by hand.
Only use delivery lines with a suitable internal diameter.
Caution
Only couple delivery line couplings which have been cleaned and
have fully operational gaskets. Soiled couplings are not properly sealed and allow water to leak out under pressure. This leads inevitably
to blockages.
09_0046_0512GB
5 — 17
Starting up
5.6 Shutting down machine after initial operation
After the function check, you can shut down the machine.
5
1
4
3
2
Item
5 — 18
Designation
1
Main switch (under hood)
“Power supply OFF / ON”
2
Ignition switch
3
Toggle switch
“Mixer unit BACKWARDS -- 0 -- FORWARDS”
4
Toggle switch
“Auger pump BACKWARDS -- 0 -- FORWARDS”
5
“Charge monitor” indicator lamp
"
Switch off the auger pump at the “Auger pump BACKWARDS -0 -- FORWARDS” switch (4).
"
Switch off the mixer at the “Mixer unit BACKWARDS -- 0 -- FORWARDS” switch (3).
"
Switch off the machine at the “Ignition switch” (2).
"
Set the output controller to “Max”.
"
Open the hood.
"
Switch off the power supply to the machine at the “Power supply OFF / ON” (1) main switch (under hood).
"
Close and secure the hood.
"
Secure the machine against unauthorised starting or use.
09_0207_1203GB
Operation
6
Operation
In this section you will find information on machine operation. You will
learn what operations are required for setting up the machine, operation and for cleaning.
6.1 Requirements
Before starting to use the pump, you must carefully carry out the
working steps for commissioning and installing the machine. Before
you fill material into the machine and pump it through the delivery
line you must be sure that
-- the machine functions correctly,
-- the delivery line is designed to withstand the intended delivery
pressure and
-- the delivery line has been laid professionally.
Notes
Should a malfunction occur when the pump is in operation, first consult the chapter ”Faults, Cause and Remedy”. Contact Putzmeister’s
After Sales department for advice, if you are unable to rectify the
fault yourself.
05_0018_0510GB
6—1
Operation
6.2 Emergency shut-down
procedures
Make sure you are completely familiar with the procedures for shutting down the machine in an emergency situation before you start
operating the machine.
Danger
Proceed immediately as described below if an emergency occurs
while you are operating the machine.
EMERGENCY STOP button
The control cabinet of the machine is fitted with an EMERGENCY
STOP button.
Caution
Familiarise yourself with the position of the EMERGENCY STOP buttons on your machine.
Danger
In the event of impending danger, press the EMERGENCY STOP button!
Press:
lock EMERGENCY STOP button
Rotate:
unlock EMERGENCY STOP button
Fortsetzung nächste Seite
6—2
05_0304_1203GB
Operation
"
Press the EMERGENCY STOP button.
⇒ The auger pump must come to a halt immediately.
⇒ The agitator stops (if available).
⇒ The hydraulic system is deactivated (if available).
"
Take first aid measures, where necessary.
"
Note the incident and report in accordance with company codes of practice.
"
Look for the cause of the fault and have it rectified/rectify it
completely.
"
Unlock the EMERGENCY STOP button by turning it.
"
Acknowledge the EMERGENCY STOP using the rocker switch.
Notes
To cancel the EMERGENCY STOP status, unlock the depressed
EMERGENCY STOP button by turning it.
"
05_0304_1203GB
Start up the machine in accordance with the rules for starting
up the machine.
6—3
Operation
6.3 Initial pumping
The process from the start of forward pumping to the time at which
a continuous flow of material exits from the delivery line is known as
priming the pump. This can take place at the start of building site
operations, but also after pumping interruptions.
At the beginning of pump operation the entire delivery pipe has to be
wetted.
Pumping must generally be started with the aid of a cement grout.
Notes
The grout lubricates the inside of the delivery line and prevents blokkages.
Operating the screw conveyor dry will destroy the conveying hose!
"
Rinse the delivery line out briefly with water before connecting
it. Use one or two of the sponge balls provided as standard
accessories soaked in water to do this.
"
Approx. 20 -- 40 l of grout are required, depending on the
length of the delivery line.
"
Now mix in cement grout and add this to the hopper.
"
Switch on the auger pump.
"
Pump the grout slowly into the delivery line.
The process of priming with grout finishes when the 2 sponge balls
and a full jet of material exit from the delivery line.
With the first mixture, pump the grout through the delivery line. As it
leaves the delivery line, collect the grout in a suitable container and
dispose of it.
6—4
05_0024_0511GB
Operation
6.4 Adjusting the auger
pump
The tensioning casing is used to retension the auger pump. The
wear of the auger pump can be compensated by reclamping. The
delivery pressure can also be adjusted by pretensioning or relieving
the auger barrel.
"
Use the test pressure gauge to set the delivery pressure of the
auger pump.
"
Pressure test the auger pump using water.
Maintenance chart: Setting the auger pump
1
2
Item
Designation
1
Clamping sheath
2
Tensioning screw
Notes
Set the auger pump with the test pressure gauge to a water pressure
of approx. 15-20 bar.
05_0065_0603GB
6—5
Operation
6.5 Raising / lowering
the lifting mixer unit
Site mixes are mixed in the lifting mixer unit and filled into the hopper
as a ready mix.
While a mixture is being delivered, the next one can be prepared in
the lifting mixer unit.
A
2
1
B
Item
Designation
1
Control lever for the lifting mixer unit
2
Lifting mixer
The lifting mixer unit control lever (1) is used to operate the lifting mixer unit (2). The control lever only has a momentary contact function
in the central position.
Position A: Lifting the mixer unit
Position B: Lowering the mixer unit
Notes
The mixer unit on the lifting mixer unit is switched off during this procedure.
6—6
05_0302_1203GB
Operation
You must press the control lever valve all the time when raising or
lowering the lifting mixer unit.
"
You must pull the lock on the control lever in order to actuate
the lever.
⇒ The control lever can be actuated.
"
Move the lifting mixer unit control lever downwards.
⇒ The lifting mixer swings down.
"
Move the lifting mixer unit control lever upwards.
⇒ The lifting mixer swings upwards and empties into the hopper.
The lifting device has a safety device which stops the mixer drum
from lowering accidentally. This safety device is unlocked by retracting or extending the lifting cylinder.
Danger
Despite these safety precautions, you must switch off the machine
when working under the mixer drum and support the mixer drum mechanically from below so that it cannot drop.
05_0302_1203GB
6—7
Operation
6.6 Pumping operations
Carefully carry out the operations for starting up the machine and
setting up the machine and ensure that it is functioning perfectly before you fill the hopper with medium and begin pumping it through
the delivery line.
Notes
Should a malfunction occur when the pump is in operation, first consult the Chapter ”Faults, Cause and Remedy”. Contact Putzmeister’s
After Sales department for advice, if you are unable to rectify the
fault yourself.
"
Switch the main switch on.
Notes
To prevent blockages in the delivery lines, the inside of the line must
be prelubricated with a laitance.
At the start of pumping, the entire delivery line must be lubricated
with a laitance.
"
Prelubricate the delivery line with a laitance. Refer also to the
section: ”Starting pumping”.
The pump is generally started at a low speed of rotation. Once the
delivery line has been lubricated, pumpable material is first delivered
at the lowest possible speed of rotation. If the pump is working
soundly, the delivery rate can be increased.
Caution
Never pump demixed medium or medium that is lumpy due to the
commencement of congealing into the delivery line with force. Blokkages are very easily caused by this.
"
6—8
Add pumpable material to the hopper.
⇒ The material in the hopper is mixed together.
05_0064_0603GB
Operation
6.7 Pumping
When you have emptied the mixture from the mixer into the hopper,
you can pump the material from the hopper into the delivery line.
"
Switch on the auger pump. Refer also to chapter: “Starting up”,
section: “Pump functions”.
⇒ The cardan shaft and the auger pump start delivering.
The mixture is conveyed by the cardan shaft in the hopper to the auger pump.
Notes
Start with a low output and increase this continuously.
You may change the rate of output using the output regulator. If the
auger pump comes to a halt due to overload, this can be rectified by
reducing the delivery rate. Further improvements are possible by reducing the load on the auger pump (reduction of delivery line length,
larger diameter).
05_0089_0605GB
6—9
Operation
6.8 Output regulation
You can adjust the delivery rate at the output controller.
1
Item
1
Designation
Output controller
"
With the pump running, turn the output controller towards “+”.
⇒ The delivery rate is increased.
"
With the pump running, turn the output controller towards “--”.
⇒ The delivery rate is reduced.
Notes
Start with a low output and increase this continuously.
When interrupting pumping or shutting down the machine, always
set the delivery rate to the highest setting.
6 — 10
05_0090_0605GB
Operation
6.9 Breaks in pumping
You should avoid breaks in pumping as far as possible, as the medium in the delivery line can start to set, or can become segregated.
Note the following points if breaks are unavoidable:
-- Never leave the delivery pipe under pressure.
-- Relieve the delivery line of its load during short pumping breaks
by briefly reverse pumping.
-- Switch off the auger pump during long breaks.
-- During long breaks, the agitator can remain switched on to prevent segregation of critical materials.
Caution
Never pump demixed medium or medium that is lumpy due to the
commencement of congealing into the delivery line with force. Blokkages are very easily caused by this.
05_0028_0511GB
6 — 11
Operation
6.10 Blockages
Blockage can occur inside the pump itself as well as in the delivery
line. When a blockage occurs, the flow of material at the end of the
line stops and the pressure gauge indicates a rising pressure. If a
blockage occurs inside the pump, the overload protection may
switch off the drive motor.
Blockages can be avoided. However, they do still occur from time to
time and are usually caused by:
-- insufficient lubrication of the delivery line,
-- mortar which is hard to pump and segregates easily,
-- leaks at the couplings of the delivery hoses.
Rectifying blockages
Rectify blockages as follows:
"
Pump in reverse for a short time to decrease the pressure in
the delivery line.
"
Switch off the drive motor.
Danger
Only disconnect the delivery line when you are certain that the system is depressurised.
You must wear protective goggles.
Turn your face away when opening the line coupling.
"
Uncouple the delivery line and clear the blockages in the line
by shaking and tapping it.
Danger
Never attempt to blow out a blockage with compressed air. This
would present a danger to life because the delivery line can burst!
6 — 12
"
With stubborn blockages, rinse the line with water.
"
When you start the drive motor up again, add a cement grout
to the delivery line.
05_0029_0804GB
Operation
6.11 Using the spray gun
To use the spray gun, proceed as follows:
"
Connect the delivery line to the spray gun.
"
Connect the air hose to the air valve fitting and the spray gun.
"
Connect the air valves to the air valve fitting.
2
1
3
Item
"
Designation
1
Remote control valve
2
Spray gun
3
Air valve
Close the remote control valve(1) on the spray gun.
Danger
The machine must not be started when the remote control valve is
open.
Risk of injury from material sprayed from spray gun.
"
Start the drive motor. Refer also to the chapter: “Starting up” -section: “Starting the drive motor”.
"
Switch the pump on. Refer also to chapter: “Starting up” -- section: “Pump functions”.
"
Open the air valves on the air valve fitting.
Continuation next side
05_0091_0605GB
6 — 13
Operation
Notes
Switch the pump on or off by opening or closing the remote control
valve on the spray gun.
If the machine is switched off via the remote control valve, the machine is still on standby and can be started again at any time by reopening the remote control valve.
"
Open the air cock on the spray gun.
⇒ The Cardan shaft and the auger pump start delivering.
"
Set the required delivery rate. Refer also to the section: “Delivery rate adjustment”.
"
Adjust the air to the required quantity with the air cock.
Adjusting the air nozzle
tube
>A
Diameter A
Item
Designation
1
Air nozzle tube
2
Mortar nozzle
The distance from the air nozzle tube(1) to the mortar nozzle(2) must
be greater than the diameter of the mortar nozzle(2). The larger the
distance selected, the fewer blockages occur between the air nozzle
tube(1) and the mortar nozzle(2). The smaller the distance setting,
the more cleanly and evenly the spray gun sprays.
6 — 14
05_0091_0605GB
Operation
Practical tip
Guide the spray gun back and forth at an even pace using uninterrupted horizontal movements. Circular movements are ineffectual.
Direct the jet slightly upwards when plastering walls, but in all other
cases always spray at right angles to the surface to be plastered.
The distance between nozzle and wall should be between 20 and
30 cm. The closer the nozzle is to the wall, the sharper the jet is outlined, spray with less air here if necessary.
Guide the spray gun back and forth in smooth movements
05_0091_0605GB
6 — 15
Operation
6.12 Cleaning the machine
At the end of work, the machine and delivery line must be cleaned. A
clean machine and delivery line are therefore indispensable to permit fault-free delivery when they are next used.
Material residues and contamination deposited in the machine and
delivery line can impair operation!
Environmental protection
During all cleaning work, observe the waste disposal regulations that
apply to your region.
Cleaning additives or diesel fuel must not be permitted to enter the
sewage system.
Information on cleaning
Prior to cleaning the machine with water or a steam jet (H.P. cleaner)
or other cleaning agents, cover or seal all openings which water /
steam or cleaning agents must not penetrate, for safety or operating
reasons. Especially at risk are electric motors, control cabinets and
electrical plug connectors.
Caution
The machine must only be cleaned on the outside with a steam jet /
high-pressure cleaner.
The hood must remain closed.
No water into electric systems
Continuation next side
6 — 16
05_0030_0512GB
Operation
Notes
In the first six weeks of operation, clean all painted surfaces with
cold water only at a maximum water pressure of 5 bar. Do not use
any aggressive cleaning additives. Only after this time will the paint
have hardened completely, allowing you to use steam jet equipment
or similar tools.
Under no circumstances use sea water or any other salty water for
cleaning purposes. Should sea water get onto the machine you must
rinse it off without fail.
Water which sprays the machine from all directions does not have
any damaging effect. The system is splash-proof but not waterproof.
Notes
Completely remove the covers / seals after the cleaning process!
Caution
The machine and lines must be drained fully of residual water if there
is a risk of freezing.
05_0030_0512GB
6 — 17
Operation
Machine
Clean the machine first, then the delivery line.
"
Pump the hopper empty.
"
Allow the machine to pump in reverse for a short time and disconnect the delivery line.
Danger
You should only uncouple the delivery line when you have checked
on the pressure gauge that the system is fully depressurised.
You must wear protective goggles.
Turn your face away when opening the line coupling.
6 — 18
"
Switch off the machine as described in the chapter: ”Shutting
down the machine after operation”.
"
Now wash the machine clean with water. Rinse out the hopper
and mixer drum until it is clean.
"
Now pump water from the hopper through the pump until the
water begins to exit the pressure connection cleanly once
more. The machine is now fully cleaned out.
"
Drain the leavings at the drainage connection and rinse the
hopper out once more with water.
"
Now clean the delivery line.
05_0031_0511GB
Operation
Delivery line
Material deposits inside the delivery line can cause damage and can
continue to accumulate and thereby reduce the line cross-section. To
allow problem-free operation at the next use, it is vital that all delivery
lines are clean.
Danger
You clean the delivery line with compressed air at your own risk.
Putzmeister accepts no liability for damage caused by compressed
air cleaning.
Notes
A frequent error committed when cleaning the delivery lines is pumping water through the delivery line before a sponge ball has been
inserted. This later leads to blockages in the delivery line since residual sand remains in the line.
2
1
15000300
Item
Designation
1
Sponge ball
2
Delivery line
"
Soak the Putzmeister sponge ball(1) in water and push it into
the delivery line(2).
Continuation next side
05_0032_0511GB
6 — 19
Operation
The delivery line is cleaned by water pressure. Use the water connector included in the accessory package for this purpose.
2
1
15000400
Item
Designation
1
Water connection piece
2
Delivery line
"
Connect the water connector to the delivery line.
"
Use the water pressure to push the leavings and sponge balls
out of the delivery line.
If the machine does not have a water pump and the water line pressure is not sufficient for cleaning the delivery line, you must use the
pump for cleaning.
Notes
Using the pump for cleaning increases wear of the pump components. If the water line pressure is repeatedly insufficient, use an auxiliary water pump.
"
Then reconnect the delivery line to the outlet connection.
"
Half fill the mixing drum with water.
Continuation next side
6 — 20
05_0032_0511GB
Operation
"
Start the pumping process and pump water through the delivery line until the sponge ball exits the hose end.
"
Repeat the cleaning process until only clean water exits the
line.
2
1
14700101
Item
Designation
1
Pressure connection
2
Rubber seal
Clean all seals and the seal seats. Grease the seals before reassembling them. Dirty couplings are not sealed and will inevitably lead to
blockages.
Caution
The machine and lines must be drained fully of residual water if there
is a risk of freezing.
05_0032_0511GB
6 — 21
Operation
Spray gun
Clean the air cock and air nozzle tube on the spray gun. In addition,
use the probe to clean the air nozzle tube.
2
3
1
15100102
Item
6 — 22
Designation
1
Air cock
2
Air nozzle tube
3
Probe
05_0054_0511GB
Operation
6.13 High-pressure cleaner
(optional)
A hydraulically driven high-pressure cleaner can be installed as
an option.
The high-pressure cleaner is used to clean the outside of the machine with pressurised water.
Notes
The high-pressure cleaner is not a suction pump.
It must be connected to the mains water supply.
A pressure switch monitors the water supply (min. 0.5 bar) in the water block so that the high-pressure cleaner cannot operate dry.
High-pressure cleaner
Caution
Never direct the water jet at electric components on the machine
(e.g. control cabinet, electric motors) or at soundproofing equipment
inside the hood.
Under no circumstances may explosive or inflammable materials
be conveyed. The high-pressure water pump is designed to deliver
clean water or other non-aggressive or abrasive media with a similar
specific weight to water.
05_0303_1203GB
6 — 23
Operation
Take note of the following points before initial operation of the highpressure cleaner:
-- The high-pressure cleaner is not a suction pump. It must be connected to the mains water supply.
-- The high-pressure cleaner must never be run without water.
Make sure that the water inlet is connected correctly.
Danger
Always wear protective goggles and protective clothing when working.
Never direct the water jet at other personnel - the high operating
pressure can lead to serious injuries.
3
4
2
1
5
6 — 24
Item
Designation
1
Cleaning gun
2
Cleaning gun connection
3
Water inlet connection
4
Water hose
5
High-pressure hose
05_0303_1203GB
Operation
"
Switch off the machine. Refer also to chapter “Starting up” -section “Shutting down the machine after initial operation”.
"
Connect the high-pressure hose (5) to the cleaning gun (1).
"
Connect the high-pressure hose on the cleaning gun (5) to the
cleaning gun connector (2).
"
Connect the mains water supply to the water inlet connector (3)
using a suitable water hose (4).
"
Close the ball valve to the high-pressure cleaner.
"
Close the ball valve to the water dosing block.
"
Open the water supply.
Caution
The high-pressure cleaner must never be run without water.
Make sure that the water inlet is connected correctly.
Open the cleaning gun and keep it open until water runs out of
the spray nozzle.
⇒ In this way you prevent the high-pressure cleaner from sukking in air.
"
1
Item
1
05_0303_1203GB
Designation
“High-pressure cleaner ON / OFF” rocker switch
6 — 25
Operation
"
Start the engine. Refer also to chapter: “Starting up” -- section:
“Starting the engine”.
"
Press the “Change to high-pressure cleaner” button.
⇒ The high-pressure cleaner is selected.
"
Open the cleaning gun.
⇒ The operating pressure can be read off at the pressure
gauge.
1
2
Item
Designation
1
Handwheel
2
Pressure gauge
The high-pressure water pump has a control range between
5 and 120 bar and is dependent on the engine speed.
The pressure can be regulated by turning the handwheel.
6 — 26
05_0303_1203GB
Operation
Tip
Do not direct the cleaning jet vertically onto the surfaces to be cleaned. Try to “peel off” the dirt layer from the painted surfaces. Maintain a minimum clearance of 30 cm between the cleaning lance and
the surface being cleaned.
Caution
After cleaning with the high-pressure cleaner, you have to select
the mixer unit again.
Otherwise the mixer unit will not function when the machine is operated again.
"
Press the “Change to high-pressure cleaner” button.
⇒ The mixer unit is selected.
"
Switch off the machine and shut off the water supply.
Notes
Before removing the pressure hose for the cleaning gun from the
cleaning gun connection, open the cleaning gun and keep it open
until any pressure present has been relieved.
It is not possible to operate the mixer and high-pressure cleaner simultaneously.
Caution
In frosty weather, you must drain any residual water out of the highpressure cleaner and line with connections for the water supply and
cleaning gun open.
05_0303_1203GB
6 — 27
Faults, Cause and Remedy
7
Faults, Cause and Remedy
This chapter gives you a summary of faults and their possible causes, and also ways in which you may rectify them.
Observe the safety regulations when searching for a fault.
Danger
Work on the electrical and hydraulic equipment of the machine must
be carried out by a qualified electrician, a hydraulic technician or by
instructed persons under the supervision and guidance of a qualified
electrician, or hydraulic technician, and in accordance with electrical
and hydraulic engineering rules and regulations.
06_0001_0507GB
7—1
Faults, Cause and Remedy
7.1 Machine, general
The following section provides a description of possible causes of
faults and their remedies.
Caution
Inspection and maintenance personnel must have authorisation and
the necessary technical qualification. They must have completed
training relevant to working with the equipment on the machine and
be conversant with the content of the operating instructions.
Notes
Consult the relevant service department at Putzmeister
Mörtelmaschinen GmbH if you cannot rectify the fault by yourself.
Refer also to the documentation provided by the engine manufacturer for more information on the causes of faults and remedies.
Refer also to chapter: “General Technical Description” - section:
“Technical data”.
Use only original spare parts.
Putzmeister Mörtelmaschinen GmbH accepts no liability for damage
caused as a result of using non-original spare parts.
Drive motor does not start or struggles to start.
Cause
Remedy
Hood safety device activated
Close the hood
Place the machine in a horizontal position. Take the maximum
permissible inclination angle into account
User switched on
Switch off user
Start up the drive motor under no load
Remote control switched on
(latched pushbutton “Remote
control OFF / ON” set to “ON”),
remote control not connected,
however
7—2
Deactivate remote control or plug in radio remote control
06_0050_0905GB
Faults, Cause and Remedy
Drive motor does not start or struggles to start.
Cause
Remedy
Empty or faulty battery
Check the electrolyte level, charge the battery and replace it if
necessary
Ambient temperature too low
Use an engine oil grade suitable for the ambient temperature
Insufficient fuel in the tank
Add fuel
Incorrect fuel
Replace with the correct fuel
Fuel system dirty or blocked
Clean the fuel system
Fuel filter dirty or clogged
Clean the fuel filter, replace if necessary
Air in the fuel line
Bleed the fuel line
Engine oil with incorrect
lubricant grade
Replace engine oil
Valve play incorrect
Have checked and adjusted
Valves worn or defective
Have replaced
Engine oil pressure too low
Switch off the machine immediately
Check the engine oil system
Refer also to the documentation of the engine manufacturer.
Incorrect timing of fuel
injection
Have checked and adjusted
Injection nozzle dirty or worn
Clean and have replaced if necessary
Injection pump faulty
Have replaced
Starter faulty
Have replaced
06_0050_0905GB
7—3
Faults, Cause and Remedy
The drive motor does not reach full power.
Cause
Remedy
Incorrect fuel grade
Replace with the correct fuel
Fuel filter dirty or clogged
Clean the fuel filter, replace if necessary
Air in the fuel line
Bleed the fuel line
Engine oil level insufficient
Add engine oil
Engine oil filter dirty or
clogged
Clean engine oil filter, replace if necessary
Dry air filter dirty
Clean filter element, replace if necessary
Radiator dirty
Clean the cooling fins on the radiator
Injection nozzle dirty or worn
Clean and have replaced if necessary
Injection pump dirty or worn
Have injection pump replaced
Injection pressure incorrect
Have checked and adjusted
Insufficient compression
Check, have repaired if necessary
Valve play incorrect
Have checked and adjusted
Valves worn or defective
Have replaced
Bearing defective
Have replaced
7—4
06_0050_0905GB
Faults, Cause and Remedy
The drive motor stops suddenly.
Cause
Remedy
Insufficient fuel in the tank
Add fuel
Fuel system dirty or blocked
Clean the fuel system
Fuel filter dirty or clogged
Clean the fuel filter, replace if necessary
Engine oil level insufficient
Add engine oil
Engine oil filter dirty or
clogged
Clean engine oil filter, replace if necessary
Radiator dirty
Clean the cooling fins on the radiator
Coolant level too low
Add coolant
Coolant concentration is too
high
Add water
Hydraulic filterclogged
Change the hydraulic filter
V-belt not tight enough or torn
Tighten or replace the V-belt
Heat dissipation impeded
Remove objects and obstructions in the area where heat is
dissipated
Always use the mixture ratio specified
Close the hood
Drive motor overloaded
Reduce the drive motor load
Injection nozzle dirty or worn
Clean injection nozzle, have replaced if necessary
Bearing defective
Have replaced
Danger
Allow the drive motor and radiator to cool down before topping up
the coolant. Risk of scalding.
06_0050_0905GB
7—5
Faults, Cause and Remedy
The drive motor is smouldering.
Cause
Remedy
Incorrect fuel grade
Replace with the correct fuel
Fuel system dirty or blocked
Clean the fuel system
Dry air filter dirty
Clean filter element, replace if necessary
Injection nozzle dirty or worn
Clean injection nozzle, have replaced if necessary
Fault in injection system
Have checked and remedied
Hydraulic fluid overheating.
Cause
Remedy
Radiator dirty
Clean the cooling fins on the radiator
Hydraulic oil level insufficient
Add hydraulic oil
Material emerges alternately with a thick and thin consistency.
Cause
Remedy
Worn screw conveyor parts
Tighten auger components or replace
7—6
06_0050_0905GB
Faults, Cause and Remedy
No material is exiting from the end of the delivery line.
Cause
Remedy
Blockages in the delivery line
and shutdown of the pump
due to activation of overpressure safety device.
Carefully complete the priming procedure before pumping
material. Refer also to chapter: “Operation” -- section: “Priming”.
This prevents blockages where possible.
Caution
You should only uncouple the delivery line once
you have checked the pressure gauge to see that
the system is fully depressurised.
You must wear protective goggles.
Turn your face away when opening the line
coupling.
Turn off the machine. Depressurise the delivery line. Disconnect
the delivery line and release the blockage by tapping and
shaking. Flush out the delivery line with water if necessary.
Start priming slowly after removing a blockage.
Flow of material interrupted.
Cause
Remedy
The material exits the delivery
line irregularly and is spraying
with force.
Check whether the hopper is nearly empty thus allowing air to be
sucked in. For this reason, always ensure that there is sufficient
material in the hopper.
The flow of material is being
constantly interrupted without
spraying.
Check whether the delivery line forms a loop or is kinked.
06_0050_0905GB
7—7
Faults, Cause and Remedy
Decreasing delivery pressure.
Cause
Remedy
Worn screw conveyor parts.
Tighten auger components or replace
Auger pump produces no or insufficient power.
Cause
Remedy
Delivery rate is not set to
maximum.
Increase delivery rate
Pump functions cannot be executed on the control cabinet!
Cause
Remedy
Remote control is active.
Set the “Remote control OFF / ON” latched pushbutton to “OFF”.
(optional)
Notes
Should frequency interference be generated on the construction site
e.g. by other radio-controlled construction machinery or electricity
pylons, you will have to control the machine via the control cabinet.
7—8
06_0050_0905GB
Faults, Cause and Remedy
The cardan shaft is not running.
Cause
Remedy
The grille on the hopper is
open or the safety switch is
defective.
Close the grille on the hopper and check the safety switch.
Please contact your specialist workshop if the cardan shaft still
does not rotate when the grille is closed.
(depending on model)
The vibrating screen is open or
the safety switch is defective.
Close the vibrating screen and check the safety switch.
Please contact your specialist workshop if the cardan shaft still
does not rotate when the grille is closed.
Material is not stirred sufficiently.
Cause
Remedy
Mixing paddles on the mixer
are heavily worn.
Replace worn parts.
(depending on model)
Mixer does not move, or speed insufficient.
(depending on model)
Cause
Remedy
Mixer control is not fully open.
Increase mixer speed.
06_0050_0905GB
7—9
Faults, Cause and Remedy
The mixing apparatus in the mixer drum is not running.
(depending on model)
Cause
Remedy
The grille on the mixer is open
or the safety switch is defective.
Close the grille on the mixer drum and check the safety switch.
The grille on the hopper is
open or the safety switch is
defective.
Close the grille on the hopper and check the safety switch.
The mixer is jammed (mixture
too dry or stone chippings).
Switch the mixer drive switch on the switchboard to reverse drive,
keep your finger on the switch and add water. Repeat this process until the mixer is running freely again. The machine must be
shut down and the mixer drum cleared if this is not successful.
Please contact your specialist workshop if the mixing mechanism
still does not rotate when the grille is closed.
Please contact your specialist workshop if the mixing mechanism
still does not rotate when the grille is closed.
Please contact your specialist workshop if the mixing mechanism
still does not rotate when the grille is closed.
High-pressure cleaner does not switch on.
(optional)
Cause
Remedy
Insufficient delivery pressure
The delivery pressure must be at least 0.5, connect a booster
pump upstream if necessary.
7 — 10
06_0050_0905GB
Faults, Cause and Remedy
If water supply stops.
(depending on model)
Cause
Remedy
No water supply from mains.
Use a pressure booster pump to supply the machine from a tank
containing clean water. Connect the pressure line on the pressure
booster pump to the water connection on the machine.
Water dosage flow volume insufficient.
(depending on model)
Cause
Remedy
Clogged water filter.
Check the water filter for dirt and clean.
Check the lines for kinks and leaks.
Water dosage unit does not supply any water.
(depending on model)
Cause
Remedy
Water dosage unit failure.
Unscrew the sealing plug on the water dosing block and check
the turbine for ease of movement.
Check the lines for kinks and leaks.
Check the water filter for dirt and clean.
06_0050_0905GB
7 — 11
Faults, Cause and Remedy
7.2 Electrical system
The following is a description of possible causes of faults, which affect the electrical system, and their remedies.
Heavy current
Work on the electrical system and equipment of the machine must
be carried out by a qualified electrician or by instructed persons under the supervision and guidance of a qualified electrician and in
accordance with the electrical engineering rules and regulations.
Charging indicator lamp flickers briefly when the main switch is actuated instead of lighting
up permanently.
Cause
Remedy
Switch B1 on the motherboard
is closed.
Open switch B1 (starting switch for checking the software)
Charging indicator lamp stays lit while the drive motor is running.
Cause
Remedy
The battery is not charging
properly.
Check the cables, dynamo regulator.
Charging indicator lamp flickers briefly during machine operation.
Cause
Remedy
Relay 3K65 is faulty
Check relay 3K65 and replace if necessary. See circuit diagram.
Continuation next side
7 — 12
06_0022_0804GB
Faults, Cause and Remedy
The “Charge monitor” indicator lamp does not light up when the main switch is switched on.
Machine cannot be started.
Cause
Remedy
Empty or faulty battery.
Check the electrolyte level, charge the battery and replace it if
necessary.
Loose battery connection or
oxidised terminals.
Check the battery connection and repair it if necessary.
Loose connections or
damaged wiring.
Check the wiring and connections and repair them if necessary.
Drive motor does not start even though the main switch is actuated.
Cause
Remedy
EMERGENCY STOP chain is
activated (EMERGENCY STOP
button pressed).
Unlock the EMERGENCY STOP button.
06_0022_0804GB
7 — 13
Faults, Cause and Remedy
7.3 Chassis
The following is a description of possible causes of faults, which affect the chassis, and their remedies.
Ball hitch does not engage after fitting on tractor unit
Cause
Remedy
Inner section of ball hitch
contaminated or movement
obstructed.
Clean and lubricate ball hitch, have replaced at specialist
workshop if necessary.
Ball diameter at tractor unit
greater than Ø 50 mm.
Replace ball.
In new condition, the ball on the towing vehicle has a maximum
diameter of Ø 50 mm and a minimum of ∅ 49 mm (DIN 74058).
If the diameter of the ball is larger than 50 mm, it must be
replaced.
To much play between ball hitch and ball means there is a risk of disconnecting
Cause
Remedy
Ball on tractor unit worn,
ball diameter smaller than
Ø 49 mm.
Replace ball.
In new condition, the ball on the towing vehicle has a maximum
diameter of Ø 50 mm and a minimum of Ø 49 mm (DIN 74058).
If the diameter of the ball falls below 49 mm, it must be replaced.
Ball hitch worn.
Swivel range exceeded.
Have specialist workshop replace ball hitch.
Rivet bent.
7 — 14
06_0016_0603GB
Maintenance
8
Maintenance
In this chapter you will find information on the maintenance work necessary for the safe and efficient operation of the machine.
Following the general maintenance information, you will find the
maintenance charts necessary for this machine. A summary of the
maintenance charts listed by number is included in the table of contents.
We should like here to emphasise expressly that all prescribed
checks, inspections and preventative maintenance work must be
conscientiously carried out. Otherwise we will refuse any liability or
warranty claim. Our After Sales department is available to you with
advice and help at any time should you be in doubt.
07_0001_0505GB
8—1
Maintenance
8.1 Maintenance intervals
The following table shows the intervals for the various maintenance
tasks.
Caution
Inspection and maintenance personnel must have authorisation and
the necessary technical qualification. They must have completed
training relevant to working with the equipment on the machine and
be conversant with the content of the operating instructions.
Notes
For the maintenance work intervals and performance, please also
refer to the documentation provided:
– by the engine manufacturer
Use only original spare parts.
Putzmeister Mörtelmaschinen GmbH accepts no liability for damage
caused as a result of using non-original spare parts.
For maintenance work, consult a Putzmeister service engineer, or a
dealer authorised by Putzmeister as shown in the service reference
in the table.
Have the initial after-sales service carried out by a Putzmeister
Mörtelmaschinen GmbH service engineer, or by a dealer authorised
by Putzmeister Mörtelmaschinen GmbH.
8—2
07_0111_1204GB
Maintenance
n
Check
Criteria
J
Adjust
⇔
Replace
Z
Clean
Reference
other intervals
every 2 years
annually
every 1000 h
Action
every 500 h
Maintenance chart
every 400 h
Maintenance work that should be
performed by a service technician
authorised by Putzmeister.
every 300 h
Section contains
a more detailed
description
every 150 h
Description
every 100 h
MC
every 50 h
Service
once after 50 h
Section
daily
Reference
General machine
Visual inspection:
defects and leaks,
rectify defects, seal leaks
n n
Check that the fastening
bolts are seated correctly
n
n
n
Electrical cabling:
visual inspection, have
repaired if necessary
n n
n
Battery: check the acid
levels
n
monthly
n
n
Operational safety check
(German Accident
Prevention Regulation).
Section:
General tightening
torques
MC 41--011
⇔
Have a qualified service
expert check for defects
07_0111_1204GB
200 h
n
Charge the battery
Delivery line: visual
inspection for suitability,
wear and damage,
replace if necessary
n
200 h
n
MC 41--011
Service
Service
n
8—3
Reference
other intervals
every 2 years
annually
every 1000 h
every 500 h
every 400 h
every 300 h
every 150 h
every 100 h
every 50 h
once after 50 h
Action
daily
Maintenance
General machine
Lubricate the machine
⇔
MC 40--066
Section:
Operating
materials
Check the auger pump
for wear and adjust or
replace if necessary
n
MC 46--028
EMERGENCY STOP
button fully functional,
have repaired if
necessary
n
Section:
Function check of
the EMERGENCY
STOP button
Safety devices fitted
and fully functional, have
replaced if necessary
n
Section:
Safety equipment
J
MC 46--028
Safety equipment
Auger pump
Check the output on the
pressure gauge to detect
wear, adjust if necessary
or replace
Replacing the screw
conveyor
Checking the performance of the auger pump.
8—4
⇔
in case
of wear
MC 46--027
MC 46--030
⇔
in case
of wear
MC 46--028
07_0111_1204GB
Reference
other intervals
every 2 years
annually
every 1000 h
every 500 h
every 400 h
every 300 h
every 150 h
every 100 h
every 50 h
once after 50 h
Action
daily
Maintenance
Engine
Check engine oil level,
top up if necessary
Section:
Checks
n
Engine oil
⇔
Engine oil filter
⇔
⇔
200 h
⇔
200 h
MC 44--059
MC 44--059
⇔
Check the dry air filter
and clean if necessary
n
Z
After
cleaning
for the
6th time
⇔
Z
Clean the dry air filter
dust discharge valve
weekly
Check the intake air line,
replace if necessary
200 h
MC 44--096
n
⇔
Intake air line
Check fuel level,
top up if necessary
MC 44--096
Service
Section:
Filling the machine
with fuel
n
Fuel filter
Z
⇔
MC 44--140
Clean the fuel line filter,
replace if necessary
Z
⇔
MC 44--140
Fuel line:
check for leaks and wear,
replace if necessary
n
Drain sludge from fuel
tank
⇔
Z
n if
there is
a risk of
freezing
Cooler antifreeze
protection
Check radiator, clean
cooling fins if necessary
07_0111_1204GB
n
Z
MC 44--095
MC 44--137
8—5
Reference
other intervals
every 2 years
annually
every 1000 h
every 500 h
every 400 h
every 300 h
every 150 h
every 100 h
every 50 h
once after 50 h
Action
daily
Maintenance
Engine
Radiator hose:
check for leaks and wear,
replace if necessary
Check coolant level,
top up if necessary
⇔
Section:
Checks
n
⇔
Coolant
MC 44--090
n
Check the V-belt
Tighten or replace the
V-belt
Visual check: leaks
n
200 h
MC 44--138
⇔
Service
n
n n
Check engine feet mounting, tighten if necessary
n
Check that hose connections and clamps are
fastened securely,
tighten if necessary
n n
200 h
200 h
Section:
General tightening
torques
J
Service
n
Check the valve play and
adjust
800 h
Z
Cleaning the solenoid
Every
6 months
n
Check the turbocharger
Check the injection
pressure of the fuel
injection nozzle
1500 h
Check the fuel injection
pump
3000 h
Check the fuel injection
timer
3000 h
Combustion pipes
8—6
3000 h
n
n
n
⇔
MC 41--003
Service
Service
Service
Service
Service
07_0111_1204GB
Reference
other intervals
every 2 years
annually
every 1000 h
every 500 h
every 400 h
every 300 h
every 150 h
every 100 h
every 50 h
once after 50 h
Action
daily
Maintenance
Hydraulic system
Hydraulic hoses: visual
inspection for ageing,
leaks and damage,
replace if necessary
n
Visual check: leaks
n
MC 44--062
Check the hydraulic fluid
level, top up if necessary
n
Section:
Checks
n
Hydraulic fluid
⇔
Hydraulic filter
⇔
Have a qualified service
expert check for defects
n
⇔
⇔
6 years
⇔
200 h
⇔
200 h
n
MC 44--062
MC 44--092
MC 44--093
Service
Compressor
Check the compressor oil
level, top up if necessary
Section:
Checks
n
n
Check the V-belt
n
MC 44--138
Compressor oil
⇔
MC 44--019
Clean the ventilation
plugs
Z
MC 44--019
Mixer
Empty and clean the
mixer
Lubricate the mixer shaft
bearings
07_0111_1204GB
Section:
Cleaning the machine
n
⇔
3 times
a day
MC40--066
Section:
Operating
materials
8—7
other intervals
Reference
every 2 years
annually
every 1000 h
every 500 h
every 400 h
every 300 h
every 150 h
every 100 h
every 50 h
once after 50 h
Action
daily
Maintenance
n if
there is
a risk of
freezing
MC 52--010
Water supply fitting (depending on model)
Water supply fitting
antifreeze protection
High-pressure cleaner (optional)
Check the high-pressure
cleaner oil level,
top up if necessary
High-pressure cleaner
antifreeze protection
8—8
n
n
200 h
n if
there is
a risk of
freezing
MC 52--008
MC 52--026
07_0111_1204GB
Reference
other intervals
every 2 years
annually
every 15,000 km
every 10,000 km
every 5,000 km
every 1,000 km
Action
once after 50 km
after wheel change
daily
Maintenance
Axle and wheels (depending on model)
Lighting equipment fully
functional, have repaired
if necessary
n
Check the tyres for wear,
replace if necessary
n
Check inflation pressure,
correct if necessary
n
Check that wheel nuts/
bolts are seated correctly,
tighten if necessary
Section:
Lighting equipment
Section:
Technical data
n
J
J
After the
first 500 km
Section:
Technical data
Grease wheel bearings
⇔
⇔
Check the wheel bearings, adjust the play if
necessary
n
n
After the
first 500 km
Service
Check that the fastening
bolts are seated correctly,
tighten if necessary
n
n
J
After the
first 500 km
Section:
General tightening
torques
n
n
Check support wheel for
ease of movement, have
repaired if necessary
Support wheel: check
mounting, bracket and
locking toggle, repair if
necessary
07_0077_0803GB
J
n
Check that the support
wheel is fully functional /
moves easily, repair if
necessary
Support wheel: check that
the locking toggle is
seated correctly, tighten if
necessary
Service
n
Service
Service
n
n
Service
8—9
Reference
other intervals
every 2 years
annually
every 15,000 km
every 10,000 km
every 5,000 km
every 1,000 km
once after 50 km
after wheel change
Action
daily
Maintenance
Axle and wheels (depending on the model)
Ball hitch: check indicator,
have replaced if
necessary
Section:
Ball hitch
n
Ball hitch: check indicator,
replace if necessary
n
n
Grease ball hitch
⇔
⇔
Check that the ball hitch
is fully functional / moves
easily, repair if necessary.
n
n
Service
Ball hitch: check that the
fastening bolts are seated
correctly, tighten if
necessary
n
n
Service
Service
⇔
6 months /
as required
n
Ball hitch: check play,
repair if necessary
20,000 km
⇔
Lubricate the towing gear
8 — 10
6 months /
as required
Service
Section:
Lubrication diagram
Trailer coupling rings:
check that the fastening
bolts are seated correctly,
tighten if necessary
n
n
Service
Clean the towing gear
and lubricate
Z
Z
Service
Check the towing gear,
repair if necessary
n
n
Service
07_0077_0803GB
Reference
other intervals
every 2 years
annually
every 15,000 km
every 10,000 km
every 5,000 km
every 1,000 km
once after 50 km
after wheel change
Action
daily
Maintenance
Axle and wheels (depending on the model)
Towing gear: check that
the fastening bolts are
seated correctly, tighten if
necessary
Towing gear: check that
the locking toggle is
seated correctly, tighten if
necessary
Towing gear: check the
rubber gaiter, replace if
necessary
n
n
Service
J
50 km after
height
adjustment
n
n
n
6 months
Service
⇔
Towing gear: check the
dampers, replace if
necessary
n
n
Towing gear: check the
play on the towing tube
bearing, repair if
necessary
n
n
Service
Z
Service
⇔
Service
Towing gear: clean the
spur gearing and lubricate
Lubricate the moving
gear
07_0077_0803GB
⇔
20,000 km,
at least after
3 years
Service
8 — 11
Maintenance
8.2 Other risks during
maintenance work
Personal protective clothing
Certain maintenance, inspection and servicing activities may constitute a risk to life and limb of the maintenance, inspection and servicing personnel or third parties.
Refer to the chapter “Safety regulations” for information on requirements relating to personal protective equipment.
Danger
Failure to wear personal protective equipment poses a risk of serious
personal injury. Always wear your personal protective equipment
when performing maintenance, inspection and servicing work.
The additional personal protective equipment described in the chapter “Safety regulations” is also required.
Personnel requirements
Maintenance, inspection and servicing work may only be carried out
by specialist personnel. Personnel must have successfully completed a specialist training course that qualifies them to carry out such
activities.
Inspection and maintenance personnel must have authorisation and
the necessary technical qualification.
If none of your personnel are qualified to perform maintenance, inspection and servicing work, contact the After Sales department of
the manufacturer to appoint a qualified specialist to maintain your
machine.
Have the initial after-sales service carried out by a Putzmeister
Mörtelmaschinen GmbH service engineer, or by a dealer authorised
by Putzmeister Mörtelmaschinen GmbH.
8 — 12
07_0110_1201GB
Maintenance
Other risks
Certain maintenance, inspection and servicing activities may constitute a special risk of accident because protective devices may have
to be removed to perform certain activities, for example. The following section outlines special residual risks that may arise during
maintenance, inspection and servicing work.
Danger
Risk of injury from contact between skin and operating materials
(e.g. hydraulic fluid). Avoid contact with operating materials. Always wear personal protective equipment. Observe the safety data
sheets provided by the fluid manufacturer.
Danger
Risk of burns from hot operating materials and surfaces (e.g. engine,
exhaust system and frame). Allow hot operating materials and surfaces to cool first. Always wear personal protective equipment. Cover
hot surfaces using heat-resistant materials.
Danger
Risk of drawing in, pinching and shearing when raising or lowering
mixing equipment. Working in this area is only permitted if the mixing
equipment is adequately secured.
Danger
There is a risk of injury from thrashing hydraulic hoses. Mechanically
pre-tightened hydraulic hoses may thrash around when the threaded
union is loosened. Always wear personal protective equipment.
Hold hydraulic hoses firmly when loosening the threaded union.
Danger
Risk of injury from accidental machine start-up. Before performing
any maintenance, inspection or servicing work, shut down the machine and secure it against accidental start-up (e.g. lock control
equipment). If this is not possible, enlist the help of a second person
to prevent the machine from starting accidentally.
07_0110_1201GB
8 — 13
Maintenance
Danger
Eye and skin injuries from escaping hydraulic fluid if threaded unions
are opened without first dumping the pressure in the entire system.
Danger
Injuries caused by the machine rolling away as a result of the brake,
support legs or chocks becoming released.
8 — 14
07_0110_1201GB
Maintenance
8.3 Operating materials
This section lists all the operating materials used in your machine.
Caution
Putzmeister accepts no liability for damage resulting from the use of
unauthorised operating materials. The documentation provided by
the manufacturer is always decisive.
Consult the relevant service department at Putzmeister
Mörtelmaschinen GmbH should you have any questions.
Environmental protection
You must carefully collect all operating materials, e.g. used oil, filters
and auxiliary materials and dispose of them separately from other waste. Observe the national and regional regulations applicable to your
area.
Only work with waste disposal companies who are approved by the
responsible authorities.
You must keep used oils of various types separate in order to keep
disposal costs as low as possible. Make sure different oils are never
mixed.
Make contact with the appropriate authorities or waste disposal companies.
Refer also to section: “Maintenance intervals” for the change intervals of the operating materials.
Refer also to chapter: “General Technical Description” -- section:
“Technical data” for more information on fluid capacities.
Caution
The capacities are only approximate values. These may vary depending on the model and the quantity of oil remaining. The upper oil
dipstick mark is always decisive.
07_0015_0905GB
8 — 15
Maintenance
Fuel
Fill the fuel tank only with fuels available from regular commercial
outlets -- otherwise the diesel engine could be damaged.
Use summer or winter diesel fuel depending on outside temperature!
Caution
When filling with fuel, pay particular attention to cleanness!
Danger
Fill the machine with fuel only when the motor is at a standstill!
No smoking is allowed when you are filling up!
Never fill the fuel tank near naked flames or ignitable sparks.
Ensure that no fuel spills onto hot machine components while you are
filling up. There is a risk of the fuel igniting!
Avoid naked flames at the machine and lock the fuel tank after refuelling - risk of fire!
Do not spill fuel!
Make sure that there are fire extinguishers in the vicinity of the machine.
8 — 16
07_0015_0905GB
Maintenance
Engine oil
The drive motor requires a year-round high pressure multigrade
SAE 10W-40 oil.
The specified oil grades ensure perfect operation at ambient temperatures between --10 °C and 45 °C.
If the machine is used at other ambient temperatures, a separate request must be made regarding the required oil grade.
The oil should only be changed at operating temperature.
The first engine oil change is due during the initial customer service.
Notes
The drive motor has already been filled by the respective engine manufacturer.
Please refer to the documentation provided by the engine manufacturer for specifications on approved operating materials and the necessary fluid capacities.
Refer also to the documentation of the engine manufacturer.
Coolant
All water-cooled drive motors are filled with antifreeze ex works with
a mixing ratio of 50% potable water. This produces antifreeze protection up to --35 °C.
Caution
Use only coolants and antifreezes specified by the engine manufacturer.
Antifreeze protection in accordance with manufacturer’s specifications.
Refer also to the documentation of the engine manufacturer.
If there is insufficient antifreeze, the drive motor, cooling system and/
or lines may burst in freezing conditions.
07_0015_0905GB
8 — 17
Maintenance
Hydraulic oil
The hydraulic system is filled with a
-- mineral hydraulic fluid (HLP 46) or
-- biologically degradable hydraulic fluid based on a synthetic ester
base (HLP-E 46)
Notes
Please only use a hydraulic fluid complying with the requirements
standard specified in the lubricant recommendation when topping
up or for a full fluid change. Observe the manufacturer’s information
in doing so.
Danger
Never mix hydraulic fluids with different characteristics*, i.e. do not
mix biologically degradable hydraulic fluid with mineral hydraulic
fluids etc.
Compressor oil
The compressor requires a year-round grade high pressure multigrade SAE 15W-40 oil.
The oil should only be changed at operating temperature.
Notes
Please only use a conventional multigrade engine oil complying with
the requirements standard specified in the lubricant recommendation when topping up or for a full fluid change. Observe the manufacturer’s information in doing so.
8 — 18
07_0015_0905GB
Maintenance
Mixer bearing
Use a multipurpose grease with a lithium soap based marked
DIN 51 502: K2K, NLGl Class 2 to lubricate the mixer bearings.
The mixer bearings must be greased by hand at least three times a
day.
Caution
Under no circumstances should you grease the plastic bushes with
Molykote grease!
Axle and wheels
Lubricate the axle and wheels at least once a year using a universal
grease for antifriction bearings and friction bearings (dropping point
approx. 190 °C).
Maintenance in accordance with the moving gear manufacturer’s
specifications!
High-pressure cleaner
(option)
07_0015_0905GB
The high-pressure cleaner requires a year-round high-pressure multigrade oil SAE 20W-30.
8 — 19
Maintenance
8.4 Maintenance work in
the engine compartment
When performing maintenance work in the engine compartment that
requires the hood to be opened completely, proceed as follows:
Danger
Never open the engine hood with the engine running.
Risk of injury!
1
2
3
6
4
5
5
Item
"
Designation
1
Jack ring
2
Timber block
3
Targa hoop
4
Hood
5
Gas-filled spring
6
Hexagon nut
Place a timber block (2) of sufficient size on the Targa hoop (3)
between the jack ring (1) and the hood (4).
⇒ This ensures that the hood is not damaged by the jack
ring (1) when it is folded open.
Caution
The timber block must be large enough to prevent the hood from
opening, resting on the jack ring and sustaining damage!
8 — 20
07_0112_1204GB
Maintenance
Raise the hood (4) as far as the stop.
"
Danger
When the engine is switched off and the hood is subsequently opened, drive components may still be hot. Risk of injury!
"
Remove the hexagon nut (6) from the lower gas-filled spring.
"
Hold the hood firmly, unhook the gas spring (5) sidewards from
the bracket.
Danger
The hood could fall once the gas-filled spring has been detached risk of injury.
Carefully rest the hood back on the timber block as soon as the
gas-filled spring has been detached.
"
1
2
Item
Designation
1
Hood
2
Timber block
The engine compartment is now freely accessible.
07_0112_1204GB
8 — 21
Maintenance
Maintenance charts
The following section contains the necessary maintenance charts
for this machine. A summary of the maintenance charts listed by
number is included in the table of contents.
8 — 22
07_0109_1201GB
40-066
Maintenance Chart
40--066
Page 1 of 2
Lubrication diagram
This maintenance chart shows you the location of the lubrication nipples for lubricating with a grease gun. You will find the maintenance
intervals in the maintenance summary at the start of this chapter.
Notes
Maintenance, inspection and servicing work poses a particular risk
of accident. Therefore always read the chapter “Safety regulations”
and the description “Other risks during maintenance work” at the beginning of the “Maintenance” chapter.
The following special tool is required:
Grease gun
Notes
Use only lubricants specified in the lubricant recommendation table.
The specified lubrication interval applies to normal operation. Under extreme operating conditions, more frequent lubrication may be
necessary.
All the lubrication nipples have a red protective cap. There may be
further lubrication nipples at the positions marked in the illustrations.
At some points the lubrication nipples are located on the opposite
side of the machine or inside the machine. Always lubricate until
grease begins to escape.
WK40_066_1204GB
8 — 25
Maintenance Chart
40--066
Page 2 of 2
4
3
1
2
Lubrication points on the machine.
8 — 26
No.
Designation
1
Support foot
2
Mixer grille latch
3
Bearing flange on lifting mixer
4
Auger pump drive
WK40_066_1204GB
41-003
Maintenance Chart
41--003
Page 1 of 3
Cleaning the solenoids
This maintenance chart describes how to clean the solenoid.
You will find the maintenance intervals in the maintenance summary
at the start of this chapter.
Notes
Maintenance, inspection and servicing work poses a particular risk
of accident. Therefore always read the chapter “Safety regulations”
and the description “Other risks during maintenance work” at the beginning of the “Maintenance” chapter.
No further maintenance charts required.
No special tools required.
14100200
1
WK41_003_1203GB
Diesel engine solenoid
8 — 27
Maintenance Chart
41--003
Page 2 of 3
The starting solenoid for the diesel engine can become stiff from deposits of oil. This will mean that the machine will not start well. To prevent this occurring, dismantle the solenoid every six months -- particularly at the beginning of the cold season -- and clean as follows:
"
Connect the solenoid to a power source:
Black to negative
Blue/red and white to positive
Amperage 50 A
Cable size 2.5
"
Then immerse the disconnected solenoid approximately half
way into a container filled with paraffin.
14100300
Immerse the solenoid half way up in paraffin
Caution
Never use petrol or water. Petrol attacks the rubber components and
water can cause corrosion.
"
Now turn the power on for 2 seconds, then off for 2 seconds.
Repeat this action approximately 10 times.
Caution
The solenoid will become warm as a result of the high level of power
consumption. This is why you should not switch on the power for longer than 2 seconds - the solenoid could otherwise break.
8 — 28
WK41_003_1203GB
Maintenance Chart
41--003
Page 3 of 3
"
Switch off the solenoid and remove it from the paraffin-filled
container. Then switch it on and off again another 5-6 times for
2 seconds to allow the remaining paraffin to drain out of the
solenoid.
14100400
Remove the solenoid from the paraffin-filled container.
Caution
Do not overheat the solenoid since this may cause it to break.
"
Now remove the plug and clean the outside of the solenoid.
14100500
Rub down the solenoid with a cleaning cloth
WK41_003_1203GB
8 — 29
Maintenance Chart
41--011
Page 1 of 2
41-011
Checking acid level in the battery
This maintenance chart describes how to check the battery acid level.
You will find the maintenance intervals in the maintenance summary
at the start of this chapter.
Notes
Maintenance, inspection and servicing work poses a particular risk
of accident. Therefore always read the chapter “Safety regulations”
and the description “Other risks during maintenance work” at the beginning of the “Maintenance” chapter.
Refer also to the maintenance charts:
General maintenance work
Danger
The gases given off by the battery are explosive. Avoid the creation
of sparks or naked flames near the battery.
Battery acid (sulphuric acid) is caustic. Do not allow acid to come
into contact with skin or clothing. If acid comes into contact with the
skin, rinse off immediately with plenty of water.
Eye and skin protection
Wear protective goggles and gloves to protect yourself against
injuries from battery acid.
8 — 30
WK41_011_1203GB
Maintenance Chart
41--011
Page 2 of 2
Proceed as follows to check the acid level:
3
1
2
Item
"
Designation
1
Battery
2
Minimum/maximum mark
3
Cap on battery cell
Check the acid level at the minimum/maximum mark.
To fill with distilled water, proceed as follows:
WK41_011_1203GB
"
Open each battery cell and fill with distilled water. The plates in
the cells must be completely submerged in acid.
"
Ensure that you close all the cells correctly.
8 — 31
Maintenance Chart
44--019
Page 1 of 3
44-019
Changing the oil in the compressor
This maintenance chart describes how to change the oil in the
compressor.
You will find the maintenance intervals in the maintenance summary
at the start of this chapter.
Notes
Maintenance, inspection and servicing work poses a particular risk
of accident. Therefore always read the chapter “Safety regulations”
and the description “Other risks during maintenance work” at the beginning of the “Maintenance” chapter.
No further maintenance charts required.
No special tools required.
Notes
You must make it impossible for dirt or other impurities to enter
the compressor’s oil system. The compressor’s function can be impaired by small particles. Never leave oil filler cap off longer than necessary.
Change the oil once the compressor has warmed up.
Use SAE 15W40 engine oil according to the chapter “Lubricant recommendation”.
8 — 32
WK44_019_1203GB
Maintenance Chart
44--019
Page 2 of 3
Preparation
The following tasks must be carried out on the deactivated machine
before starting the oil change:
"
Place the machine in a horizontal position.
"
Open the hood.
"
Remove the plastic plug in the base of the machine below the
compressor.
Carry out the following steps for a full oil change:
Full oil change
1
2
3
4
5
1
2
3
4
5
Oil filler plug
Sealing ring
Oil drain plug
Oil filler
Oil inspection glass
"
Place a sufficiently large oil sump pan near the compressor
under the machine.
"
Slowly unscrew the oil drain plug (3) and let the oil drain into
the oil sump pan.
"
Open the oil filler plug (1) to speed the process of draining.
"
Once the used oil has completely drained, screw the oil drain
plug (3) back into the drain opening with a new seal ring (2)
and tighten it.
"
Fill fresh oil into the oil filler (4) until the oil level is visible in the
centre of the oil inspection glass (5).
Caution
Max. oil level: overflow at oil filler (4).
Min. oil level: lower edge of oil inspection glass (5).
WK44_019_1203GB
8 — 33
Maintenance Chart
44--019
Page 3 of 3
"
Screw the oil filler plug (1) back into the oil filler (4) with a new
seal ring (2) and tighten.
"
Close the opening in the machine base under the compressor
using the plastic plug.
Environmental protection
Always collect the old compressor oil. Guard against oil spillage. Discard collected oil in accordance with regulations!
Clean the ventilation
plugs
1
1
Ventilation plug
You must unscrew and wash the ventilation plug (1) with petrol every
month.
Danger
Oils, fuel and other operating fluids can pose a threat to health if they
come into contact with the skin, or similar.
You must, therefore, always wear personal protective clothing and
equipment when you are handling toxic, caustic or other operating
materials that are injurious to health and always take note of the manufacturer’s information.
Avoid naked flames - fire hazard!
8 — 34
WK44_019_1203GB
44-059
Maintenance Chart
44--059
Page 1 of 4
Changing the engine oil and engine oil filter
This maintenance chart describes how to change the engine oil and
engine oil filter.
You will find the maintenance intervals in the maintenance summary
at the start of this chapter.
Notes
Maintenance, inspection and servicing work poses a particular risk
of accident. Therefore always read the chapter “Safety regulations”
and the description “Other risks during maintenance work” at the beginning of the “Maintenance” chapter.
Refer also to the maintenance charts:
General maintenance work
The following special tool is required:
Oil filter wrench
Oil drain hose
Notes
For changing the engine oil/engine oil filter, refer also to the documentation of the engine manufacturer.
Change the engine oil once the engine has warmed up. It is appropriate to change the engine oil and oil filter at the same time.
Use only original spare parts. Putzmeister Mörtelmaschinen GmbH
accepts no liability for damage caused as a result of using non-original spare parts.
WK44_059_1203GB
8 — 35
Maintenance Chart
44--059
Page 2 of 4
Caution
Ensure that dirt or other impurities cannot enter the engine oil system.
Maintenance and care work on the engine must only be carried out
by a specialist authorised by Putzmeister Mörtelmaschinen GmbH or
a technically qualified specialist workshop authorised by the engine
manufacturer.
Environmental protection
Always collect the old engine oil with care. Guard against oil spillage. Separate the collected engine oil and old engine oil filter from
other waste.
Dispose of all components in accordance with current applicable
regulations!
Comply with the relevant national and regional regulations.
Only work with waste disposal companies who are approved by the
responsible authorities.
Changing the engine
oil filter
The engine oil filter is located on the same side as the engine.
Change the engine oil filter as follows:
"
Place an oil catch pan under the engine oil filter.
"
Always collect the escaping engine oil with care.
Danger
Take care when changing the engine oil filter.
There is a risk of burning. Work with protective gloves.
8 — 36
"
Change the oil filter. Refer also to the documentation of the engine manufacturer.
"
Dispose of the oil in the filter and the old filter element according to regulations.
WK44_059_1203GB
Maintenance Chart
44--059
Page 3 of 4
Changing the engine oil
The oil drain plug for changing the engine oil is located underneath
the engine.
Use the oil drain hose included in the scope of delivery.
Change the engine oil as follows:
Caution
Change the engine oil with the machine horizontal and supported.
"
Place a sufficiently large oil catch pan under the machine.
"
Guide the oil drain hose through the opening in the bottom
plate on the right-hand wheel housing and connect it.
Danger
Take care when draining hot engine oil.
There is a risk of burning. Work with protective gloves.
Use the oil drain hose.
"
Change the engine oil. Refer also to the documentation provided by the engine manufacturer.
Notes
Please refer to the documentation of the engine manufacturer for
specifications on the tightening torques, the permissible lubricants
and the necessary filling quantities.
Caution
The capacities are only approximate values and may vary depending on the model and quantity of oil remaining. The upper mark on
the oil dipstick is always decisive.
WK44_059_1203GB
"
Remove the oil drain hose again.
"
Dispose of the old oil in accordance with regulations.
8 — 37
Maintenance Chart
44--059
Page 4 of 4
Checking for leaks
8 — 38
The following checks are necessary after changing the oil and oil filter:
"
Start the engine. Refer also to chapter: “Starting up” -- section:
“Starting the engine”.
"
Allow the engine to run for approximately 2 minutes, checking
for leaks from the oil drain plug and engine oil filter.
"
Check the engine oil pressure at the “Engine oil pressure” signal lamp.
"
Switch off the engine and check the oil level using the oil dipstick.
"
Top up the oil level as necessary.
"
Check the oil filter cartridge for leaks.
"
Seal up any leaks that occur.
WK44_059_1203GB
44-062
Maintenance Chart
44--062
Page 1 of 5
Checking and replacing hydraulic hoses
This maintenance chart describes how to inspect and replace the
hydraulic hoses.
You will find the maintenance intervals in the maintenance summary
at the start of this chapter.
Notes
Maintenance, inspection and servicing work poses a particular risk
of accident. Therefore always read the chapter “Safety regulations”
and the description “Other risks during maintenance work” at the beginning of the “Maintenance” chapter.
Refer also to the maintenance charts:
General maintenance work
Caution
Work on hydraulic equipment may only be carried out by persons
with special knowledge and experience in hydraulic systems,
who can provide appropriate certification of their expertise (training certificates).
Danger
Hydraulic hose lines must not be more than six years old, including
a storage period of two years. Take note of the date of manufacture
on the hydraulic hose lines.
Risk of burns from hot machine components.
Allow the subassemblies to cool down.
Ensure that all pressures in the hydraulic system and in the delivery
line have fallen to 0 bar.
Wear a face mask and gloves whenever you work on the hydraulic
system. Escaping oil is toxic and can penetrate the skin.
WK44_062_1203GB
8 — 39
Maintenance Chart
44--062
Page 2 of 5
Check for leaks
10400800
Damage to hydraulic hoses
Notes
Check all hydraulic hoses (including hose fittings) with the machine
switched off.
You must replace the hydraulic hoses at the slightest sign of damage
or even a mere indication threatening damage.
Dark and moist patches on the fitting are external signs of incipient
damage. Check:
-- the hydraulic hoses for kinks, cracks or a porous surface and
-- whether the hoses have been laid without restrictions.
Notes
Beware of strong sunlight, the action of heat and the effects of chemicals.
8 — 40
WK44_062_1203GB
Maintenance Chart
44--062
Page 3 of 5
Checking the flared
screwed joints
10400100
Tighten until there is a clearly perceptible increase in force
"
Check whether the flared screwed joints are tight.
Notes
You may only tighten leaking flared screwed joints with the permitted
tightening torque. Tighten the threaded union until you clearly feel
an increase in the force required if you do not have a torque wrench
available. You must replace these flared screwed joints if leaking
continues.
Flared screwed joints
Pipe outside Type Md [Nm]
diameter
Type Md [Nm]
6
L
20
16
S
130
8
L
40
18
L
120
10
L
45
20
S
250
L
55
25
S
400
S
80
30
S
500
L
70
38
S
800
12
15
WK44_062_1203GB
Pipe outside
diameter
8 — 41
Maintenance Chart
44--062
Page 4 of 5
Replacing hydraulic
hose lines
When replacing hydraulic hoses, proceed as follows:
Danger
Shut down the machine before starting work and secure it against
unauthorised or accidental starting.
Ensure that all pressures in the hydraulic system and in the delivery
line have fallen to 0 bar.
Hydraulic hoses may be mechanically prestressed. There is a risk of
injury from whipping hoses.
"
Relieve oil pressure completely.
Notes
Mark all hydraulic hoses and their corresponding connection points
for reassembly.
Environmental protection
Carefully collect escaping hydraulic fluid without fail and dispose of
in accordance with regulations! Guard against oil spillage. Biologically degradable hydraulic fluids must also be disposed of separately from other waste, just like mineral hydraulic fluids.
Comply with the relevant national and regional regulations.
Only work with waste disposal companies who are approved by
the responsible authorities.
8 — 42
"
Collect escaping hydraulic fluid in a suitable oil catch pan.
"
Take care when undoing the joints.
"
Close the connection points with a plug immediately after you
have removed the old hydraulic hoses. No dirt may enter the
hydraulic circuit and the hydraulic circuit must not be drained.
"
Dispose of the collected hydraulic fluid properly.
WK44_062_1203GB
Maintenance Chart
44--062
Page 5 of 5
Caution
Cleanliness is of the greatest possible importance in the maintenance of hydraulic systems. Ensure that dirt or other impurities cannot enter the hydraulic system. Even small particles may cause valves to be scored, pumps to seize and throttle and control bores to
become blocked. Never leave the reservoir lid open longer than necessary.
"
Make sure the hydraulic hoses are kept free of dirt at all times!
"
Fit the new hydraulic hoses without kinks or friction points!
Notes
Always tighten connections to the permitted tightening torque.
WK44_062_1203GB
"
Vent the hydraulic system.
"
Check the hydraulic functions in a series of test runs.
Check the hydraulic system for leaks and top up the hydraulic
fluid level as required.
"
Check all hydraulic hoses again!
"
Refit safety equipment and replace all markings and information plates.
8 — 43
Maintenance Chart
44--090
Page 1 of 3
44-090
Changing the coolant
This maintenance chart describes how to change the coolant.
You will find the maintenance intervals in the maintenance summary
at the start of this chapter.
Notes
Maintenance, inspection and servicing work poses a particular risk
of accident. Therefore always read the chapter “Safety regulations”
and the description “Other risks during maintenance work” at the beginning of the “Maintenance” chapter.
Refer also to the maintenance charts:
General maintenance tasks
Antifreeze protection for the radiator
Cleaning the cooling fins on the radiator
Notes
See also the documentation provided by the engine manufacturer
for information on maintenance and antifreeze protection for the cooling system as well as fluid capacities.
Change the coolant with the machine horizontal and supported.
Caution
Use only coolants and antifreezes specified by the engine manufacturer.
If there is inadequate antifreeze, the engine, radiator and/or lines
may burst in freezing conditions.
Danger
Change or add coolant only when the machine is at a standstill.
Open the cap on the expansion tank only when the engine has cooled.
There is a risk of burning. Work with protective gloves.
8 — 44
WK44_090_1203GB
Maintenance Chart
44--090
Page 2 of 3
Environmental protection
Carefully collect the escaping coolant and keep it separate from
other waste.
Dispose of all components in accordance with current applicable
regulations!
Comply with the relevant national and regional regulations.
Only work with waste disposal companies who are approved by
the responsible authorities.
The following steps describe how to change the coolant:
"
Place a sufficiently large catch pan under the machine.
"
Always take care when collecting escaping coolant.
"
Replace the coolant. Refer also to the documentation provided by the engine manufacturer.
"
When preparing coolant, observe the specifications regarding
antifreeze protection. Always add antifreeze in the correct ratio.
Refer also to the documentation provided by the engine manufacturer.
Maintenance chart: Antifreeze protection for the radiator
Refer also to chapter: “General Technical Description” -- section:
“Technical data” for more information on fluid capacities.
Caution
The capacities are only approximate values and may vary depending on the design and quantity remaining. The upper fill level mark
is always decisive.
"
WK44_090_1203GB
Dispose of the used coolant according to regulations.
8 — 45
Maintenance Chart
44--090
Page 3 of 3
Check for leaks
The following checks are necessary after the coolant has been changed:
"
Start the engine. Refer also to chapter: “Starting up” -- section:
“Starting the engine”.
"
Leave the engine to run for approximately 2 minutes, checking
for leaks from the cooling system.
"
Switch off the engine and check the coolant level at the expansion tank.
"
Top up the coolant level if necessary.
"
Seal up any leaks that occur.
"
Check the radiator for contaminant deposits and remove them
if necessary.
Maintenance chart: Cleaning the cooling fins on the radiator
8 — 46
WK44_090_1203GB
44-092
Maintenance Chart
44--092
Page 1 of 5
Changing the hydraulic fluid
This maintenance chart describes how to change the hydraulic fluid.
You will find the maintenance intervals in the maintenance summary
at the start of this chapter.
Notes
Maintenance, inspection and servicing work poses a particular risk
of accident. Therefore always read the chapter “Safety regulations”
and the description “Other risks during maintenance work” at the beginning of the “Maintenance” chapter.
Refer also to the maintenance charts:
General maintenance tasks
Changing the hydraulic filter
Checking and replacing hydraulic hoses
Notes
Change the hydraulic fluid with the machine at service temperature.
It is practical to change the hydraulic fluid and hydraulic filter at the
same time.
Change the hydraulic fluid with the machine horizontal and supported.
WK44_092_1204GB
8 — 47
Maintenance Chart
44--092
Page 2 of 5
Caution
Work on hydraulic equipment may only be carried out by persons
with special knowledge and experience in hydraulic systems,
who can provide appropriate certification of their expertise (training certificates).
Cleanliness is of the greatest possible importance in the maintenance of hydraulic systems. Ensure that dirt or other impurities cannot enter the hydraulic system. Even small particles may cause valves to be scored, pumps to seize and throttle and control bores to
become blocked.
Never leave the hydraulic fluid reservoir open longer than necessary!
Clean bungs, filler lids and the area around them before changing
oil.
Check all seals and replace if damaged.
Wear a face mask and gloves whenever you work on the hydraulic
system. Escaping fluid is toxic and can penetrate the skin.
Danger
Change the hydraulic fluid only with the machine at a standstill and
the hydraulic system depressurised! Ensure that all pressures have
fallen to 0 bar. Only open the plug screw once pressure has been
fully dumped.
Take care when changing the filter and draining hot oil.
There is a risk of burning.
8 — 48
WK44_092_1204GB
Maintenance Chart
44--092
Page 3 of 5
Environmental protection
Collect the old hydraulic fluid and dispose of it in accordance with
the local specifications. Guard against oil spillage. Separate the collected hydraulic fluid and the used filter inserts from other waste.
Dispose of all components in accordance with current applicable
regulations!
Comply with the relevant national and regional regulations.
Only work with waste disposal companies who are approved by
the responsible authorities.
The hydraulic fluid reservoir is located under the hood in the engine
compartment.
The following steps describe how to change the hydraulic fluid:
Place a sufficiently large oil catch pan under the machine.
"
7
6
1
5
4
Item
WK44_092_1204GB
3
2
Designation
1
Hydraulic fluid reservoir
2
Oil drain plug
3
Screw plug
4
Dirt trap
5
Fill level indicator
6
Oil filler
7
Cover for oil filler pipe
"
Carefully unscrew the oil drain plug on the hydraulic fluid reservoir and drain the old fluid into the oil catch pan.
"
In addition, you can turn the cap on the oil filler pipe to open it
slightly so that the hydraulic fluid can drain faster.
8 — 49
Maintenance Chart
44--092
Page 4 of 5
"
Insert the oil drain plug again with a new seal ring and tighten.
"
Dispose of the old oil in accordance with regulations.
"
Remove the screw plug from the dirt trap.
"
Remove the screen from the dirt trap and clean thoroughly
(e.g. using benzene).
"
Insert the screen in the dirt trap again.
"
Screw the screw plug back onto the dirt trap.
"
Change the hydraulic filter.
Maintenance chart: Changing the hydraulic filter
Notes
Only fill the hydraulic fluid reservoir through the filling screen in the
filler pipe.
Only fill the reservoir to the “Maximum” mark in the fill level indicator.
Use only the hydraulic fluids oils specified in the lubricant recommendation.
"
Refill the hydraulic fluid reservoir through the filling screen in
the oil filler.
Refer also to chapter: “General Technical Description” -- section:
“Technical data” for more information on fluid capacities.
Caution
The capacities are only approximate values and may vary depending on the model and quantity of oil remaining. The upper mark on
the fill level indicator is always decisive.
8 — 50
WK44_092_1204GB
Maintenance Chart
44--092
Page 5 of 5
"
Check the hydraulic fluid level at the fill level indicator for the
hydraulic fluid reservoir.
"
Check all lines and threaded unions, tightening where necessary. Check the flared screwed joints. Replace any defective
hydraulic hoses.
Maintenance chart: Checking and replacing hydraulic hoses
WK44_092_1204GB
"
Refit safety equipment and replace all markings and information plates.
"
Carry out all function checks.
"
Check the hydraulic functions with a series of test runs,
check the system for leaks and top up the hydraulic fluid level
as necessary.
8 — 51
Maintenance Chart
44--093
Page 1 of 4
44-093
Changing the hydraulic filter
This maintenance chart describes how to change the hydraulic filter.
You will find the maintenance intervals in the maintenance summary
at the start of this chapter.
Notes
Maintenance, inspection and servicing work poses a particular risk
of accident. Therefore always read the chapter “Safety regulations”
and the description “Other risks during maintenance work” at the beginning of the “Maintenance” chapter.
Refer also to the maintenance charts:
General maintenance work
Notes
Change the hydraulic fluid filter with the machine at service temperature.
It is practical to change the hydraulic fluid and hydraulic filter at the
same time.
Caution
Work on hydraulic equipment may only be carried out by persons
with special knowledge and experience in hydraulic systems,
who can provide appropriate certification of their expertise (training certificates).
Cleanliness is of the greatest possible importance in the maintenance of hydraulic systems. Ensure that dirt or other impurities cannot enter the hydraulic system. Even small particles may cause valves to be scored, pumps to seize and throttle and control bores to
become blocked.
Never leave the hydraulic fluid reservoir open longer than necessary!
Clean bungs, filler lids and the area around them before changing
filters.
Check all seals and replace if damaged.
8 — 52
WK44_093_1204GB
Maintenance Chart
44--093
Page 2 of 4
Wear a face mask and gloves whenever you work on the hydraulic
system. Escaping oil is toxic and can penetrate the skin.
Danger
Change the hydraulic fluid filter only with the machine at a standstill
and the hydraulic system depressurised! Ensure that all pressures
have fallen to 0 bar. Only open the plug screw once pressure has
been fully dumped.
Take care when changing the filter and draining hot oil.
There is a risk of burning.
Environmental protection
Always take care when collecting the old hydraulic fluid.
Guard against oil spillage. Separate the collected hydraulic fluid
and the used filter inserts from other waste.
Dispose of all components in accordance with current applicable
regulations!
Comply with the relevant national and regional regulations.
Only work with waste disposal companies who are approved by
the responsible authorities.
WK44_093_1204GB
8 — 53
Maintenance Chart
44--093
Page 3 of 4
Changing the return line
suction filter
The return line suction filter is located on the hydraulic fluid reservoir.
Replace the filter cartridge on the return line suction filter when the
contamination indicator shows.
Change the return line suction filter as follows:
1
2
3
4
5
Item
8 — 54
Designation
1
Hydraulic fluid reservoir
2
Return line suction filter
3
Cover
4
Contamination indicator sensor
5
Filter cartridge (case with filter insert)
"
Place an oil catch pan of sufficient size in position.
"
Unscrew the cover (4) from the return line suction filter (2).
"
Remove the complete filter cartridge (5).
"
Allow the hydraulic fluid to drain from the filter cartridge into the
catch pan. Always take care when collecting the old hydraulic
fluid.
WK44_093_1204GB
Maintenance Chart
44--093
Page 4 of 4
"
Remove the filter insert from the case.
"
Dispose of the old filter insert and the drained hydraulic fluid
in accordance with local specifications.
Caution
You must never attempt to clean filter inserts. You must always replace them.
Before you fit the new hydraulic filter, you must check all O-rings
and other seals on the filter inserts and replace them if damaged.
WK44_093_1204GB
"
Clean the case thoroughly.
"
Check all O-rings and other sealing elements. Replace them if
damaged.
"
Insert the new filter insert in the case.
"
Insert the complete filter cartridge into the return line suction
filter.
"
Screw the cover back onto the return line suction filter.
"
Refit safety equipment and replace all markings and information plates.
"
Carry out all function checks.
"
Check the hydraulic functions with a series of test runs,
check the system for leaks and top up the hydraulic fluid level
as necessary.
8 — 55
Maintenance Chart
44--095
Page 1 of 2
44-09Antifreeze
5
protection for the radiator
This maintenance chart describes antifreeze protection for the radiator.
If there is a danger of frost, you should check that there is sufficient
antifreeze in the coolant and top up if necessary.
For all water-cooled engines, antifreeze with Putzmeister item number 273563002 is used ex works in a mixing ratio of 50 % potable
water. This produces antifreeze protection up to --35 °C.
You will find the maintenance intervals in the maintenance summary
at the start of this chapter.
Notes
Maintenance, inspection and servicing work poses a particular risk
of accident. Therefore always read the chapter “Safety regulations”
and the description “Other risks during maintenance work” at the beginning of the “Maintenance” chapter.
Refer also to the maintenance charts:
General maintenance tasks
Changing the coolant
The following special tool is required:
Antifreeze tester
Notes
See also the documentation provided by the engine manufacturer for
information on maintenance and antifreeze protection for the cooling
system as well as fluid capacities.
8 — 56
WK44_095_1203GB
Maintenance Chart
44--095
Page 2 of 2
Caution
Use only coolants and antifreezes specified by the engine manufacturer.
If there is inadequate antifreeze, the engine, radiator and/or lines
may burst in freezing conditions.
Danger
Change or add coolant only when the machine is at a standstill.
Open the cap on the expansion tank only when the engine has cooled.
There is a risk of burning. Work with protective gloves.
Mixing different types of antifreeze may generate hazardous materials! Refer also to the documentation provided by the engine manufacturer.
The following steps describe the antifreeze protection measures:
"
Open the cap on the expansion tank.
"
Check the antifreeze content using the antifreeze tester.
"
Top up the antifreeze if necessary.
Maintenance chart: Changing the coolant
Notes
It is practical to add antifreeze when changing the coolant.
Only fill the expansion tank to the “Maximum” mark on the fill level
indicator.
"
WK44_095_1203GB
Close the cap on the expansion tank again.
8 — 57
Maintenance Chart
44--096
Page 1 of 3
44-096
Cleaning and changing the dry air filter
This maintenance chart describes how to clean the dry air filter and
replace the filter inserts.
You will find the maintenance intervals in the maintenance summary
at the start of this chapter.
Notes
Maintenance, inspection and servicing work poses a particular risk
of accident. Therefore always read the chapter “Safety regulations”
and the description “Other risks during maintenance work” at the beginning of the “Maintenance” chapter.
Refer also to the maintenance charts:
General maintenance work
Danger
Wear respiratory protection and protective goggles to protect
against particles of dust!
Risk of burning from hot engine components. Allow the subassemblies to cool down.Work with protective gloves.
8 — 58
WK44_096_1203GB
Maintenance Chart
44--096
Page 2 of 3
Cleaning and changing
filter element
The following steps describe how to clean and change the filter element:
"
Open the retaining clips and fold them out of the way.
"
Remove the filter cover.
"
Pull the filter insert carefully from the filter housing.
Avoid disturbing dust where possible.
Notes
Never clean with oil, petrol or other flammable liquids or solvents.
"
Clean the inside of the filter housing and cover with a clean
cloth. Pay particular attention to cleaning the sealing surfaces.
"
Inspect the filter element.If it is damaged, check all dry air filter
connections and replace any damaged parts. A damaged filter
element must be replaced and not reinstalled!
Face-mask and respiratory protector
A face-mask and respiratory protector protect you against particles
of dust entering your body through your respiratory passages.
"
Replace the filter cover on the filter housing to protect the air
intake system during cleaning.
"
Clean the filter element by blasting dry air along the folds from
the inside to the outside.
Notes
When blowing out, the air pressure must not exceed 5 bar.
The filter element must not be damaged. A suitable distance must
be maintained between hose nozzle and filter element.
"
WK44_096_1203GB
Record the cleaning date on the filter element so that you have
documentation of the number of cleaning procedures carried
out.
8 — 59
Maintenance Chart
44--096
Page 3 of 3
Notes
Filter inserts should be replaced after the third time of cleaning,
or annually, depending on the degree of contamination.
Cleaning the dust discharge valve
8 — 60
"
Place the cleaned or new filter element in the filter housing.
"
Slide the filter lid back onto the casing. Ensure that it is correctly seated.
"
Close the retaining clips. Ensure that the clips are also correctly seated.
"
Reset the relevant air filter maintenance indicator after cleaning
or changing the air filter insert by pressing the Reset button.
Clean the dust discharge valve as follows:
"
Empty the dust discharge valve by pressing the discharge slot
in direction of the arrow.
"
Clean the discharge slot.
"
Removing any dust caking by pressing the upper valve area.
WK44_096_1203GB
44-137
Maintenance Chart
44--137
Page 1 of 3
Cleaning the radiator
This maintenance chart describes how to clean the radiator. The air
side of the radiator can become clogged if the unit is operating in
dusty conditions.Consequently, it is important to clean the cooling
fins in the radiator at regular intervals.
You will find the maintenance intervals in the maintenance summary
at the start of this chapter.
Notes
Maintenance, inspection and servicing work poses a particular risk
of accident. Therefore always read the chapter “Safety regulations”
and the description “Other risks during maintenance work” at the beginning of the “Maintenance” chapter.
Refer also to the maintenance charts:
General maintenance work
Caution
Do not use diesel fuel for cleaning purposes. Diesel fuel attacks rubber parts and encourages dust deposits in the cooling fins.
Do not use high-pressure cleaners. The cooling fins could be bent
by the high pressure jet.
Danger
Never clean the radiator when at operating temperature.
There is a risk of burning.
Always carry out cleaning work when the machine is cold.
Wear respiratory protection and protective goggles to protect
against particles of dust!
WK44_137_1203GB
8 — 61
Maintenance Chart
44--137
Page 2 of 3
"
Brush off light dirt with a soft brush or paint brush on the air
side.
If they are badly clogged, wash out the cooling fins and dry them
with compressed air.
Caution
Prior to cleaning with water or other cleaning agents, cover or seal
all openings which water or cleaning agents must not penetrate for
safety or operating reasons. Electric motors and switch cabinets are
particularly at risk.
Completely remove the covers / seals after the cleaning process!
No water into electric systems
8 — 62
"
Remove all electrical components such as fans (if fitted).
"
Attach all necessary covers/seals.
WK44_137_1203GB
Maintenance Chart
44--137
Page 3 of 3
Notes
Use a water hose with the correct nozzle to clean the radiator against
the air flow. A line pressure of 4 bar is sufficient for this purpose.
Where possible, always direct the water jet in the direction of the
cooling fins.
A cold cleaner can be used.
You may use a paint brush or soft brush in addition to the water jet
if the dirt is difficult to shift.
Please also ensure that the cooling fins are not damaged while doing this.
Spray the radiator down with a water jet
WK44_137_1203GB
"
In case of heavy contamination, wash out the cooling fins
against the air flow.
"
Then dry the cooling fins with compressed air.
"
Completely remove all covers / seals after the cleaning process!
"
Refit all dismantled electrical components such as fans (if fitted).
8 — 63
Maintenance Chart
44--138
Page 1 of 2
44-138
Checking the V-belt
This maintenance chart describes how to check the V-belt.
You will find the maintenance intervals in the maintenance summary
at the start of this chapter.
Notes
Maintenance, inspection and servicing work poses a particular risk
of accident. Therefore always read the chapter “Safety regulations”
and the description “Other risks during maintenance work” at the beginning of the “Maintenance” chapter.
Refer also to the maintenance charts:
General maintenance work
No special tools required.
Notes
See also the engine manufacturer’s operating instructions for chekking the V-belt.
Caution
Maintenance work on the engine should only be carried out by a service engineer from Putzmeister Mörtelmaschinen GmbH, or by a
specialised dealer authorised by Putzmeister Mörtelmaschinen
GmbH.
Danger
Risk of burning from hot engine components. Allow the subassemblies to cool down. Work with protective gloves.
8 — 64
WK44_138_1203GB
Maintenance Chart
44--138
Page 2 of 2
Checking the V-belt
Check V-belt tension
WK44_138_1203GB
"
Check the V-belt tension by pressing with your thumb.
The V-belt must be retightened if it can be pressed in more
than 8 mm.
"
Have the V-belt tightened or replaced if necessary.
"
Check the V-belt for damage or wear and have replaced if necessary.
8 — 65
Maintenance Chart
44--140
Page 1 of 5
44-140
Fuel filter
This maintenance chart describes how to change and drain the fuel
filter.
You will find the maintenance intervals in the maintenance summary
at the start of this chapter.
Notes
Maintenance, inspection and servicing work poses a particular risk
of accident. Therefore always read the chapter “Safety regulations”
and the description “Other risks during maintenance work” at the beginning of the “Maintenance” chapter.
Refer also to the maintenance charts:
General maintenance work
The following special tool is required:
Filter wrench
Notes
For changing the fuel filter, see also the engine manufacturer’s documentation.
Use only original spare parts. Putzmeister Mörtelmaschinen GmbH
accepts no liability for damage caused as a result of using non-original spare parts.
Caution
Ensure that dirt or other impurities cannot enter the fuel system.
8 — 66
WK44_140_1203GB
Maintenance Chart
44--140
Page 2 of 5
Danger
Avoid fire and naked flame when changing the fuel filter. There is
a danger of fire.
Take care when changing the fuel filter. There is a risk of burning.
Work with protective gloves.
Environmental protection
Collect escaping fuel and avoid the fuel spillage.
Dispose of fuel and used filter cartridges according to regulations.
Comply with the relevant national and regional regulations.
Only work with waste disposal companies who are approved by
the responsible authorities.
Changing the fuel filter
Several fuel filters may be available depending on the design.
1
2
3
Different models available
Item
WK44_140_1203GB
Designation
1
Fuel filter
2
Filter head
3
Filter cartridge
8 — 67
Maintenance Chart
44--140
Page 3 of 5
Change the fuel filter as follows:
Changing the fuel line
filter
"
Close the fuel cock (if available).
"
Place a suitable oil sump pan under the fuel filter.
"
Unscrew the filter cartridge (3) using a filter wrench.
"
Collect the fuel from the filter and dispose of the filter cartridge
according to regulations.
"
Clean the sealing surface on the filter head (2) with a lint-free
cloth.
"
Lightly oil the sealing surface on the filter head and the seal on
the new filter cartridge with engine oil.
"
Screw on the new oil filter cartridge by hand until the seal is in
position.
"
Tighten the filter cartridge by a further half rotation.
"
Open the fuel cock (if available).
There is one filter in the engine fuel line depending on the model.
1
2
Different models available
Item
8 — 68
Designation
1
Fuel line filter (depending on model)
2
Hose clamp
WK44_140_1203GB
Maintenance Chart
44--140
Page 4 of 5
Change the fuel filter as follows:
"
Close the fuel cock (if available).
"
Place a suitable oil sump pan under the fuel line filter.
"
Loosen the hose clamps (2) upstream and downstream of
the fuel line filter (1).
Notes
Raise the ends of the hoses to prevent fuel from running out.
Checking for leaks
WK44_140_1203GB
"
Pull the fuel line filter from the hoses.
"
Collect the escaping fuel and dispose of the fuel line filter according to regulations.
"
Attach the new fuel line filter to the hoses. Pay attention to the
flow direction.
"
Tighten the hose clamps again.
"
Open the fuel cock (if available).
The following checks are necessary after you have changed the
fuel filter:
"
Start the engine. Refer also to chapter: “Starting up” -- section:
“Starting the engine”.
"
Leave the machine to run for approx. 2 minutes.
"
Then inspect all new fuel filters and fuel systems for leaks.
"
Seal up any leaks that occur.
8 — 69
Maintenance Chart
44--140
Page 5 of 5
Draining water from the
fuel filter
Several fuel filters may be available depending on the design.
1
2
3
Different models available
Item
Designation
1
Fuel filter
2
Filter cartridge
3
Drain plug
Drain water from the fuel filter as follows:
8 — 70
"
Hold a suitable container under the drain plug (3) on the fuel
filter.
"
Open the drain plug and drain the water out until fuel escapes.
"
Close the drain plug again.
"
Comply with regulations when disposing of the water and fuel
mixture.
WK44_140_1203GB
46-027
Maintenance Chart
46--027
Page 1 of 5
Disassembly and assembly of the auger pump
This maintenance chart describes how to replace the auger pump.
You will find the maintenance intervals in the maintenance summary
at the start of this chapter.
Notes
Maintenance, inspection and servicing work poses a particular risk
of accident. Therefore always read the chapter “Safety regulations”
and the description “Other risks during maintenance work” at the beginning of the “Maintenance” chapter.
Refer also to the maintenance charts:
Replace the screw conveyor.
Notes
You must replace the wear parts if wear is identified during a visual inspection or if there is inadequate pressure build-up in the delivery line.
WK46_027_1203GB
8 — 71
Maintenance Chart
46--027
Page 2 of 5
Disassembling the auger pump
1
2
4
8 — 72
Item
Designation
1
Clamping nut
2
Pressure connection
3
Tie bolt
4
Auger pump
3
"
Unscrew the clamping nuts (1) on the tie bolt (3).
"
Pull off the pressure connection (2).
WK46_027_1203GB
Maintenance Chart
46--027
Page 3 of 5
2
1
2
3
Item
Designation
1
Auger pump
2
Through bolts
3
Cardan shaft
"
Unscrew the through bolts (2) from the Cardan shaft (3).
"
Pull the auger pump (1) from the hopper.
Notes
Replace the screw conveyor barrel and/or the screw conveyor with
a new unit, if there is wear.
WK46_027_1203GB
8 — 73
Maintenance Chart
46--027
Page 4 of 5
Assembling the auger pump
4
2
3
1
Item
8 — 74
Designation
1
O-ring
2
Spacer ring
3
Auger pump
4
Pressure connection
"
Clean the O-ring (1) as required, replace if worn.
"
Grease the O-ring (1) slightly before placing in the spacer
ring (2) and then insert both into the side of the hopper.
"
Insert the auger pump (3) into the spacer ring (2), then slide
the pressure connection (4) onto the tie bolt and the auger
pump (3) and align.
WK46_027_1203GB
Maintenance Chart
46--027
Page 5 of 5
2
1
2
3
Item
Designation
1
Auger pump
2
Through bolts
3
Cardan shaft
Fit the Cardan shaft (3) and auger pump (1) together and secure with the through bolts (2).
"
Caution
Only use new self-locking hexagon nuts.
1
Item
"
WK46_027_1203GB
2
Designation
1
Washer
2
Clamping nut
Place the washers (1) onto the tie bolts and screw on the clamping nuts (2), tightening the whole unit evenly.
8 — 75
Maintenance Chart
46--028
Page 1 of 3
46-02Adjusting
8
the auger pump
This maintenance chart describes how to adjust the auger pump.
You will find the maintenance intervals in the maintenance summary
at the start of this chapter.
Notes
Maintenance, inspection and servicing work poses a particular risk
of accident. Therefore always read the chapter “Safety regulations”
and the description “Other risks during maintenance work” at the beginning of the “Maintenance” chapter.
Refer also to the maintenance charts:
Disassembly and assembly of the auger pump
Replacingthe the screw conveyor
The following special tool is required:
Checking gauge, Putzmeister Art. No. 208745.002
The performance of the auger pump is checked by means of water
pressure with the machine running.
8 — 76
"
Check whether the drain connection on the hopper is closed.
"
Fill the hopper with water.
WK46_028_1203GB
Maintenance Chart
46--028
Page 2 of 3
1
3
2
4
5
Item
Designation
1
Pressure gauge
2
Pressure connection
3
Delivery line
4
Checking gauge
5
Shut-off valve
"
Connect a delivery line (3) to the pressure connection (2).
"
Connect the checking gauge (4) to the end of the delivery line.
"
Switch the machine on.
"
Start operating the pump.
"
Slowly close the shut-off valve (5) on the checking gauge (4).
⇒ Note that the pressure will increase.
Notes
If water pressure of approx. 20 bar is not reached at the checking
gauge, increase the tension of the clamping sheath.
WK46_028_1203GB
8 — 77
Maintenance Chart
46--028
Page 3 of 3
1
2
Item
"
Designation
1
Clamping sheath
2
Clamping bolt
By tightening the clamping bolts (2) evenly, you increase the
pretensioning.
⇒ The pressure increases.
Caution
If the clamping sheath (1) is tightened excessively, increased wear
to the auger parts may result.
Pretension the clamping sheat only enough to achieve the required
pressure.
If the required pressure cannot be achieved even at high pretension,
you must dismantle the auger pump and check it for wear.
Notes
Repeat the test procedure to achieve an accurate measured result.
8 — 78
"
Switch off the machine.
"
Release the water pressure on the checking gauge.
"
Disconnect the checking gauge.
WK46_028_1203GB
Maintenance Chart
46--030
Page 1 of 2
46-030
Replacing the screw conveyor
This maintenance chart describes how to replace the screw conveyor.
You will find the maintenance intervals in the maintenance summary
at the start of this chapter.
Notes
Maintenance, inspection and servicing work poses a particular risk
of accident. Therefore always read the chapter “Safety regulations”
and the description “Other risks during maintenance work” at the beginning of the “Maintenance” chapter.
Refer also to the maintenance charts:
Disassembling and assembling the auger pump
Notes
Only use genuine Putzmeister replacement parts.
34000300
Use original spare parts marked with the Putzmeister logo.
WK46_030_1204GB
8 — 79
Maintenance Chart
46--030
Page 2 of 2
1
4
2
3
Item
Designation
1
Clamping sheath bolts
2
Screw conveyor barrel
3
Screw conveyor
4
Clamping sheath
"
Unscrew all clamping sheath bolts (1) and remove the auger
barrel (2) and auger (3) from the clamping sheath (4).
"
Clamp the screw conveyor barrel (2) and remove the auger (3)
by rotating it anti-clockwise.
"
Spray the new screw conveyor (3) with Putzmeister silicone
spray.
"
Insert the screw conveyor (3) into the clamped screw conveyor
barrel (2) rotating it clockwise.
"
Line up the end of the screw conveyor (3) and the screw conveyor barrel (2) so that they are flush.
Caution
The screw conveyor should be treated with Putzmeister silicone
spray only prior to assembly.
Do not use used oil. Used oil corrodes the rubber.
8 — 80
WK46_030_1204GB
52-008
Maintenance Chart
52--008
Page 1 of 2
High-pressure cleaner
This maintenance chart describes how to check the fluid level on the
high-pressure cleaner.
You will find the maintenance intervals in the maintenance summary
at the start of this chapter.
Notes
Maintenance, inspection and servicing work poses a particular risk
of accident. Therefore always read the chapter “Safety regulations”
and the description “Other risks during maintenance work” at the beginning of the “Maintenance” chapter.
Refer also to the maintenance charts:
General maintenance tasks
High-pressure cleaner antifreeze protection measures
Fluid level check
The high-pressure cleaner is located under the hood in the engine
compartment.
Check the fluid level as follows:
1
2
3
Different models available
Item
"
WK52_008_1203GB
Designation
1
High-pressure cleaner
2
Inspection glass
3
Bleed connection
Check the fluid level for the high-pressure cleaner (1) at the
inspection glass (2) and top up fluid if necessary.
8 — 81
Maintenance Chart
52--008
Page 2 of 2
Top up fluid
Top up the fluid as follows:
"
Open the bleed connection.
Notes
Ensure that dirt or other impurities cannot enter the high-pressure
cleaner.
Top up the fluid level of the high-pressure cleaner to the middle of
the inspection glass.
Caution
The high-pressure cleaner requires a year-round high-pressure multigrade oil SAE 20W-30.
8 — 82
"
Now add new fluid through the bleed connection until the required fluid level has been reached.
"
Close the bleed connection securely.
WK52_008_1203GB
52-010
Maintenance Chart
52--010
Page 1 of 3
Water supply fitting antifreeze protection
This maintenance chart describes antifreeze protection measures
for the water supply fitting.
You will find the maintenance intervals in the maintenance summary
at the start of this chapter.
Notes
Maintenance, inspection and servicing work poses a particular risk
of accident. Therefore always read the chapter “Safety regulations”
and the description “Other risks during maintenance work” at the beginning of the “Maintenance” chapter.
Refer also to the maintenance charts:
General maintenance tasks
High-pressure cleaner antifreeze protection measures
Freezing temperatures can cause the water in the water supply fitting
and lines to freeze and result in components bursting.
Caution
The machine and lines must be drained fully of residual water if
there is a risk of freezing.
Only operate and store the machine in a frost-free location.
The following steps describe the antifreeze protection measures:
"
Add antifreeze to the high-pressure cleaner.
Maintenance chart: High-pressure cleaner antifreeze protection
WK52_010_1204GB
8 — 83
Maintenance Chart
52--010
Page 2 of 3
4
1
2
3
5
6
8
9
Item
8 — 84
7
Designation
1
Water supply fitting
2
Water meter
3
Ball valve
4
Air valve
5
Water inlet connection
6
Air hose
7
High-pressure cleaner connector
8
High-pressure hose
9
Cleaning gun
"
Attach the air hose (6) to the water inlet connector (5).
"
Attach the high-pressure cleaner connector (7).
WK52_010_1204GB
Maintenance Chart
52--010
Page 3 of 3
"
Start the engine. Refer also to chapter: “Starting up” -- section: “Starting the engine”.
"
Set the water quantity (approx. 30 l) on the water meter (2).
Caution
The water meter setting must be higher than 0. Otherwise the water
supply fitting may become damaged.
WK52_010_1204GB
"
Open the air valve (4) on the air valve fitting.
"
Open the ball valve (3) on the water supply fitting and leave
open until water stops flowing from the water sprinkler into the
mixer drum.
"
Close the ball valve on the water supply fitting.
"
Close the air valve on the air valve fitting.
"
Connect the high-pressure hose (8) to the cleaning gun (9).
"
Connect the high-pressure hose to the high-pressure cleaner
connector (7).
"
Open the air valve on the air valve fitting.
"
Open the cleaning gun and keep it open until water no longer
escapes from the spray nozzle.
"
Close the air valve on the air valve fitting.
"
Detach the air hose from the water inlet connector.
"
Switch off the machine. Refer also to chapter “Starting up” -section “Shutting down the machine after initial operation”.
8 — 85
Maintenance Chart
52--026
Page 1 of 4
52-02High-pressure
6
cleaner antifreeze protection measures
This maintenance chart describes antifreeze protection measures for
high-pressure cleaners.
You will find the maintenance intervals in the maintenance summary
at the start of this chapter.
Notes
Maintenance, inspection and servicing work poses a particular risk
of accident. Therefore always read the chapter “Safety regulations”
and the description “Other risks during maintenance work” at the beginning of the “Maintenance” chapter.
Refer also to the maintenance charts:
General maintenance tasks
High-pressure cleaner
Freezing temperatures can cause the water in the high-pressure
cleaner and lines to freeze and result in components bursting.
Caution
The machine and lines must be drained fully of residual water
if there is a risk of freezing.
Only operate and store the machine in a frost-free location.
8 — 86
WK52_026_1204GB
Maintenance Chart
52--026
Page 2 of 4
The following steps describe the antifreeze protection measures:
1
Item
1
"
Designation
“High-pressure cleaner ON / OFF” rocker switch
Switch off the high-pressure cleaner using the “High-pressure
cleaner ON / OFF” (1) rocker switch.
⇒ The high-pressure cleaner is switched off.
Caution
After cleaning with the high-pressure cleaner, you have to select
the mixer unit again.
Otherwise the mixer unit will not function when the machine is operated again.
WK52_026_1204GB
"
Shut off the water supply.
"
Disconnect the water supply line.
8 — 87
Maintenance Chart
52--026
Page 3 of 4
3
1
2
4
5
7
8
Item
8 — 88
6
Designation
1
High-pressure cleaner
2
Ball valve
3
Air valve
4
Water inlet connection
5
Air hose
6
High-pressure cleaner connector
7
High-pressure hose
8
Cleaning gun
WK52_026_1204GB
Maintenance Chart
52--026
Page 4 of 4
"
Attach the air hose (5) to the water inlet connector (4).
"
Connect the high-pressure hose (7) to the cleaning gun (8).
"
Connect the high-pressure hose to the high-pressure cleaner
connector (6).
"
Start the engine. Refer also to chapter: “Starting up” -- section: “Starting the engine”.
"
Open the air valve (3) on the air valve fitting.
"
Actuate the cleaning gun (8) and release only when water
stops escaping from the spray nozzle.
"
Switch off the machine. Refer also to chapter “Starting up” -section “Shutting down the machine after initial operation”.
"
Close the air valve on the air valve fitting.
"
Detach the air hose from the water inlet connector.
"
Open the ball valve (2) on the high-pressure cleaner (1).
Caution
Close the ball valves before starting the machine again.
WK52_026_1204GB
8 — 89
Decommissioning
9
Decommissioning
This chapter contains information on decommissioning the machine.
9.1 Temporary decommissioning
If the machine is to be shut down temporarily, take the following measures.
"
Stop material feed.
"
Pump the hopper empty.
"
Allow the machine to pump in reverse for a short time and disconnect the delivery line.
Danger
You should only uncouple the delivery line when you have checked
on the pressure gauge that the system is fully depressurised.
You must wear protective goggles.
Turn your face away when opening the line coupling.
"
Switch off the machine as described in the chapter ”Shutting
down the machine after operation”.
"
Clean the machine as described in the chapter ”Cleaning the
machine”.
"
Shut down the machine only in current-free condition.
Continuation next side
10_0013_0511GB
9—1
Decommissioning
Shutting the machine
down
If you wish to take the drive motor out of service or place in storage,
it must be greased and preserved as necessary.
Notes
Preservation and greasing the machine prevents corrosion and premature ageing. It is necessary, if the machine:
– is not used for longer periods;
– is exposed to corrosive atmospheres during storage or transportation.
Filling up the fuel tank
"
Lubricate the machine as described in the Lubrication diagram.
"
Shut down the machine only in current-free condition.
"
Protect the machine with a suitable agent.
Fill up the fuel tank when work is completed. This prevents excessive
condensation building up in the tank.
Notes
Never fill the reservoir beyond the ”Filling” mark. This prevents fuel
from emerging from the reservoir due to heating or inclination.
Never allow the fuel tank to run completely empty.
Danger
No smoking is allowed when you are filling up!
Never fill the fuel tank near naked flames or ignitable sparks.
Ensure that no fuel spills onto hot machine parts while you are filling
up. There is a risk of the fuel igniting!
Frost protection
The machine must be drained fully of residual water if there is a risk
of freezing.
Caution
The machine must be drained fully of residual water if there is a risk
of freezing.
9—2
10_0013_0511GB
Decommissioning
9.2 Final decommissioning, disposal
The final decommissioning and disposal requires complete disassembly of the machine into its individual components.
When disposing of all machine components, ensure that there is no
possibility of damage to health or the environment.
Environmental protection
Final disposal of the machine is carried out by a qualified specialist
company.
Danger
When decommissioning the machine permanently, escaping lubricants, solvents, preserving agents, etc. may pose a risk of injury.
They can cause chemical burns in the event of direct skin contact.
Risk of injury at sharp-edged machine components.
Continuation next side
10_0014_0512GB
9—3
Decommissioning
Material used
The main materials used for machine construction were:
Material
Use for / in
Copper
-- Cables
-- Machine frame
-- Mixing hopper parts
-- Hopper parts
Steel
-- Pump units
-- Compressor components
-- Air valve components
-- Gaskets
Plastic, rubber, PVC
-- Hoses
-- Cables
-- Wheels
Parts requiring separate
disposal
Tin
-- PCBs
Polyester
-- PCBs
The following components and working materials must be separated
prior to disposal:
Designation
Applies to ....
-- Electrical supply
Electronic scrap
-- PCBs with electrical
components
-- High-pressure cleaner
-- Hydraulic pump
Oil
-- Hydraulic motor
-- Drive motor
-- Compressor
9—4
10_0014_0512GB
Appendix
10 Appendix
10.1 General tightening
torques
Tightening torques depend on bolt grade, thread friction and bolt
head bearing area. The values given in the following tables are for
guidance. These values should only be used if no other values are
specified in the relevant chapters of the Operating Instructions or in
spare parts sheets.
Caution
Bolts must always be replaced with bolts of the same size and
grade.
Bolts with adhesive in the locking threads and self-locking nuts must
always be replaced after removal.
Continuation next side
11_0003_0507GB
10 — 1
Appendix
The tables below give the maximum tightening torques (maximum
torque) in Nm for a friction factor of mtotal = 0.14, with the thread
lightly-oiled or lightly-greased.
Notes
All tightening torques X 1.1 apply for bolts with cement in the thread.
Set screws -- metric triangular thread, DIN 13, Part 13
Dimensions Tightening torque
[mm]
Md [Nm]
M
SW
8.8
10.9 12.9
10000900
SW = Width across flats (A/F)
X.X = Grade 8.8, 10.9, 12.9
M 4
7
3.0
4.4
5.1
M 5
8
5.9
8.7
10
M 6
10
10
15
18
M 8
13
25
36
43
M 10
17
49
72
84
M 12
19
85
125
145
M 14
22
135
200
235
M 16
24
210
310
365
M 18
27
300
430
500
M 20
30
425
610
710
M 22
32
580
820
960
M 24
36
730
1050
1220
M 27
41
1100
1550
1800
M 30
46
1450
2100
2450
Set screws -- metric precision thread, DIN 13, Part 13
Dimensions
Tightening tor[mm]
que Md [Nm]
M
SW 8.8 10.9 12.9
M 8¢1
13
27
39
46
M 10 ¢ 1.25
17
52
76
90
M 12 ¢ 1.25
19
93
135
160
M 12 ¢ 1.5
19
89
130
155
M 14 ¢ 1.5
22
145
215
255
M 16 ¢ 1.5
24
225
330
390
M 18 ¢ 1.5
27
340
485
570
M 20 ¢ 1.5
30
475
680
790
M 22 ¢ 1.5
32
630
900
1050
M 24 ¢ 2
36
800
1150
1350
M 27 ¢ 2
41
1150
1650
1950
M 30 ¢ 2
46
1650
2350
2750
10000900
SW = Width across flats (A/F)
X.X = Grade 8.8, 10.9, 12.9
10 — 2
11_0003_0507GB
Appendix
10.2 Lubricant recommendation
We have listed all suitable lubricants and hydraulic fluids in the tables below. Putzmeister accepts no liability for the quality of the lubricants and hydraulic fluids listed or for changes in quality made by
the lubricant producer without changing the grade designation.
Notes
If your machine is filled with extremely flammable hydraulic fluid ex
works (HFC in accordance with 7th Luxembourg Report), please
only use Putzmeister hydraulic fluid, item no. 239879002, when you
top up or change the hydraulic fluid.
If your machine is filled with synthetic ester ex works, please only
use Putzmeister hydraulic fluid, item no. 239693000, when you top
up or change the hydraulic fluid.
Putzmeister accepts no liability for damaged caused by mixing hydraulic fluids from different producers.
Putzmeister accepts no liability for damaged caused by mixing oils
from different producers.
If you wish to use hydraulic fluids with a viscosity grade different
to VG46 (e,g, for higher ambient temperatures), please consult
Putzmeister Mörtelmaschinen before filling your machine with this
fluid.
When changing fluid from HLP to HEES, the residual oil content must
not exceed 2%, i.e., a so-called flushing cycle must be carried out
with a complete fill of new hydraulic fluid. For reasons of seal compatibility, the fluid should also be changed a max. of 6 months after putting the machine into service. You should also remember here that all
filters must be replaced after 50 operating hours because the new
fluid may dislodge any deposits and convey them to the filters.
Continuation next side
11_0006_0511GB
10 — 3
Appendix
Caution
Note the following to avoid any damage:
– If the hydraulic fluid temperature of the machine you wish to operate is below 0 _C, run the machine to operating temperature first.
Allow the machine to run for a few minutes under no load.
– The machine should only be operated at full load when the temperature of the hydraulic fluid (VG46) is 10 _C or more.
– The ideal temperature of the hydraulic fluid (HLP or HEES, VG46)
is between 40 _C and 70 _C.
Danger
Never mix different types of hydraulic fluid, i. e. biodegradable hydraulic fluids with mineral hydraulic fluids, etc.
Continuation next side
10 — 4
11_0006_0511GB
Appendix
Marking
in accordance with
DIN 51502
Requirements
standard
Engine oil
Gear-lubricant oil
Lubrication
(manual)
Centralised
lubrication
system
HD
HYP
K2K--20
K1K--20
API CD/SF
API GL4
DIN 51 825
DIN 51 825
mineral
Characteristics
Viscosity grade,
NLGI Class
11_0006_0511GB
mineral, lithium soap
SAE 15W--40
DIN 51511
SAE 90
DIN 51512
standard
SAE 80
DIN 51512
Winter
NLGI Class 2
DIN 51818
NLGI Class 1
DIN 51818
Part no.
000173005
Part no.
000101006
—
Part no.
360000009
Part no.
360001008
Aral Multi
Turboral engine
oil
SAE 15W--40
Aral transmission
oil
HYP SAE 85W--90
Aral gearlubricant oil
HYP SAE 80W
BP Vanellus
Multigrade
BP Energear
EP 90
BP Energear
EP 80W
BP Energrease LS 2
BP multipurpose
grease L2
BP Energrease
LS--EP 1
DEA Cronos
Super DX
SAE 15W--40
Deagear EP--A
SAE 85W--90
Deagear EP--A
SAE 80W
Glissando 20
Paragon EP 1
ELF
PERFORMANCE
XC 15W--40
TRANSELF EP
SAE 80W--90
TRANSELF EP
SAE80W
ELF MULTI 2
ELF ROLEXA 1
ESSOLUBE
MHX 15W--40
ESSO GEAR OIL
GP--D 85W--90
ESSO GEAR OIL
GP D 80W
BEACON 2
BEACON EP 1
Mobil DTE 25
Mobil DTE 24
Mobil DTE 27
Shell Rimula TX
Shell Spirax EP 90
Shell Spirax
MA 80 W
Shell Retinax A
Shell
Alvania EP
grease 1
Wintershall
Multi-Rekord
Wiolin
Multipurpose
transmission oil
85W--90
Wiolin
Multipurpose
transmission oil
80W
Wiolub LFK 2
Wiolub LFM 1
Aral Aralub
HL 2
Aral multipurpose
grease
—
10 — 5
Appendix
10.3 The correct mortar
mixture
Today, premixed dry mortars are produced in such a way that they
may be easily processed by mortar machines. Please also observe
the advice of the material manufacturers.
Site mixes, however, are subject to particular laws which must be adhered to at all times.
While mortar for manual application needs only to be prepared to
have good cured mortar characteristics and workability, mortar produced with mortar machines also has to be easy to pump and spray.
Although mortar which is too fat or sticky does not usually tend to
cause blockages and separation, it will still cause high pump pressure. On the other hand, mortar which is too lean or short causes low
delivery pressure which can easily cause separation and blockages
in the pump or delivery line.
Consistency
Pumping mortar must be ductile, i.e. not too thick or thin. Mixtures
which are too thin tend to allow the sand to settle and cause blockages. Mixtures which are too stiff cannot be sucked in.
Mortar pumps pump what is known as ”trowel-quality consistence”
mortar best.
You can improve mortar consistence and quality, save water and improve the pumping ability of the mortar with the use of certain additives.
Continuation next side
10 — 6
11_0005_0511GB
Appendix
Mortar sand
The type of sand (grading curve) and the type of sand grain both
determine render quality and have a strong influence on the pumping characteristics of the mortar produced from it.
Good grading curves are important. The sand must contain coarse,
medium and fine grains and should also possess so-called ”consumable” constituents. ”Single grain sand” types, as they are known, in
which the proportion of a single grain size group is excessive are not
conducive to pumping, although their use is often unavoidable. It is
important, in such an event, to mix different types of sand to obtain a
satisfactory grain grading.
Well-graded sand grains with grain sizes up to 4 mm are easier to
pump than fine beach sand (single grain sand)
In general, grain size must not exceed 4 mm.
A good grain combination for plastering sand is as follows:
Binder
Grain size below 0.2 mm
=
5%
Grain size from 0.2 --1.0 mm
=
60%
Grain size from 1.0 --4.0 mm
=
35%
The choice of binder depends on the intended application of the
mortar. The following points are of significance in obtaining good
pumping characteristics:
Slaked lime always produces grainy and firm, non-segregated mortar. It is often a ’miracle cure’ against blockages, particularly if the
sand is difficult to pump. In general, the addition of lime has a very
favourable influence on the pumping characteristics of the mortar.
Pure cement mortar must be regarded as dangerous. In this case,
you should obtain a pumpable mixture by including additives in the
mix.
Continuation next side
11_0005_0511GB
10 — 7
Appendix
Additives
Take extra care when choosing an additive from the extensive range
which is available. We are only able to give general guidelines, e.g.
chemical additives:
It has always proved to be useful to add a concrete liquifier without
air-entraining agents and this also saves on water and improves the
quality of the mixture (please contact local representatives or building materials suppliers for more information).
The following materials have also proved to be useful in practice for
avoiding blockages in the case of sharp mortar:
Stone dust, fly ash etc.
If you are unsure of which mixture to use, please contact our specialist staff who will be pleased to prepare it for you. Please also bear in
mind that we can only make recommendations for mixtures. The user
is responsible for the quality and workability of a particular mortar.
Continuation next side
10 — 8
11_0005_0511GB
Appendix
Site mixes
The following are our non-binding recommendations for common
mortar compositions:
Cement mortar
This can be used to plaster pedestals, concrete elements etc. It is
composed of river sand and cement.
Mix ratios:
approx. 1 quantity (by volume) of cement, 2 of river sand (0-4 mm)
and additive.
Base plaster
This is used to plaster brickwork.
Mix ratios:
Different mixtures are possible in this case, depending on the region,
method of operation and the available materials:
1 quantity (by volume) of slaked lime, 4 of river sand (0-4 mm) without the addition of mortar additive.
or
1 quantity (by volume) of hydraulic powder chalk, 2 of river sand,
1 of pit sand (the sand quantities could be reversed if required, depending on the sand type
or
1 quantity (by volume) of cement, 0-5 of chalk, 3 of river sand, 1 of
quarry sand (possibly with additives or air-entraining agents).
11_0005_0511GB
10 — 9
Appendix
10.4 Template for EC declaration of conformity
The original EC declaration of conformity is included in the machine’s
scope of supply. Store this in a safe place.
2006/42/EC, II 1.A.
1 de
en
2 de
en
EG--Konformitätserklärung im Sinne der EG--Maschinenrichtlinie 2006/42/EG, Anhang II 1.A.
EC declaration of conformity as defined by Machinery Directive 2006/42/EEC Annex II 1.A.
Hiermit erklâren wir, dass die Maschine -- Bezeichnung / Typ / Maschinennummer
Herewith we declare that the machine –Designation / Model / Serial No.
3 de folgenden einschlâgigen Bestimmungen entspricht:
en Applied harmonized standards in particular
4 de Angewendete harmonisierte Normen, insbesondere
en complies with the following provisions applying to it
5 de Angaben zum Dokumentationsbevollmâchtigten
en Party authorized to produce documentation
2006/42/EC
97/23/EC
EN 12001
EN 1829
Putzmeister Mörtelmaschinen GmbH
Max--Eyth--Straße 10
D--72631 Aichtal
6 de Angaben zum Unterzeichner / Datum / Unterschrift
en Signer / Date / Signature
Putzmeister Mörtelmaschinen GmbH
Max--Eyth--Straße 10
D--72631 Aichtal
7 de Geschâftsführer
en Managing Director
2006/42/EC
de
en
es
fr
EN 12001
de
en
es
fr
Förder--, Spritz-- und Verteilmaschinen für Beton und Mörtel -- Sicherheitsanforderungen
Conveying, spraying and placing machines for concrete and mortar — Safety requirements
Máquinas para el transporte, proyección y distribución de hormigón y mortero – Requisitos de segurida
Machines pour le transport, la projection et la distribution de béton et mortier -- Prescriptions de sécurité
EN 1829
de
en
Hochdruckreiniger, Hochdruckwasserstrahlmaschinen -- Sicherheitsanforderungen
High pressure cleaners – High pressure water jet machines – Safety requirements
2006/95/EC
de
en
EG--Niederspannungsrichtlinie
Low voltage equipment
2004/108/EC
97/23/EC
10 — 10
de
en
de
en
EG--Maschinenrichtlinie
Machinery Directive
Directiva CE de máquinas
Directive--CE relative aux machines
Elektromagnetische Vertrâglichkeit (EMV)
Electromagnetic compatibility (EMC)
EG--Druckgerâterichtlinie
Pressure equipment
11_0025_1004GB
Index of Key Words
Index of Key Words
This chapter contains the main key words with the number of the
page on which they are to be found as a header in the left-hand margin. This Index of key words is listed alphabetically by the main concepts. These are subdivided into associated sub-concepts, marked
with a dash.
i
Index of Key Words
A
D
F
Accessories, 2 — 25
Dangers
- Coolant, 2 — 16
- Hydraulic fluid, 2 — 15
- Risk of burns, 2 — 15
- Risk of scalding, 2 — 15
Fault, 2 — 24
Declaration of conformity, 10 — 10
Final decommissioning, 9 — 3
Delivery line, 5 — 17
- Extending, 2 — 4
Foreword, 1 — 2
Air valve fitting, 3 — 3, 3 — 20
Alignment, 4 — 14
Auger pump, 3 — 3, 3 — 16, 8 — 76
- Adjusting the auger pump, 8 — 76
- Assembly, 8 — 74
- Disassembly, 8 — 72
- Screw conveyor, 8 — 79
Axle and wheels, 8 — 9
Designated use, 2 — 3
Disposal, 9 — 3
B
Ball hitch, 4 — 7
- Coupling, 4 — 7
- Disconnecting, 4 — 9
- Permitted slewing circle, 4 — 10
- Troubleshooting, 7 — 14
Driving, 4 — 1
Dry air filter, 3 — 4, 8 — 58
- Dust discharge valve, 8 — 60
- Filter element, 8 — 59
Dust extraction, 3 — 22
E
Blockages, 2 — 18, 6 — 12
- Rectification, 6 — 12
EC declaration of conformity, 10 — 10
C
Chassis, Tyres, 3 — 5
Checks, 5 — 2
- Engine oil level, 5 — 4
- Fuel level, 5 — 4
- Hydraulic fluid level, 5 — 5
- Operating materials, 5 — 3
- Visual checks, 5 — 2
Cleaning, 6 — 16
- Compressed air cleaning, 6 — 19
- Delivery line, 6 — 19
- Machine, 6 — 18
- Spray gun, 6 — 22
Cleaning solenoid, 8 — 27
Compressor, 3 — 4, 8 — 7
Control cabinet, 3 — 3, 3 — 13
Cooling system, Check for leaks,
8 — 46
ii
Frost protection, 9 — 2
Fuel filter, 8 — 66
- Changing, 8 — 67
- Checking for leaks, 8 — 69
- Fuel line filter, 8 — 68
- Water drainage, 8 — 70
Fuel tank, 3 — 4
- Filling up, 9 — 2
Function, 3 — 12
Before a journey, 4 — 4
Breaks in pumping, 6 — 11
Faults, Cause and Remedy
- Chassis, 7 — 14
- Electrical system, 7 — 12
- Machine, general, 7 — 2
Emergency, 2 — 24
EMERGENCY STOP button, 3 — 10,
5 — 12, 6 — 2
EMERGENCY--STOP, 2 — 21
Engine, 3 — 4, 3 — 15, 8 — 5
- Cooling system, 8 — 44
- Starting, 5 — 8
Function checks, 5 — 11
- Auger pump, 5 — 16
- EMERGENCY STOP button, 5 — 12
- Hood safety device, 5 — 13
- Mixer unit, 5 — 16
- Protective grille cut-out, 5 — 14
- Safety equipment, 5 — 11
Function description, Compressor,
3 — 19
Engine compartment, 3 — 4
G
Engine oil, 8 — 37
General set--up, 3 — 12
Engine oil filter, 8 — 36
- Checking for leaks, 8 — 38
Ground clearance, 4 — 4
Environmental protection, 2 — 22
Index of Key Words
H
M
N
High--pressure cleaner, 3 — 23
Machine, Shutting down, 5 — 18
Noise, 2 — 21, 2 — 23
High--pressure gun, 3 — 23
Machine designation, 3 — 2
High-pressure cleaner, 6 — 23, 8 — 8,
8 — 81
- Antifreeze protection measures,
8 — 86
Machine model, 3 — 2
Hood safety device, 3 — 11, 5 — 13
Maintenance chart
- Antifreeze protection for the radiator,
8 — 56
- Battery, 8 — 30
- Coolant, 8 — 44
- Dry air filter, 8 — 58
- Engine oil, 8 — 35
- Engine oil filter, 8 — 35
- Fuel filter, 8 — 66
- High-pressure cleaner, 8 — 81
- High-pressure cleaner antifreeze protection measures, 8 — 86
- Hydraulic filter, 8 — 52
- Hydraulic fluid, 8 — 47
- Hydraulic hoses, 8 — 39
- Radiator, 8 — 61
- Replacing the screw conveyor, 8 — 79
- V-belt, 8 — 64
- Water supply fitting antifreeze protection measures, 8 — 83
Hydraulic and pneumatic equipment,
2 — 19
- Bleeding, 2 — 20
- Check, 2 — 19
- Pressure, 2 — 20
Hydraulic components
- Hydraulic control block, 3 — 4, 3 — 18
- Hydraulic pump, 3 — 4
Hydraulic control, 3 — 17
Hydraulic fluid reservoir, 3 — 4,
8 — 49
Hydraulic hoses, 8 — 39
- Flared screwed joints, 8 — 41
Hydraulic system, 8 — 7
- Fluid change, 8 — 47
- Hydraulic filter, 8 — 52
I
Icons, 1 — 4
Initial pumping, 6 — 4
L
Liability, 2 — 5
- Exclusion of liability, 2 — 5
Lifting mixer unit
- Lowering, 6 — 6
- Raising, 6 — 6
Lighting, 4 — 11
Lubricant recommendation, 8 — 32
Lubricants, Mixer bearing, 8 — 19
Machine number, 3 — 1, 3 — 2
Machine versions, 3 — 1
O
Oil change, Compressor, 8 — 32
Onwards sale, 2 — 2
Operating elements, 3 — 3
Operating materials, 5 — 3, 8 — 15
- Axle and wheels, 8 — 19
- Compressor oil, 8 — 18
- Coolant, 8 — 17
- Engine oil, 8 — 17
- Fuel, 8 — 16
- High--pressure cleaner, 8 — 19
- Hydraulic oil, 8 — 18
Operator, 2 — 21
- High--pressure gun, 2 — 24
- Machine, 2 — 24
Option, High--pressure cleaner,
3 — 23
Optional, High-pressure cleaner,
6 — 23, 8 — 8
Other risks, 8 — 12, 8 — 13
Output regulation, 6 — 10
Maintenance intervals, 8 — 2
Maintenance work
- In the engine compartment, 8 — 20
- Other risks, 8 — 12
Mixer, 8 — 7
- Lifting mixer unit, 3 — 3, 6 — 6
Modifications, 2 — 4
Mortar mixture, 10 — 6
- Additives, 10 — 8
- Base plaster, 10 — 9
- Binder, 10 — 7
- Cement mortar, 10 — 9
- Consistency, 10 — 6
- Sand, 10 — 7
- Site mixture, 10 — 9
Lubrication diagram, 8 — 25
iii
Index of Key Words
P
S
T
Permitted drawbar load, 4 — 10
Safety components, Spare parts,
2 — 28
Technical data, 3 — 5
- Chassis, 3 — 5
- Dimensions, 3 — 5
- Tyres, 3 — 5
- Weight, 3 — 5
Personal protective clothing, 2 — 9,
8 — 12
Personnel, 2 — 6
Personnel selection and qualifications, 2 — 6
- Hydraulics technician, 2 — 6
- Qualified electrician, 2 — 6
- Training, 2 — 6
Place of work, 2 — 21, 2 — 24
Protective equipment
- Ear defenders, 2 — 9
- Face--mask and respirator protector,
2 — 10
- Protective gloves, 2 — 9
- Protective goggles, 2 — 10
- Protective helmet, 2 — 9
- Safety boots, 2 — 9
- Safety harness, 2 — 10
Protective grille, 3 — 11
- Cut-out, 5 — 14
Pumping, 6 — 9
Pumping operations, 6 — 8
- Blockages, 6 — 12
- Breaks in pumping, 6 — 11
- Initial pumping, 6 — 4
- Requirements, 6 — 1
Safety devices, 2 — 4
Safety equipment, 2 — 8, 3 — 10,
5 — 11, 8 — 4
- EMERGENCY STOP button, 3 — 10
- Hood safety device, 3 — 11, 5 — 13
- Protective grille, 3 — 11
- Protective grille cut-out, 5 — 14
- Safety switch , 3 — 11
Safety functions, Safety--related parts
(SRP), 2 — 27
Safety switch, 3 — 11
Safety--related parts (SRP), 2 — 27
Set--up site
- Inclination angles, 4 — 13
- Requirements, 4 — 12
- Selection, 4 — 12
- Supporting ground, 4 — 12
Setting up, 4 — 13
Shut-down, 6 — 2
Test run, 5 — 8
Tightening torques, 10 — 1
Towing gear, 3 — 3, 4 — 5
- Adjusting, 4 — 6
Transport, 4 — 1
Transport position, 4 — 3, 4 — 5
- Machine lifting mixer unit, 4 — 3
Transporting the machine, 4 — 2
U
Unauthorised use, 2 — 26
Use contrary to the designated use,
2—4
Shutting the machine down, 9 — 2
V
Sound emissions, Noise, 2 — 23
V-belt, Checking, 8 — 65
Sound power level, 3 — 9
Sources of danger, 2 — 7
- Coupling system, 2 — 7
- Hot machine components, 2 — 7
W
Spare parts, 2 — 22, 2 — 28
Water connection, 4 — 15
- Water supply, 4 — 15
Spare parts sheets, 2 — 28
Water quality, 4 — 15
Water supply fitting, 8 — 8, 8 — 84
- Antifreeze protection measures,
8 — 83
Rating plate, 3 — 3, 3 — 8
Spray gun, 3 — 21, 6 — 13
- Air--regulation cock, 3 — 21
- Material lever, 3 — 21
- Remote control valve, 3 — 21
Refuelling, machine, 5 — 7
SRP, 2 — 27
Residual risk, 2 — 11
Starting up, 2 — 17
- Function checks, 5 — 11
- Starting the engine, 5 — 8
R
Radiator, 3 — 4, 5 — 6
- Antifreeze protection, 8 — 56
- Cleaning, 8 — 61
Return line suction filter, 3 — 4,
8 — 54
Risk of crushing and bumping,
2 — 12
- Auger pump, 2 — 13
- Transporting the machine, 2 — 12
Storing the machine, 2 — 22, 2 — 25
Risk of injury, 2 — 11
Support foot, 4 — 14
Summary of components, 3 — 3
- Engine compartment, 3 — 4
- Machine, 3 — 3
Supporting ground, 4 — 12
Symbols, 1 — 4
iv
Working area, 2 — 21, 2 — 24
Putzmeister
Mörtelmaschinen GmbH
Putzmeister Limited
Putzmeister France
Max-Eyth-Straße 10
72631 Aichtal
Postfach 21 52
72629 Aichtal
Tel. (0 71 27) 599-0
Fax (0 71 27) 599-743
Carrwood Road
Chesterfield Trading Estate
Chesterfield
Derbyshire
S41 9QB
Tel. (0 12 46) 264200
Fax (0 12 46) 260077
Zone Industrielle
Rue Jean Jaurès
91861 Epinay sous Sénart
Tel. (1) 69 39 69 39
Fax (1) 60 47 20 68
Putzmeister Iberica S.A.
Putzmeister (SA) (Pty)
Ltd.
Putzmeister America
Camino de Hormigueras 173
28031 Madrid
Tel. (1) 428 81 00
Fax (1) 428 81 06
1485 Citrus Street.
Honeydew/Johannesburg
PO Box 5146
2118 Cresta / South Africa
Tel. 0027-(0)11-794-3790
Fax 0027-(0)11-794-4119
Mortar Maschine
1733 90th Street
Sturtevant, WI 53177
Phone: (262) 886 3200
Fax: (262) 886 3212
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Postfach 2152
D-72629 Aichtal
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