ManualArchive 2106T3450 Operating Instructions

Operating Instructions
BSA 100-D
2106T3450
Vehicle Series (VS) Vehicle Series Power Take-Off (VS PTO)
TK Series Trailer-Mounted
A520154 A
Table of contents
1 Guide to the Operating Instructions

1.1 Foreword . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1.2 Icons and Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2 Safety Regulations
2.1 Personnel Qualifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
2.2 Safety Regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
3 General Technical Description

3.1 Principles of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
3.2 Flat Pack Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
3.3 Trailer-Mounted Overview Diagram . . . . . . . . . . . . . . . . . . . 34
3.4 Centralized lubrication system . . . . . . . . . . . . . . . . . . . . . . . 35
3.5 Changeover delay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Without changeover delay . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
With changeover delay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Potentiometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
3.6 Machine Rating Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
3.7 Symbols for the Control System . . . . . . . . . . . . . . . . . . . . . . 39

3.7.1 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
3.7.2 Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
3.7.3 Concrete Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 310
3.8 Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 311

3.8.1 Electric Control Cabinet with Engine Display BSA100D . . . . . . 312
3.8.2 Electric Control Cabinet with Engine Display BSA120D . . . . . . 314
3.8.3 Electric Motor Start Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 316
3.9 Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 317

3.9.1 General BSA100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 317
3.9.2 General BSA120 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 317
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Table of contents
3.9.3 System Pressures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 317

3.9.4 System Filtration BSA100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 317
3.9.5 System Filtration BSA120 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 318
3.9.6 Oil Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 319
3.9.7 Main Hydraulic Pump BSA100 . . . . . . . . . . . . . . . . . . . . . . . . . . . 319
3.9.8 Main Hydraulic Pump BSA120 . . . . . . . . . . . . . . . . . . . . . . . . . . . 320
3.9.9 Secondary Hydraulic Pump BSA100 . . . . . . . . . . . . . . . . . . . . . . . 320
3.9.10 Accumulator Hydraulic Pump BSA120 . . . . . . . . . . . . . . . . . . . . 321
3.9.11 Remixer Hydraulic Pump BSA120 . . . . . . . . . . . . . . . . . . . . . . . . 321
3.9.12 Main Control Block BSA100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 322
3.9.13 Main Control Block BSA120 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 323
3.9.14 Accumulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 324
3.9.15 Accumulator Dump Valve BSA120 . . . . . . . . . . . . . . . . . . . . . . . 325
3.9.16 Spool Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 325
3.10 Hydraulic Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 326

3.10.1 Delivery Cylinder Pump System . . . . . . . . . . . . . . . . . . . . . . . . . . 326
3.10.2 S-Tube Shifting System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 327
3.10.3 Auxiliary System BSA100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 328
3.10.4 Auxiliary System BSA120 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 328
3.11 Hopper Grate Cutout Device . . . . . . . . . . . . . . . . . . . . . . . . . 328
3.12 Optional Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 331

3.12.1 Auto-Lube System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 331
3.12.2 Cable and Radio Remote Control Unit . . . . . . . . . . . . . . . . . . . . . 332
Cable Remote 12V (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 332
Cable Remote RPM/VOL 12V (Optional) . . . . . . . . . . . . . . . . . . . 333
3.12.3 Radio remote control (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . 334
Radio Remote with ON/OFF/REV/RPM/VOLUME (Optional) . . 334
3.12.4 Hydraulic Outriggers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 335
3.12.5 Remixer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 336
3.12.6 Water Pump (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 337
3.12.7 Cylinder Stroke Counter (optional) . . . . . . . . . . . . . . . . . . . . . . . . 338
3.12.8 Vibrator Kit (optional BSA100 / standard BSA120) . . . . . . . . . . 339
3.12.9 Volume Control Kit (optional BSA100) . . . . . . . . . . . . . . . . . . . . 340
II
Table of contents
4 Travel and set up

4.1 Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
4.2 Towing of Trailer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
4.3 Requirements for the setup site . . . . . . . . . . . . . . . . . . . . . 43

4.3.1 Accessibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
4.3.2 Approach route . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
4.3.3 Space for truck mixers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
4.3.4 Supporting Ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
4.4 Clearance from pits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
4.5 Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
4.6 Stationary delivery lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

4.6.1 Danger Zone . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
4.6.2 Instructions for laying the line . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
4.6.3 Fastening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
5 Operation
5.1 Preliminary Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
5.2 Hand signals for pumping . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
5.3 Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
5.3.1 Pre-Operation Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
5.3.2 Trailer Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
5.3.3 Filling the Machine with fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
5.3.4 Considering Concrete Properties . . . . . . . . . . . . . . . . . . . . . . . . . . 56
5.3.5 Delivery System Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
5.4 Start-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
5.4.1 Start-Up of Concrete Pump Powered by a Diesel Engine . . . . . . . 59
5.4.2 Emergency Stop Button Locations . . . . . . . . . . . . . . . . . . . . . . . . . 511
5.4.3 Start-Up of Concrete Pump Powered by an Electric Motor . . . . . . 512
5.4.4 Checking the Hopper Grate Safety Cutout Device . . . . . . . . . . . . 514
5.4.5 Filling the Agitator Hopper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 514
5.4.6 Priming of Concrete Pump and Delivery System . . . . . . . . . . . . . 516
5.4.7 Pumping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 517
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Table of contents
5.4.8 Transfer tube damping (BSA120) . . . . . . . . . . . . . . . . . . . . . . . . . 518
5.5 Maintenance During a Pour . . . . . . . . . . . . . . . . . . . . . . . . . . 519

5.5.1 Monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 519
5.5.2 Operational Tips and Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . 521
5.5.3 Blockages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 522
5.5.4 Avoiding Blockages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 523
5.5.5 Clearing a Blockage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 523
5.6 Breaks in Pumping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 524

5.6.1 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 525
5.6.2 Overheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 525
5.6.3 Restarting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 526
5.7 Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 527

5.7.1 Preparations for cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 529
5.7.2 Delivery Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 533
5.7.3 How to Clean which Delivery Line . . . . . . . . . . . . . . . . . . . . . . . . 533
5.7.4 Suction Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 535
5.7.5 Highpressure Water Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . 537
5.7.6 Cleaning with Auxiliary Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . 538
5.7.7 Hopper, Delivery Cylinder & Stransfer Tube . . . . . . . . . . . . . . . 539
5.7.8 Postwashing Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 542
5.8 Shutting Down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 544
5.9 Pumping Concrete with the Emergency Stroke

Change Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 545
5.9.1 BSA100D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 545
5.9.2 BSA120D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 546
6 Maintenance
Lock Out Tag Out Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . 62
6.1 Daily Tasks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
6.1.1 Daily Visusal Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
6.1.2 Function Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
6.1.3 When Pumping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
6.1.4 After every Job . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
6.1.5 Maintenance Intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
6.1.6 Hydraulic Oil Tank BSA100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
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Table of contents
6.1.7 Hydraulic Oil Tank BSA120 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
6.2 Recommended Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

6.2.1 Hydraulic Fluids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 610
6.2.2 Oils and Greases . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 612
6.3 Inspecting the Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 612
6.4 Adding Hydraulic Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 613
6.5 Lubricating the Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 614

6.5.1 Lubrication Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 614
6.6 Replacing the Return Oil Filter Element . . . . . . . . . . . . . . . 615
6.7 Replacing the Suction Filter Element and the High

Pressure Filter Element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 617
6.8 Changing the Hydraulic Fluid; Cleaning the

Hydraulic Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 617
6.8.1 Draining the Hydraulic Oil Tank . . . . . . . . . . . . . . . . . . . . . . . . . . 618
6.9 Checking and Adjusting Hydraulic System Pressures . 619

6.9.1 Checking Standby Pressure of The Main Hydraulic
Pump BSA100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 620
6.9.2 Adjusting Standby Pressure of The Main Hydraulic
Pump BSA100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 620
6.9.3 Checking Main System and Relief Pressure BSA100 . . . . . . . . . . 621
6.9.4 Adjusting Main System and Relief Pressure BSA100 . . . . . . . . . . 622
6.9.5 Checking S-Tube Shift Circuit Pressure BSA100 . . . . . . . . . . . . . 623
6.9.6 Adjusting S-Tube Shift Circuit Pressure BSA100 . . . . . . . . . . . . . 625
6.9.7 Adjusting Remixer Relief Pressure . . . . . . . . . . . . . . . . . . . . . . . . 626
6.10 Replacing Proximity Switch . . . . . . . . . . . . . . . . . . . . . . . . . . 627
6.11 Performing Maintenance on the Accumulator . . . . . . . . . 628

6.11.1 Checking Accumulator Pre-Charge Pressure . . . . . . . . . . . . . . . . . 632
6.11.2 Decreasing Accumulator Pressure . . . . . . . . . . . . . . . . . . . . . . . . . 633
6.11.3 Increasing Accumulator Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . 634
6.11.4 Replacing Accumulator Bladder . . . . . . . . . . . . . . . . . . . . . . . . . . 636
6.12 General Tightening Torques . . . . . . . . . . . . . . . . . . . . . . . . . . 636

6.12.1 Set Screws and Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 636
6.12.2 Flared Screwed Joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 637
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Table of contents
6.13 Function Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 641
6.14 Hydraulic Hose Inspection and Replacement . . . . . . . . . . 643
6.15 Changing the Suction Filter Element . . . . . . . . . . . . . . . . . . 6 47

Changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 49
6.16 Changing the Pressure Filter Element . . . . . . . . . . . . . . . . 6 53

Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 55
Changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 56
6.17 Delivery Piston Replacement . . . . . . . . . . . . . . . . . . . . . . . . . 6 59

6.17.1 Piston replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 61
Removing a piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 62
Fitting a piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 63
6.18 Replacing the STransfer Tube . . . . . . . . . . . . . . . . . . . . . . . 665

Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 665
6.18.1 Dismantling the Stransfer tube bearing . . . . . . . . . . . . . . . . . . . . 665
6.18.2 Stransfer tube bearing gasket set . . . . . . . . . . . . . . . . . . . . . . . . . 666
6.18.3 Removing the Stransfer tube shaft bearings . . . . . . . . . . . . . . . . . 667
6.18.4 Stransfer tube shaft bearing gasket set . . . . . . . . . . . . . . . . . . . . . 670
6.18.5 Removing the wear plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 672
6.18.6 Removing the Stransfer tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . 674
6.18.7 Replacing the wear sleeve on the Stransfer tube . . . . . . . . . . . . . 675
6.18.8 Fitting the wear plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 676
Machines with 5bolt wear plate . . . . . . . . . . . . . . . . . . . . . . . . . . 677
Machines with 2bolt wear plate . . . . . . . . . . . . . . . . . . . . . . . . . . 678
6.18.9 Replacing the seal ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 679
6.18.10 Fitting the Stransfer tube bearing . . . . . . . . . . . . . . . . . . . . . . . . . 680
6.18.11 Wear sleeve and collared washer . . . . . . . . . . . . . . . . . . . . . . . . . . 680
6.18.12 Mounting the switch lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 681
6.19 Adjusting the STransfer Tube . . . . . . . . . . . . . . . . . . . . . . . 6 83

6.19.1 Shutting down the machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 83
6.19.2 Starting the machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 84
6.19.3 Set the gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 84
6.19.4 Set the switching overlap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 88
Wear plate with wear ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 88
Wear plate with sample markings . . . . . . . . . . . . . . . . . . . . . . . 6 90
6.19.5 Switching overlap on fully hydraulic control (VHS) . . . . . . . . . . . 6 92
VI
Table of contents
6.20 Measuring the Wall Thickness

(Machines with Stransfer tube) . . . . . . . . . . . . . . . . . . . . . . 6 95
6.20.1 Stransfer tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 97
6.20.2 Measuring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 98
7 Troubleshooting Guide
7.1 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
7.2 Hydraulic Oil Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
7.3 Main Hydraulic Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
7.4 Secondary Hydraulic Pump . . . . . . . . . . . . . . . . . . . . . . . . . . 74
7.5 Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
7.6 Hydraulic Drive Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
7.7 S-Tube Shifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
7.8 Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
7.9 Remixer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 710
7.10 Concrete Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 711
Index
A520154 A_TOC_1001 VII

Table of contents
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VIII
1 Guide to the Operating Instructions
In this chapter you will find notes and information that will help you use these Operating
Instructions. Do not hesitate to contact us if you have any queries:
Putzmeister America, Inc.

Customer Support Group
1733 90th Street
Sturtevant, WI 53177
USA
24 Hr Customer Support: 18008900269
FAX: 12628847259
On the Web: www.putzmeister.com
or the Distributor or Dealer that looks after you.
Address:
Telephone:
Telefax:
email:
A520154_01_0903 11
Guide to the Operating Instructions
1.1 Foreword
These Operating Instructions are intended to familiarize you with the machine and to
assist in the proper use of the machine in various possible applications.
The Operating Instructions contain important information on how to operate the machine
safely, properly and economically. Observing these instructions helps to avoid danger, to
reduce repair costs and downtimes, and to increase the reliability and service life of the
machine.
The Operating Instructions must be supplemented by the respective local, state and
federal laws and regulations for accident prevention and environmental protection.
The Operating Instructions must always be available wherever the machine is in use.
These Operating Instructions must be read and applied by any person who carries out
work with and on the machine such as:
Operation, including setting up, troubleshooting in the course of work, or tearing down
the machine;
Service, (maintenance, inspection, repair)
Transport.
In addition to the Operating Instructions and relevant rules and regulations for accident
prevention and environmental protection at the job site and machine operation.
Should you have any questions following your study of the Operating Instructions, the
Branch or Agency serving you, or Putzmeister America in Racine, WI will be happy to
give you more information.
When corresponding, please have the machine model and the machine number
available at hand.
All product descriptions, illustrations and specifications were in effect at the time the
manual was released for printing. Putzmeister America, Inc. reserves the right to make
changes in design or to make additions to or improvements in its products without
obligation to install such equipment on products previously manufactured.
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.
Copyright by Putzmeister America, Inc. 2008
12 A520154_01_0903
1.2 Icons and Symbols

The following icons and symbols are used in the Operating Instructions:
NOTICE Particular information regarding the proper use of the machine is

introduced with the icon illustrated, the word Notice printed in bold, and
a line. The associated text is printed in bold and ends with another line.
CAUTION
Particular information, rules, or precautions intended to alert against
unsafe practices or potentially hazardous situations which, if not avoided,
could result in minor or moderate equipment damage. It is introduced with
the icon illustrated, the word Caution printed in bold, and a line.
The associated text is printed in bold and ends with another line.
WARNING
potentially hazardous situations which, if not avoided, could result in
death or serious personal injury and equipment damage. It is introduced
with the icon illustrated, the word Warning printed in bold, and a line. The
associated text is printed in bold and ends with another line.
DANGER
imminently hazardous situations which, if not avoided, will result in death
or serious personal injury and equipment damage. It is introduced with the
icon illustrated, the word Danger printed in bold, and a line. The associated
text is printed in italics and ends with another line.
A520154_01_0903 13
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14 A520154_01_0903
2 Safety Regulations
Putzmeister America cannot anticipate every possible circumstance that might involve a
potential hazard. The warnings in this manual are therefore not all inclusive. If a procedure,
tool, device, or work method not specifically recommended by Putzmeister is used, you
must satisfy yourself that it is safe for you and others. You should also ensure that the
machine will not be damaged or made unsafe by the procedures you choose.
Each machine has undergone a thorough Quality Control inspection at the factory. The
design incorporates built-in safety features, however it can be potentially dangerous in the
hands of untrained or careless operators.
Knowing the characteristics of the machine and function of the controls is important for safe,
proper operation, and use. Becoming familiar with the controls and practices of concrete
pumping will result in efficient and smooth pumping.
This topic: Starts on page:

NO TAG Personnel Qualifications NO TAG
NO TAG Safety Regulations NO TAG
A520154_02_0903 21
Safety Regulations
2.1 Personnel Qualifications

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

All personnel operating, assembling, transporting, or maintaining a machine should be
aware of and comply with the following safety regulations:
No modification is to be made to the machine without prior written consent of the
Putzmeister Technical Support or Engineering Department.
Operators and anyone near the machine must wear appropriate clothing and protective
equipment (i.e., a hard hat, safety glasses, hearing protection, and safety shoes) required by
Federal, State, local and job site regulations. Wearing loose, flapping clothing, neck ties,
rings, and wrist identity chains is dangerous and must be prohibited. Hearing protection
OSHA requirements are listed in 29 CFR Ch. XVII Section 1910.95 Occupational Noise
Exposure, which can be found at www.osha.gov.
Do not operate the machine unless it has been leveled and stabilized.
Do not operate a malfunctioning machine.
Keep decals and operating instructions legible and readable.
Make sure safety devices are in good operating condition.
Do not clean, oil, adjust, or service unit while it is operating.
Use extreme caution when handling delivery system. Some machine are capable of
delivering up to 1500 psi. Pressure can remain in the delivery system even after the unit is
shut down.
Never remove the hopper grate cover when the pump is in operation. It protects against
accidental contact with the remixer shaft and other moving parts inside the hopper.
During normal operation, never enter the hopper with any part of your body; it is a danger
area and physical injury can occur, even if the engine is stopped.
Do not stand on the hopper grate.
If repair or other work must be performed inside the hopper, ensure that engine is OFF and
22 A520154_02_0903
Safety Regulations
accumulator pressure reads zero. The system uses a hydraulic accumulator which contains
a stored charge of high pressure oil to shift the S-tube. Stop engine, turn ignition key to OFF
and wait 1015 seconds until the accumulator pressure gauge reads zero.
Since hydraulic oil systems can be dangerous, know the circuit you are repairing. It may
contain high pressure and injury could occur. If in doubt, stop the machine and allow
sufficient time for the oil pressure to decrease to zero. Check pressure gauges to confirm
that they read zero.
Do not open the concrete delivery system without relieving the pressure. Pressure can be
relieved by reversing the pump and pumping backward.
When hydraulic cylinders are used to hold loads, do not loosen fittings without mechanically
supporting the load. Loosening of fittings may result in high pressure fluid leaks and
movement of the cylinder.
Do not fill the fuel tank while the engine is running or hot. Avoid the possibility of spilled fuel,
which may cause a fire.
If a fuel spill occurs, do not restart the engine until all spilled fuel has been cleaned up.
Do not pour material into hopper without grate in place. Operator must monitor material
being dumped in hopper, watching for unmixed or dry concrete, sticks, pieces of metal and
other foreign objects.
If the machine is to be left unattended on a job site, secure it from unauthorized use or
movement.
Clear area before activating outriggers.
Ensure that a proper level is maintained in the hydraulic oil tank. Oil level below minimum
can cause hydraulic pump and system damage.
Ensure that the work site has adequate lighting for safe operation.
A520154_02_0903 23
Safety Regulations
24 A520154_02_0903
3 General Technical Description
This chapter describes the components and assemblies on this machine and describes
how they function. Please note that available options will also be described. The
machine card will tell you whether the option described is fitted to your machine.

3.1 Principles of Operation 32
3.2 Flat Pack Assembly 33
3.3 Trailer-Mounted Overview Diagram 34
3.4 Lubrication System 35
3.5 Changeover Delay 36
3.6 Machine Rating Plate 38
3.7 Symbols for the Control System 39
3.8 Electrical System 311
3.9 Hydraulic System 315
3.10 Hydraulic Circuit 324
3.11 Hopper Grate Cutout Device 328
3.12 Optional Equipment 331
A520154_03_1001 31
General Technical Description
3.1 Principles of Operation

The machine is a hydraulically and electrically operated concrete pump that is designed
to pump wet concrete through a delivery system of pipes and hoses. It is of rugged
construction and durable design, enabling the machine to pump even the harshest
mixes within its published ratings/specifications. Normal operation is controlled at the
conveniently located control panel on the unit. A versatile multi-function cable remote
control for start, stop, and reverse enables the unit to be controlled 100 feet (30m) away
from the machine. A radio remote control unit is available as an option.
A diesel engine, or an electric motor operating at a preset RPM, drives the main
hydraulic pump. This direct connected variable displacement, load sensing hydraulic
pump is used to power the two hydraulic cylinders, which in turn drive two delivery
cylinder pistons. An S-tube design delivery system is employed and automatically shifts
from one delivery cylinder to the other for a continuous flow of material through the
delivery system.
A second hydraulic pump is used to supply oil at pressure for operation of the Stube
shift cylinder. This circuit also includes an accumulator.
A third hydraulic pump is used to supply oil at pressure for operation of a remixer, water
pump, and hydraulic outriggers.
In the pumping cycle, a continuous flow of material through the delivery line is produced
by the alternating operation of the delivery cylinder pistons. This is accomplished as one
of the hydraulic cylinders which has the delivery cylinder open to the hopper retracts,
pulling with it the piston of the delivery cylinder. At this point the concrete is drawn or
sucked into the delivery cylinder from the hopper. Upon reaching its full retracted
position, an electrical signal from a proximity switch sends a signal to the S-tube shift
valve. The S-tube now shifts to the loaded delivery cylinder. The hydraulic cylinder
extends and the delivery cylinder piston pushes the concrete through the S-tube, out the
discharge and into the delivery line. The cycle is repeated with the other cylinder
providing uninterrupted concrete flow.
The flat pack as shown in Illustration 31, has a water box which performs the following
functions: (1) cools the delivery pistons and piston rods, and (2) rinses the inner wall of
the delivery cylinders.
32 A520154_03_1001
3.2 Flat Pack Assembly

The flat pack assembly consists of the hopper, Stube, delivery cylinders, water box,
drive cylinders and other components as shown in Illustration 31 below:
15
1
2
14
9
3
4
5
7
8
9
10
11
12
13
A520154_03_1001 1
Illustration 31: Flat Pack Assembly
1 Stube 9 S-tube shift cylinders

2 Adapter 10 Metal screen
3 Coupling 11 Delivery cylinders
4 Hopper 12 Water box
5 Agitator safety cutout switch 13 Drive cylinders
6 Remixer 14 Cover for Stube shift cylinders
7 Hopper cleanout door 15 Folding splash guard
8 Manual lube kit
A520154_03_1001 33
3.3 Trailer-Mounted Overview Diagram

A BSA series trailer-mounted model is powered by a diesel engine. The pumping unit is
mounted on a towable trailer, which has a hitch and brake system (hydraulic or electric):
10
6
4
3 2 11
12
1
14
5 13 A520154_03_1001 2
Illustration 32: BSA Series Trailer-Mounted Concrete Pump
1 Diesel engine 8 Hydraulic control block and accumulator

2 Main hydraulic pump 9 Air Filter
3 Hydraulic system oil tank (with level indicator & 10 Battery
thermometer)
4 Control, and/or pressure gauges 11 Machine rating plate
5 Outrigger leg LH/RH 12 Trailer
6 Control box (with engine display) 13 Box for Operating Instruction
7 Flat pack assembly 14 Fuel tank
34 A520154_03_1001
3.4 Centralized lubrication system

The centralized lubrication system delivers grease from a centralized lubrication nipple
strip to all lubrication points of the pump which are difficult to access.
7 1
2
4
6
9
5
A520154_03_1001 3
Illustration 33: Lubrication System
1 Lubrication nipple strip 6 Lubrication nipples

2 Upper switch cylinder bearings 7 S tube bearing
3 Switching shaft bearings 8 Agitator shaft bearings
4 Lower switch cylinder bearings 9 Grease gun
5 Supply lines from the dry running cutout lubricant
distributor (not used)
The centralized lubrication system comprises a centralized lubrication nipple strip, a dry
running cutout and supply lines.
A520154_03_1001 35
3.5 Changeover delay

The changeover delay prevents concrete plugs from forming and curing at the ends of
the delivery cylinders. These plugs form because of
differing load statuses and pumping rates
the position of the limit switches on the cylinder
1 2 3
A520154_03_1001 4
No. 0 Designation
A Changeover without delay

1 Delivery piston
2 Limit switch
3 Concrete plug
B Changeover with delay
4 Delivery piston travel dependent on changeover delay and the pumping
rate selected
The changeover process is triggered by the inductive limit

switches.
Without changeover As soon as the delivery pistons reach the limit switches, the
delay changeover process is executed.
With changeover Once the limit switches are reached, a voltage is applied to the
delay POH valve (pushover hydraulic valve) and changeover is
delayed. That is, the delivery piston continues to travel towards the
end position and thus the concrete remaining to cure in the cylinders
can be reduced to a minimum.
36 A520154_03_1001
Potentiometer
A520154_03_1001 0
NOTICE
The delay time between reaching the limit switches and actual
changeover can be set within the range of 6200 ms.
The distance travelled by the delivery piston after it has reached the
limit switch depends on the changeover delay and the pumping rate
selected. The changeover delay will have to be adjusted if the
pumping rate is reset.
The potentiometer for adjusting the time is located in the control

cabinet.
Turning the potentiometer knob to the right increases the delay
Turning the potentiometer knob to the left reduces the delay
CAUTION
If the delay is continually increased, the delivery piston will
eventually strike against the mechanical end position. This may
damage the delivery piston and must therefore be avoided without
fail.
Knocking will be heard during changeover if the delivery piston is

striking against the mechanical end position. In this event, the delay
must be reduced again until the knocking can no longer be heard.
A520154_03_1001 37
3.6 Machine Rating Plate

The machine rating plate contains all the important information about the unit (i.e. model
and serial number). Keep a copy of the information handy for future reference.
8 9
1 10
2 11
3 4 12
5 13
A520154_03_1001 5
Illustration 35: Machine Rating Plate
1 Serial Number (machine number) 8 Gross vehicle weight rating (lb)

2 Model Designation 9 Gross axle weight rating (lb)
3 Model year 10 Tire size (e.g., LT235/65 R16 TW) (Truck, trailer
series)
4 Maximum engine RPM 11 Rim size (e.g., 16 X 6) (truck, trailer series)
5 Maximum hydraulic pressure (PSI) 12 Cold inflation pressure (PSI) of tires (e.g., 80 PSI)
(truck, trailer series)
6 Maximum concrete pressure (PSI) 13 Vehicle identification number
7 Manufacturing date
38 A520154_03_1001
3.7 Symbols for the Control System

This section gives you a summary of the symbols used for control actions.
NOTICE Some models may be equipped with an engine display module. For more
information, please refer to the Technical Enclosure Deutz Display in-
cluded with this manual.
3.7.1 Engine
1 2 3 4 5 6 7 8
A820090_03_0806D6
Illustration 36: Symbols used for Engine Functions
1 Diesel engine on 5 Engine speed in general

2 Diesel engine off 6 Engine speed
3 Charge monitor 7 Increase engine speed
4 Engine oil pressure 8 Reduce engine speed
3.7.2 Electrical System
1 2 3 4 5 6 7 8
A820090_03_0806D87
Illustration 37: Symbols used for Electrical System
1 On Off 5 EMERGENCY SHUTDOWN

activated
2 On 6 Operating position (local control)
3 OFF 7 Remote control in general
4 Activate EMERGENCY 8 Plug in remote control
SHUTDOWN
A520154_03_1001 39
3.7.3 Concrete Pump
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16
17
A820090_03_0806D8
Illustration 38: Symbols used for Concrete Pump
1 Pump On/Off 10 Agitator in general

2 Pump on 11 Agitator clockwise rotation
3 Pump off 12 Agitator counterclockwise rotation
4 Reverse pumping 13 Agitator safety cutout
5 Stroke changeover 14 Vibrator in general
6 Increase reduce pumping rate (using 15 Vibrator On
rotary controller)
7 Increase reduce pumping rate (using 16 Vibrator Off
toggle switch)
8 Increase output 17 Water pump
9 Reduce output
310 A520154_03_1001
3.8 Electrical System

Refer to the Electrical Schematic in the Technical Data Section for a complete
description of the electrical system.
NOTICE A 12 volt deep cycle battery, which is kept charged by an alternator,

provides power to all electrical components. Please remember the follow-
ing information concerning the battery and ignition key-switch:
It is important that the battery is kept fully charged. Although the
battery may have sufficient charge to start the diesel engine, it may not
have sufficient capacity to operate the system.
The ignition key-switch must remain on during pump operation to
provide electric power to the pump controls.
Leaving the ignition key-switch on with the diesel engine shut down
will discharge the battery.
The electrical system for the machine powered by a diesel engine consists of the
alternator on diesel engine, battery, electric control cabinet, and optional equipment
(e.g., cable remote control, radio remote control receiver and transmitter, vibrator, etc.)
requiring electrical power.
For more information, please refer to the electrical schematic diagram in the Technical
Data section of this manual.
A520154_03_1001 311
3.8.1 Electric Control Cabinet with Engine Display BSA100D

Control cabinet with engine display is shown below. For more information, please refer
to the Spare Parts Page and the electrical schematic that is included with this manual.
6 7
5
20 4
19 21
8 9 10 11
23 22
15
12 13 14
3
18 16
2 1 17
ACCUMULATOR MAIN SYSTEM VOLUME

PRESSURE HYDRAULIC PRESSURE CONTROL
24 25 26
A520154_03_1001 9
Illustration 39: Control Box with Engine Display (BSA100D)

1 Key switch and engine start A 2position key switch is used to start and stop the engine. Turn key to start
(I) position to start engine. Turn key to off (O) position to stop engine.
2 Engine speed selector A toggle switch is used to change the engine speed. Press the toggle switch up to
the (+ rpm) position to increase engine speed. Press the toggle switch down to the (rpm) position to
decrease engine speed.
3 Function keys Used with graphical menu structure. For more information, please refer to the Technical
Enclosure Deutz Display included with this manual.
4 Deutz display Digital display of the engine status. For more information, please refer to the Technical
Note
NOTICE The engine display will not control or operate the pump. To operate the pump, use
the pump operation functions on the control box .
5 Hour meter Records the number of pump operating hours. Engine hours can be seen on the engine
display.
6 Pump running indicator (green) If illuminated, pump is running OK.
312 A520154_03_1001
7 Reverse pumping on indicator (green) Illuminates when pumping in reverse.

8 Pump on/off toggle switch Push up to turn pump on or push down to turn pump off.
9 Pressure test and stroke change switch Momentary toggle switch (i.e., it returns to center position when
released):
Pressure Test function: Push up and hold to complete the pump stroke. At the end of the stroke, the pump
will pressure out to the maximum pressure. The maximum pressure can be read on the main system
hydraulic pressure gauge.
Stroke Change function: Temporarily push up to change the drive cylinder direction and shift the Stube
(i.e., change from pumping one cylinder to the other).
10 Reverse pumping toggle switch Push up to have pump to operate in reverse direction or push down to
have pump operate in forward direction.
11 Oil cooler fan switch Push up switch to turn on the oil cooler fan. Push down to turn off cooler fan. (not
applicable on BSA100D)
12 Engine preheat (yellow) LED If illuminated, indicates that glow plugs have been activated to preheat the
engine prior to starting the engine in cold weather. Preheat engine until preheat LED goes out. Note:
Please refer to the Start Procedure for more information on using cold start aid in the engine
manufacturers operation manual included with these operating instructions.
13 Engine fault (red) LED Turns on when an engine fault occurs. For more information on engine faults,
please refer to the engine manufacturers operation manual.
14 Alternator fault indicator (red) Turns on when the alternator output is not sufficient to keep the battery
charged.
15 Emergency stop (E-stop) indicator (red) If illuminated, an emergency shut-down has been activated.
16 Emergency stop button Push in this button to stop diesel engine in emergency situations. To release knob,
twist knob clockwise.
17 Local/remote control switch This switch should be locked in either the local or remote position. In the
local position, the concrete pump operation is controlled by the switches on the electric control box (see
items 8, 9, 10, 16) . In the remote position, the switches on the electric control cabinet are disabled and
the concrete pump operation is controlled by the switches on the cable/radio remote control unit. For
operation of the remote control unit, refer to the Cable and Radio Remote Control Unit section on page
333.
18 Diagnostic plug Female connector used for troubleshooting and diagnosing electrical components of
engine.
19 Vibrator connector (optional) Female plug for pluggingin vibrator electrical connection.
20 Vibrator toggle switch (optional) Push up to turn vibrator on. Push down to turn vibrator off.
21 Dummy plug (1/2 in./12 mm) Optional equipment.
22 Autolube switch (optional) Push in to manually activate the auto-lube system.
23 Remote control receptacle The radio receiver or cable remote control cord is plugged into this socket.
When connecting or disconnecting the radio/cable remote control cord, ensure the pump switches on the
control cabinet and remote control unit are in the OFF position. This will prevent unintended operation of
the machine.
24 Accumulator pressure gauge This 03000 PSI (205 BAR) pressure gauge indicates the pressure for the
shifting cylinder of the S-tube and pilot valves.
25 Main system hydraulic pressure gauge This 06000 PSI (410 BAR) gauge indicates the hydraulic
pressure required to pump the material.
26 Volume control Adjusts the output discharge volume of the delivery cylinders, which in turn is controlled by
the hydraulic pump. Turn knob counterclockwise to increase volume or clockwise to decrease volume. Do
not vary the pump output by varying engine speed. Optimum engine horsepower and pump flow are
attained at the rated engine speed.
A520154_03_1001 313
3.8.2 Electric Control Cabinet with Engine Display BSA120D

Control cabinet with engine display is shown below. For more information, please refer
to the Spare Parts Page and the electrical schematic that is included with this manual.
6 7 28
20 5
19 21 11
4 8 9 10
23 22
12 13 14 15
18 16
3
2 1 17
29
27 24 25 26
A520154_03_1001 10
Illustration 310: Control Box with Engine Display (BSA120D)

1 Key switch and engine start A 2position key switch is used to start and stop the engine. Turn key to start
(I) position to start engine. Turn key to off (O) position to stop engine.
2 Engine speed selector A toggle switch is used to change the engine speed. Press the toggle switch up to
the (+ rpm) position to increase engine speed. Press the toggle switch down to the (rpm) position to
decrease engine speed.
3 Function keys Used with graphical menu structure. For more information, please refer to the Technical
4 Deutz display Digital display of the engine status. For more information, please refer to the Technical
Note
NOTICE The engine display will not control or operate the pump. To operate the pump, use
the pump operation functions on the control box .
5 Hour meter Records the number of pump operating hours. Engine hours can be seen on the engine
display.
6 Pump running indicator (green) If illuminated, pump is running OK.
314 A520154_03_1001
7 Reverse pumping on indicator (green) Illuminates when pumping in reverse.

9 Pressure test and stroke change switch Momentary toggle switch (i.e., it returns to center position when
released):
Pressure Test function: Push up and hold to complete the pump stroke. At the end of the stroke, the pump
will pressure out to the maximum pressure. The maximum pressure can be read on the main system
hydraulic pressure gauge.
Stroke Change function: Temporarily push up to change the drive cylinder direction and shift the Stube
(i.e., change from pumping one cylinder to the other).
10 Reverse pumping toggle switch Push up to have pump to operate in reverse direction or push down to
have pump operate in forward direction.
11 Oil cooler fan switch Push up switch to turn on the oil cooler fan. Push down to turn off cooler fan.
12 Engine preheat (yellow) LED If illuminated, indicates that glow plugs have been activated to preheat the
engine prior to starting the engine in cold weather. Preheat engine until preheat LED goes out. Note:
Please refer to the Start Procedure for more information on using cold start aid in the engine
manufacturers operation manual included with these operating instructions.
13 Engine fault (red) LED Turns on when an engine fault occurs. For more information on engine faults,
please refer to the engine manufacturers operation manual.
14 Alternator fault indicator (red) Turns on when the alternator output is not sufficient to keep the battery
charged.
15 Emergency stop (E-stop) indicator (red) If illuminated, an emergency shut-down has been activated.
16 Emergency stop button Push in this button to stop diesel engine in emergency situations. To release knob,
twist knob clockwise.
17 Local/remote control switch This switch should be locked in either the local or remote position. In the
local position, the concrete pump operation is controlled by the switches on the electric control box (see
items 8, 9, 10, 16) . In the remote position, the switches on the electric control cabinet are disabled and
the concrete pump operation is controlled by the switches on the cable/radio remote control unit. For
operation of the remote control unit, refer to the Cable and Radio Remote Control Unit section on page
333.
18 Diagnostic plug Female connector used for troubleshooting and diagnosing electrical components of
engine.
19 Vibrator connector Female plug for pluggingin vibrator electrical connection.
20 Vibrator toggle switch Push up to turn vibrator on. Push down to turn vibrator off.
21 Dummy plug (1/2 in./12 mm) Optional equipment.
22 Autolube switch (optional) Push in to manually activate the auto-lube system.
23 Remote control receptacle The radio receiver or cable remote control cord is plugged into this socket.
When connecting or disconnecting the radio/cable remote control cord, ensure the pump switches on the
control cabinet and remote control unit are in the OFF position. This will prevent unintended operation of
the machine.
24 Accumulator pressure gauge This 06000 PSI (410 BAR) pressure gauge indicates the pressure for the
shifting cylinder of the S-tube and pilot valves.
25 Main system hydraulic pressure gauge This 06000 PSI (410 BAR) gauge indicates the hydraulic
pressure required to pump the material.
26 Suction pressure gauge
27 Control pressure gauge 01000 PSI (69 BAR)
28 Oil temperature
29 Volume switch
A520154_03_1001 315
3.8.3 Electric Motor Start Box

On BSA units with electric motors theres is an electric motor start box. The electric motor start
box is connected to a utility input power source and provides electric power to the electric motor.
On the electric motor start box panel there is one main On/Off switch, a second On/Off
switch, a green START push button, a red STOP push button, and a green RUN pilot light as
shown in Illustration 313.
2
ON
3 OFF
ON
OFF
4 RUN
START
5
6 STOP
A520154_03_1001 14
Illustration 314: Electric Motor Start Box (460V 60Hz YDelta)

1 Electric motor starter control box
2 Main power circuit breaker lever Position this lever to ON to close the main power circuit breaker
(power supply On) or to OFF to open the main power circuit breaker (power supply Off)
3 Main power ON/OFF switch Turns on or off 460V 60Hz input power. When switch is turned to ON
position, the red light on this switch illuminates.
4 Pump RUN light This green pilot light illuminates when the electric motor is running.
5 Electric motor START pushbutton Push this green button to start the electric motor.
6 Electric motor STOP pushbutton Push this red button to stop the electric motor.
DANGER
Electrocution hazard. Line voltage present with machine power off.
316 A520154_03_1001
3.9 Hydraulic System

Refer to the Hydraulic Circuit section and the Hydraulic Schematic in the Technical
Data Section for a complete description of the hydraulic system.
3.9.1 General BSA100

The hydraulic system of the BSA100 is an open loop type. This means that the
variable displacement pump pumps oil in one direction. The direction of the concrete
pumping cylinders is changed using an external valve.
3.9.2 General BSA120

The hydraulic system of the BSA120 is a closed loop type. This means that the
variable displacement pump can pump oil bidirectionally. The direction of the concrete
pumping cylinders is changed by changing the direction of the pump.
3.9.3 System Pressures

Refer to the Checking and Adjusting Hydraulic System Pressures procedure for proper
system pressure settings.
3.9.4 System Filtration BSA100

As shown in the diagram below, the hydraulic system is filtered by a return line filter
(single or double if equipped):
Yellow Red
3
Green
3
A520154_03_1001 11
Illustration 311: Hydraulic System Filtration Components (BSA100)

1 Hydraulic oil tank
2 Return filter
3 Return filter indicator gauge
CAUTION
Damage to hydraulic system can occur. Replace filter elements immediately if the
filter condition indicator is in the red range (43 PSI).
A520154_03_1001 317
3.9.5 System Filtration BSA120

As shown in the diagram below, the hydraulic system is filtered by a return line filter and
a suction filter.
Suction Gauge Pressure Gauge

3
2 4
A520154_03_1001 12
Illustration 312: Hydraulic System Filtration Components (BSA120)

2 Suction gauge
3 Pressure gauge
4 Suction filter
5 High pressure filter
318 A520154_03_1001
3.9.6 Oil Cooler

The oil cooler has several mounting configurations depending on the model. The
purpose is to cool the hydraulic fluid as it leaves the main control block or optional
equipment spool valve before going back to the hydraulic oil tank. Air flow may be
provided by an electric or hydraulically operated fan:
1
1
Electric Fan Hydraulic Fan

2 2 A520154_03_1001 13
Illustration 313: Oil Cooler
1 Hydraulic fluid outlet 2 Hydraulic fluid inlet
3.9.7 Main Hydraulic Pump BSA100

The main hydraulic pump, a variable displacement axial piston pump with a swash plate
design, is driven directly by the diesel engine. The swash plate is adjustable and
controls the stroke length of the piston, which adjusts the flow. The pump is also
equipped with a pressure compensator and a load (horsepower) limiter device.
A520154_03_1001 14
Illustration 314: Main Hydraulic Pump (BSA100)
1 Adjustment for Torque Limit 3 Adjustment for Cutoff Pressure

2 Adjustment for Differential Pressure
A520154_03_1001 319
3.9.8 Main Hydraulic Pump BSA120

The main hydraulic pump, a variable displacement axial piston pump with a swash plate
design, is driven directly by the diesel engine. The swash plate is adjustable and
controls the stroke length of the piston, which adjusts the flow. The pump is also
equipped with a pressure compensator.
A520154_03_1001 15
Illustration 315: Main Hydraulic Pump (BSA120)
3.9.9 Secondary Hydraulic Pump BSA100

The secondary hydraulic pump is an inline gear pump coupled to the main hydraulic
pump. When a remixer or other options are selected, then a double-stage pump is used.
One stage provides the flow and pressure requirements for the S-tube shifting circuit
(accumulator) and the second stage is used for the remixer circuit and other options.
3
A820090_03_0806D16
Illustration 316: Secondary Hydraulic Pump
1 Double-stage gear pump 3 To S-tube shift cylinder

2 To optional equipment (i.e., remixer,
hydraulic outriggers, and water pump.)
320 A520154_03_1001
3.9.10 Accumulator Hydraulic Pump BSA120

The accumulator hydraulic pump is a variable displacement pump. It provides the flow
and pressure requirements for the S-tube shifting circuit
A820090_03_0806D17
Illustration 317: Accumulator Hydraulic Pump
3.9.11 Remixer Hydraulic Pump BSA120

The remixer hydraulic pump is used for the remixer circuit and other options.
A820090_03_0806D18
Illustration 318: Remixer Hydraulic Pump
A520154_03_1001 321
3.9.12 Main Control Block BSA100

The main control block or manifold is mounted on top of the hydraulic tank. It is drilled
and ported to accommodate the relief valves, check valves, solenoid valves, and unload
valves used to enable operation of the concrete pump delivery cylinders as well as the
shifting of the Stube.
8
5
6
2
5
7 3
4
1
9
A820090_03_0806D19
Illustration 319: Location of Various Valves and Solenoids on the Main Control Block
1 Main control block
2 Accumulator discharge valve This 2-position 2-way solenoid operated cartridge valve relieves
accumulator pressure when the pump is stopped and the engine ignition switch is turned off.
3 Stube shift unload (accumulator charge) valve This hydraulically piloted cartridge valve adjusts
the S-tube shift circuit pressure.
4 S-tube shift relief valve This hydraulically piloted cartridge valve adjusts the S-tube shift relief
pressure.
5 S-tube shift pilot solenoid valve This 2-position 4-way solenoid operated valve controls the S-tube
shift valve.
6 S-tube shift valve This 2-position 4-way hydraulically piloted valve controls the S-tube shift
cylinders.
7 Main system pilot solenoid valve This 3-position 4-way solenoid operated valve controls the main
system valve.
8 Main system valve This 3-position 4-way spring centered hydraulically piloted valve controls the
drive cylinders.
9 Main system relief valve This adjustable relief valve controls the main system relief pressure.
322 A520154_03_1001
3.9.13 Main Control Block BSA120

The main control block or manifold is mounted on top of the hydraulic tank. It is drilled
and ported to accommodate the relief valves, check valves, solenoid valves, and unload
valves used to enable operation of the concrete pump delivery cylinders as well as the
shifting of the Stube.
3
4
1
5 6
13 7
12
8
11
9
10
A820090_03_0806D20
Illustration 320: Location of Various Valves and Solenoids on the Main Control Block
1 Accumulator dump solenoid-operated control valve
2 Pilot-operated control valve (S-tube shift)
3 Reverse pumping solenoid valve
4 Stroke change solenoid valves
5 Pushover hydraulics (POH) valve
6 Acorn nut
7 Automatic block
8 Main pressure relief adjustment
9 900 RPM adjustment
10 Manual volume control valve The manual volume control valve is used after: (1) removing the
acorn nut (item 6), (2) screwing the slotted set screw all the way in (located beneath the acorn nut on
the forward side of the compact block), and (3) replacing the acorn nut (item 6). Rotate (item 10)
clockwise to increase pumping rate or rotate counterclockwise to reduce pumping rate. This valve is
intended only for emergency operation since the pumping rate can normally be adjusted from the
electric volume control.
11 Electric volume control
12 1.2mm orifice
13 Compact block
A520154_03_1001 323
Note
NOTICE The following pressures are adjusted at the main control block using the
Checking and Adjusting Hydraulic System Pressures procedure:
S-tube shift circuit pressure
S-tube shift relief pressure
Main system relief pressure
3.9.14 Accumulator
An accumulator, which is used in the S-tube shift circuit, supplies a large volume of oil at
a high flow rate to the appropriate side of the shift cylinder.
A520154_03_1001 21
Illustration 321: Accumulator (Located on Top of Hydraulic Oil Tank)

1 Accumulator
2 Accumulator clamp
3 Hydraulic oil tank rear cover
The accumulator consists of the following components:

An outer shell
A rubber bladder inside the shell
A gas port with a gas valve on the shell top
A fluid port with necessary valves and seals on the shell bottom
The accumulator operates as follows: Upon installation of the accumulator, the bladder
is charged with dry nitrogen gas to the pressure specified on the hydraulic schematic.
The gas is used to inflate the bladder much like a balloon. The hydraulic fluid enters the
accumulator through the fluid port and fills the area at the bottom between the inner wall
of the shell and bladder. Because the fluid volume enters at a higher pressure, the
bladder is being compressed. At the appropriate time in the pump cycle, the S-tube shift
valve opens and the fluid is discharged to the shift cylinder. As soon as the oil is
discharged, the accumulator is refilled. The cycle is repeated continuously.
The accumulator will periodically require recharging, maintenance, or bladder

replacement. Refer to the Performing Maintenance on the Accumulator procedure.
324 A520154_03_1001
3.9.15 Accumulator Dump Valve BSA120

This machine is fitted with an electrical agitator safety cutout. The accumulator pressure
is dumped through an accumulator dump valve and the transfer tube halts, among other
measures, as soon as the grille on the hopper is opened.
The machine is fitted with an additional accumulator dump cock. The accumulator
pressure is also dumped when the accumulator dump cock is opened. The transfer tube
will still switch over while the machine is running, although at a lower pressure and very
slowly. This will allow you to halt the transfer tube in the centre position by switching off
the machine at the appropriate moment. You can then check the wear ring using a
mirror, for example.The transfer tube damping valve controls the switching speed of the
transfer tube.
DANGER
The transfer tube will continue to switch over when the accumulator dump
cock has been opened and the machine is running. There is still a danger of
crushing and severing of limbs.
Never reach into the hopper from below through the washout port nor
from above through the grille while the machine is running. Never poke
anything into the hopper.
3.9.16 Spool Valves

One or more spool valves may be used on a particular machine depending on the
hydraulic powered optional equipment installed (e.g., if the remixer and hydraulic
outriggers options are selected, a triple spool valve will be used; if the remixer and water
pump options are selected, a double spool valve will be used, etc.):
This option Requires this many spool valve control levers

Remixer One
Hydraulic outriggers Two (one for each outrigger cylinder)
Water pump One
Each manually operated directional control spool valve has an adjustable relief valve
and one or more control levers. Each spool valve also has a detented spool (i.e., when
the control lever is moved to a particular direction, it will remain in that position until
moved again). The spool valves are mounted between the hopper and the hydraulic oil
tank on the control panel side of the unit:
A520154_03_1001 325
4 4 4
5 5 5
1 2 3
A820090_03_0806D22
Illustration 322: Various Types of Spool Valves
1 Single spool valve 4 Manual control lever

2 Double spool valve 5 Relief valve adjustment
3 Hydraulic oil tank rear cover
Note
NOTICE For more detailed information on the hydraulically powered optional equipment,
refer to the Optional Equipment section.
3.10 Hydraulic Circuit

With the engine running, the PUMP switch in the OFF position, and the VOLUME
CONTROL turned in, the hydraulic pump is producing a minimal amount of pressure and
flow to enable lubrication of the pump. The main pump is de-stroked at this time. This
condition exists regardless of whether the engine is at idle or maximum RPM.
Set the engine speed at maximum RPM, with the throttle control on the panel. Open
VOLUME CONTROL, which is the flow control valve. In so doing, the main pump comes
on stroke and produces flow in proportion to the amount the flow control valve has been
opened. Turning the PUMP switch ON activates the Stube shift and main system
valves and directs flow to the hydraulic cylinders.
A relief valve is incorporated in the main control block to protect the system from
excessive pressures.
3.10.1 Delivery Cylinder Pump System

With the PUMP switch ON, the delivery cylinder pump circuit is energized. The cylinders
are designed to cycle alternately and the cycle is controlled by an electrical signal that is
generated at the end of each material cylinder suction or discharge stroke.
326 A520154_03_1001
A proximity switch, one for each cylinder is installed in each cylinder. As the piston in the
hydraulic cylinder passes under the proximity switch, an electrical signal is generated.As
the appropriate solenoid coil is energized, the flow of oil changes to the appropriate
hydraulic drive cylinder.
The hydraulic drive cylinders are identical. The main hydraulic system is designed to
provide the flow and pressure to the hydraulic piston or barrel side of the cylinder for
extending the rod and pushing the concrete out the Stube and discharge.
The hydraulic cylinders are tied together by hoses. The purpose of this is to transfer
hydraulic oil from one to the other during the extension/retraction stroke. As the rod of
one cylinder is extended, oil is pushed out and directed to the rod side of the other
forcing the rod to retract. The retracting rod forces the oil on the opposite side (barrel
side) back to the hydraulic oil tank.
It is possible in a no-load condition for there to be excess oil in the hydraulic loop
between the hydraulic cylinders. When this condition exists, the cylinder cannot be
totally extended and thus short strokes.
To correct this condition, actuate the PRESSURE TEST switch and hold until the
cylinder being extended is bottomed out fully. In normal operation, the check valves
installed on both cylinders are used to remove the excess hydraulic oil from the loop
between the cylinders during the extend/retract cycle. By holding the PRESSURE TEST
switch, you are forcing this excess oil out of the hydraulic loop between the two cylinders
and back to the hydraulic oil tank. Once the extending cylinder is at full stroke, regular
operation can continue.
3.10.2 S-Tube Shifting System

Installed at the rear of the main hydraulic pump is a secondary hydraulic pump. The
BSA100 uses a single or double-stage fixed displacement gear pump. The first stage is
used for the shifting circuit and the second stage is used for optional equipment (i.e.,
remixer, hydraulic outriggers, and water pump). The BSA120 uses a variable
displacement pump for the shifting circuit.
With the engine/motor running at full speed, oil flow is circulating through the S-tube shift
circuit. A relief valve is incorporated in the system.
The S-tube shift circuit is energized by activation of the PUMP switch to the ON position
and receipt of the electrical signal from the proximity switches.
As the proximity switch signal is generated, it operates the S-tube shift pilot solenoid
valve. When the solenoid coil is energized, it shifts the pilot valve spool which then
directs pilot pressure to the S-tube shift valve. The S-tube shift valve is then shifted,
allowing oil to flow to the appropriate side of the S-tube shift cylinder.
A520154_03_1001 327
Since the shifting of the S-tube from one delivery cylinder to the next requires instant
pressure and volume, which cannot be obtained by the system itself, an accumulator is
utilized. The accumulator is automatically filled with the required volume of oil and the
compression of the nitrogen bladder will provide the necessary pressure. The electrical
signal from the proximity switch is also used to open the S-tube shift unload valve,
allowing the pressurized oil to go to the S-tube shift valve and on to the S-tube shift
cylinder. The oil on the side of the S-tube shift cylinders not being pressurized is directed
back to the hydraulic oil tank. Immediately after the accumulator is discharged, the
S-tube unload valve closes and the accumulator is refilled.
As a safety to the system, an accumulator solenoid valve is used to automatically relieve

the accumulator pressure when the pump is stopped and the engine ignition switch is
turned off. When the engine ignition switch is in the off position, the solenoid valve
opens and oil from the accumulator is exhausted. The oil is directed through an orifice to
slow down the exhaust flow.
3.10.3 Auxiliary System BSA100

The second stage of the secondary hydraulic pump is the auxiliary system that provides
the necessary pressures and flows for operation of the following optional equipment:
Remixer
Hydraulic-powered outriggers
Water pump
3.10.4 Auxiliary System BSA120

The hydraulic gear pump located behind the accumulator hydraulic pump is the auxiliary
system that provides the necessary pressures and flows for operation of the following
optional equipment:
Remixer
Hydraulic-powered outriggers
Water pump
3.11 Hopper Grate Cutout Device

The hopper grate cutout device consists of a switching cam and a pressure roller switch.
The switching cam is fastened to the hinge pin of the hopper grate, the pressure roller
switch to the hopper. The pressure roller switch is acted on as soon as you open the
hopper grate. This causes the engine/motor to stop. You must switch the concrete pump
off, reset the throttle control to idle, and restart the engine/motor.
328 A520154_03_1001
1 2 3 4
A520154_03_1001 23
Illustration 323: Hopper Grate Cutout Device
1 Hopper 3 Switching cam

2 Hopper grate hinge pin 5 Pressure roller switch
CAUTION
The pressure roller switch must always be clean and free to move. In addition, the
pressure roller switch must always be in contact with the switching cam. If the
pressure roller switch is defective, the hopper grate cutout device may not
function, or the diesel engine may stop during pumping operations.
WARNING
BEFORE LIFTING HOPPER GRATE TO WORK ON CONCRETE PUMP, VERIFY
THAT HOPPER GRATE CUTOUT DEVICE IS WORKING PROPERLY BY
PERFORMING THE FOLLOWING STEPS: (1) While concrete pump is ON, reach
hand beneath cutout cover and push switch up (refer to diagram below). DO NOT
ATTEMPT TO RAISE HOPPER GRATE. (2) Verify that engine/motor stops and
concrete pump turns OFF.
A520154_03_1001 329
Hopper grate cutout cover,

which is located on side of
hopper.
Position of hopper grate cutout

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

when hopper grate is OPEN. In this po
sition, the concrete pump should auto
matically turn OFF.
A820090_03_0806D24
Illustration 324: Checking the Hopper Grate Safety Cutout Device
330 A520154_03_1001
3.12 Optional Equipment
3.12.1 Auto-Lube System

An auto-lube system, which is an option for all models, automatically lubricates all
lubrication points at the interval specified by its timer:
2
1
3
A520154_03_1001 25
Illustration 325: Auto-Lube System

1 Auto-lube manual override switch This push button, which is located on the side of the electric control
cabinet, can be pressed to manually turn on the auto-lube pump, regardless of its timer setting. This switch
illuminates when depressed.
2 Grease block This block distributes the grease from the auto-lube pump to the lubrication points. The
number of ports on the block vary depending on the equipment installed (i.e., single or double S-tube shift
cylinder, remixer, etc.).
3 Auto-lube pump This electrically operated pump consists of a pump housing, electric gear motor, timer,
and plastic reservoir with a stirring paddle. The pump automatically turns on and off at the interval specified
by the on-time and off-time rotary switches. The pump can also be manually turned on by pressing the
manual override switch (item 1).
Note
NOTICE When the auto-lube pump reservoir reaches the MIN mark located on the
reservoir, fill it to the MAX mark with an appropriate grease listed in the
Recommended Lubricants section in the Maintenance chapter.
A520154_03_1001 331
3.12.2 Cable and Radio Remote Control Unit

A cable or radio remote control unit can be connected to the control panel and used to
control the concrete pumping operation:
Note
NOTICE The cable or radio remote control unit will control the concrete pumping operation
only if: (1) It is plugged into the remote control receptacle on the control cabinet
and (2) the local/remote switch on the control cabinet is in the remote
position.
Cable Remote 12V (Optional)
A820090_03_0806D26
Illustration 326: Cable Remote Control Unit Diagram

1 Remote control receptacle on side of electric control cabinet
2 Cable remote control unit
3 Emergency stop button Push in this button to stop concrete pump in emergency situations.
Pushing in this button will not stop the engine/motor. To release knob, twist knob clockwise.
4 Pump on/off toggle switch Push to right to turn pump on or push left to turn pump off.
5 Reverse pumping toggle switch Push to right to have pump operate in reverse direction or push to
left to have pump operate in forward direction.
332 A520154_03_1001
Cable Remote RPM/VOL 12V (Optional)
A820090_03_0806D27
Illustration 327: Cable Remote Control Unit Diagram

1 Remote control receptacle on side of electric control cabinet
2 Cable remote control unit
3 Emergency stop button Push in this button to stop concrete pump in emergency situations.
NOTE: Pushing in this button will not stop the engine/motor.
To release knob, twist knob clockwise.
5 Reverse pumping toggle switch Push to right to have the pump operate in reverse direction or push
to left to have the pump operate in forward direction.
6 Volume increase/decrease toggle switch Push to right to increase volume or push to the left to
decrease volume.
7 RPM (Speed) increase/decrease toggle switch Push to right to increase engine speed (RPM) or
push to left to decrease engine speed (RPM).
A520154_03_1001 333
3.12.3 Radio remote control (optional)

A radio remote control unit can be connected via radio frequency to the control box to
control the concrete pumping operation:
Note
NOTICE The radio remote control unit will control the concrete pumping operation only if:
(1) the receiver is plugged into the remote control receptacle on the control box
and (2) the local/remote switch on the control box is in the remote position.
Radio Remote with ON/OFF/REV/RPM/VOLUME (Optional)
1
2
6
3
7
4
A820090_03_0806D28
Illustration 328: Optional Radio Remote Control Unit

1 Emergency stop button Push down button to activate Emergency Stop. Twist to unlock (reset) the
Estop.
NOTE: Pushing this button will not stop the engine/motor.
2 Power On button Press button to turn the transmitter On
3 Battery low LED Illuminates when the transmitter battery is low
4 Function buttons:
Button 1 or 2 Momentary output pump forward
Button 3 & 4 Turns off pump reverse
Button 5 or 6 Latch on pump reverse and Active LED
Button 7 RPM decrease (optional)
Button 8 RPM increase (optional)
Button 9 Volume decrease (optional)
Button 10 Volume increase (optional)
5 Power Off button Press button to turn the transmitter Off
6 Active LED/Reverse Indicator Flashes yellow when button 5 or 6 is pressed
7 Radio receiver Connected to receptacle on control box. Receives signal from transmitter.
Note: For more information, please refer to the radio remote control installation/configuration
manual in the Technical Enclosures section.
334 A520154_03_1001
3.12.4 Hydraulic Outriggers

Hydraulic front outriggers are standard. A double-spool manually operated directional
control valve is required to control the outrigger hydraulic cylinders:
1 2 2 6
3
2 2
4 5
A820090_03_0806D29
Illustration 329: Hydraulic Outriggers

1 Hydraulic outrigger cylinder (RH)
2 Hydraulic fluid lines between outrigger cylinders and outrigger spool valve
3 Trailer (reference)
4 Jack stand weldment (RH)
5 Jack stand weldment (LH)
6 Hydraulic outrigger cylinder (LH)
7 Outriggers spool valve A double-spool valve is used to control the hydraulic outriggers. One spool
is used to control the extension/retraction of the right side outrigger cylinder and the other spool
controls the left side outrigger cylinder. When lever is positioned vertically (i.e., straight up), the
hydraulic outrigger is off. Push lever towards unit to lower outrigger leg or pull lever away from unit
to raise outrigger leg.
Note
NOTICE For more detailed information on spool valves, refer to the Spool Valves
section.
A520154_03_1001 335
3.12.5 Remixer
A remixer is standard. A single-spool manually operated directional control valve is
required to control the remixer pump:
5 4
4
3 5
2 6
1
1 7
A820090_03_0806D30
Illustration 330: Remixer Assembly

1 Remixer motor This hydraulic motor is powered by the second stage of the secondary hydraulic
pump and is controlled by the remixer spool valve.
2 Torque arm
3 Bearing
4 Hopper (reference)
5 Remixer paddles
6 Hydraulic fluid lines going between spool valve and remixer motor
7 Remixer spool valve This single spool directional control valve controls the remixer pump. When
lever is positioned vertically (i.e., straight up), the remixer pump is off. Push lever towards unit to
rotate remixer paddles in counterclockwise direction or pull lever away from unit to rotate remixer
paddles in clockwise direction. This spool valve has a relief valve, which can be adjusted using the
Adjusting Remixer Relief Pressure procedure.
Note
section.
336 A520154_03_1001
3.12.6 Water Pump (optional)

A water pump is optional. A single-spool manually operated directional control valve is
required to control the water pump:
4 5
A820090_03_0806D31
Illustration 331: Water Pump Assembly

1 Water pump This water pump is driven by the gear motor shown above.
2 Coupling This coupling connects the water pump to the hydraulic gear motor.
3 Bracket This bracket mounts the water pump assembly to the frame of the truck or trailer.
4 Hydraulic gear motor This motor is powered by the second stage of the secondary hydraulic pump
and is controlled by the water pump spool valve.
5 Hydraulic fluid lines going between spool valve and gear motor
6 Water pump spool valve This single spool directional control valve controls the water pump. When
lever is in a vertical position, the water pump is off. Push lever towards unit to turn water pump on.
Note
section.
A520154_03_1001 337
3.12.7 Cylinder Stroke Counter (optional)

A cylinder stroke counter is optional:
2
A820090_03_0806D32
Illustration 332: Cylinder Stroke Counter

1 Cylinder stroke counter Increments by one each time the S-tube shifts.
2 Hydraulic system oil tank (reference)
When a stroke counter is installed, an electrical wire from the counter is connected to
the control cabinet and is part of the POH/stroke changeover circuitry. Each time that
the Stube shift cycles the counter will display a numeric value.
Note
NOTICE The stroke counter only measures the Stube shift cycles. It does not measure
pump operating hours. Engine/motor operating hours are measured by the hour
meter on the control cabinet (except for units with Deutz display).
338 A520154_03_1001
3.12.8 Vibrator Kit (optional BSA100 / standard BSA120)

A vibrator kit is an option and is installed on the hopper grate. The vibrator causes the
hopper grate to vibrate and helps prevent bridges from forming on the hopper grate,
particularly in the case of very stiff concrete. The vibrator is electrically driven and its
connector is plugged into the round socket on the side of the electric control cabinet.
The vibrator is switched on and off at the electric control cabinet.
1
3
4
A820090_03_0806D33
Illustration 333: Vibrator Kit
1 Hopper grate 3 Supply cable

2 Vibrator 4 Connector plug
A520154_03_1001 339
3.12.9 Volume Control Kit (optional BSA100)
CAUTION
Do not vary the pump output by varying engine speed. Optimum engine
horsepower and pump flow are attained at the rated engine speed.
The volume control on the machine, adjusts the output discharge volume of the delivery
cylinders, which in turn is controlled by the hydraulic pump. Discharge volume may be
increased or decreased manually with the volume control knob or electrically with the
electric volume control kit.
The volume control kit is available as an option and is installed in place of the manual
volume control. The harness of the volume control is connected to the electric control
cabinet and can be operated at the control cabinet with a VOL (+/) toggle switch or a
cable remote with VOL (+/) toggle switch, or with a radio remote control transmitter with
a VOL (+/) pushbutton.
4
1
A820090_03_0806D34
Illustration 334: Volume Control Kit (12V)
1 Volume control valve 3 Minicheck test point

2 Flow control valve (12V) 4 Decal (VOL+/)
340 A520154_03_1001
4 Travel and set up
In this section you will find information concerning safe transport of the machine.

4.1 Transport 42
4.2 Towing of Trailer 42
4.3 Requirements for the setup site 43
4.4 Clearance from pits 44
4.5 Connection 45
4.6 Stationary delivery lines 45
A520154_04_0903 41
Travel and setup
4.1 Transport
Putzmeister BSA Trailer Pumps have tandem axles that are designed for highway travel
and job site use. The steel frame trailer is fully equipped with trailer lighting and a
breakaway system in case the trailer becomes unhitched.
Note
NOTICE The driver of the towing unit must have a valid drivers licence.
4.2 Towing of Trailer

Prior to towing a trailer, the following safety precautions must be observed:
Note
NOTICE Although small when compared to some construction equipment, still requires the
same care and attention during transportation as does larger heavier type
equipment. It is designed to be towed at highway speeds not to exceed 55 MPH
(88 Km/H), depending on the road conditions, by a vehicle capable of pulling the
unit based on the Gross Vehicle Weight stamped on the units VIN plate.
Check the truck and trailer tires for proper inflation pressure: Inspect tires for cuts and
excessive wear.
Secure hitch and lock in place.
Attach the break away cable, and safety chain to the towing truck.
Attach trailer electrical cable to truck wiring to activate lights and electric trailer brakes
when so equipped.
Raise and pin the outrigger legs in retracted position.
Fully raise front jack post and store foot plate, if so equipped.
Check tail lights, stop lights and clearance lights.
Do not tow the unit with concrete in the hopper.
Remove all concrete delivery line components from the pump.
42 A520154_04_0903
Travel and setup
CAUTION
If you have changed the tires, you must retighten the wheel nuts after
approximately (31 mi.) 50 km. See the spare parts sheet for the tightening torques.
Check that the support legs are secured in the driving position.
Observe the permissible gross laden weight.
Check that the oil and water tanks are not leaking and that they are securely closed.
Keep an adequate distance from slopes and pits.
Only drive over arches, bridges or other supporting structures if the loadbearing capacity
is adequate.
Be aware of the elevated position of the trucks centre of gravity when travelling on a
slope and on ascending or descending routes.
4.3 Requirements for the setup site

As a rule, the site management determines the setup site for the machine and prepares
the site accordingly
Note
NOTICE The machine operator takes responsibility for setting up the machine safely.
Inspect the proposed site carefully and reject the setup site if you have any doubts in
respect of safety.
DANGER
Injuries to the respiratory passage. Vehicle exhaust gases contain constituents
which can be lethal or carcinogenic. Set the machine up at an adequately
ventilated site or vent the exhaust gases away from where you are working.
4.3.1 Accessibility
Ensure that the setup site is adequately ventilated. The setup site must be level. It
must be large enough for the machine to be accessible for operation and maintenance
work from all sides. You must be able to open all the guards, flaps and hoods without
hindrance. Secure a clearance of at least one metre around the entire machine.
A520154_04_0903 43
Travel and setup
4.3.2 Approach route

The approach route must be sufficiently firm that it can be driven over regardless of the
weather conditions. Walk the approach route before you drive over it. Ask for a signaller
if you have to reverse.
4.3.3 Space for truck mixers

The approach route to the concrete pump must be capable of being driven over by truck
mixers regardless of the weather conditions. There must be sufficient space around the
concrete pump for truck mixers to manoeuvre and turn. There must be sufficient space
around the hopper for two truck mixers to unload at the same time.
4.3.4 Supporting Ground

The supporting ground must be firm enough to take the forces conducted by the support
feet into the ground. There must not be any voids or unevenness of ground under the
support feet. It is recommended that you choose a setup site which has been
concreted if the concrete pump is to remain on the same setup site for a prolonged
period. It is recommended that concrete pumps working at highpressure and high
delivery rate be securely anchored.
4.4 Clearance from pits

A minimum distance must be maintained from pits, slopes, excavations etc. so that the
machine cannot topple over.
The minimum clearance a for machines with a gross weight of up to 12 tons is 1 metre.
4
5
44 A520154_04_0903
Travel and setup
4.5 Connection
In order to be able to set up a stationary concrete pump on the construction site, you
must:
Connect the stationary delivery line
Have the hydraulic power pack connected to the electrical power supply
Start up the remote control.
4.6 Stationary delivery lines

When pumping concrete, you must only use perfect and safe delivery lines, couplings
and seals. The delivery lines and couplings must be specially designed for the pressure
specified on the pump rating plate. The delivery lines are subject to wear, which is
dependent upon:
The concrete pressure
The concrete composition
The delivery line material
10
9
8
7
6
5
4
3
2
1
A520154_04_0903 1
Illustration 41: Delivery lines
1 Pressure pipe 6 Delivery pipe (adapter pipe)

2 Bolted coupling 7 Clamp coupling
3 Reducer 8 Pipe bracket
4 Clamp coupling 9 Vibration damper
5 Pipe bracket 10 Delivery pipe (adapter pipe)
A520154_04_0903 45
Travel and setup
4.6.1 Danger Zone

Danger zone for stationary delivery lines

3m A520154_04_0903 2
Illustration 42: Danger zone
DANGER
Serious injuries may be caused by explosion of a delivery line as a result of a
sudden increase in pressure. Do not remain in the danger zone of a stationary
delivery line. Cover the stationary delivery line with a metal casing or timber
cladding if persons are working in its immediate vicinity.
11001300
Illustration 43: Cover delivery line
Cover delivery lines
46 A520154_04_0903
Travel and setup
4.6.2 Instructions for laying the line

The stationary delivery line can be laid horizontally over the ground, or vertically or
inclined against walls. The entire length of the delivery line must be easily accessible
and removable.
Note the following points when laying the delivery line:

Lay the stationary delivery line without stresses.
Support the delivery line so that couplings can be easily fitted and removed. Double
wooden chocks (see illustration) are most suitable as they allow for longitudinal and
latitudinal movement by the delivery line.
A520154_04_0903 3
Illustration 44: Double wooden chocks

Use highly wearresistant pipes for sections which are difficult to access.
Begin laying the delivery line at the concrete pump, otherwise you will have to line up the
concrete pump to the delivery line.
A520154_04_0903 4
Illustration 45: Delivery line at right angle

Delivery line leading away at a right angle to the concrete pump
Route the stationary delivery line away from the concrete pump at right angles to it. This
A520154_04_0903 47
Travel and setup
minimizes the effect of pump pulsations which may be transmitted from the delivery line
to the pump and vice versa.
Fit only asnew delivery pipes near the pump, as the concrete pressure is highest here.
Secure couplings against spontaneous opening.
You must also take into account any components of the delivery line required for
distribution and cleaning such as a Tdelivery pipe with washout port, scraper pig gates,
transfer tubes, gate valves etc.
4.6.3 Fastening
Pump pulsations occur when pumping concrete. These are caused by the pump itself
and are transmitted to the conveying system. The stationary delivery line must be safely
secured and stabilised on the supporting ground.
DANGER
There is a risk of serious injury from falling items. Do not secure the stationary
delivery line to reinforcements or scaffolding as these can be moved and could
collapse. If you wish to secure the stationary delivery line to reinforcements
or scaffolding, check whether the scaffolding can bear the load.
All horizontal delivery lines must be anchored on the supporting ground.

Use pipe brackets which are secured to a suitable supporting ground capable of bearing
the load. The pump pulsations are reduced and the delivery line is prevented from
bending.
Fasten the delivery line
A520154_04_0903 5
Illustration 46: Fasten the delivery line
48 A520154_04_0903
Travel and setup
A fixed point is a 1 2 m3 large, reinforced lump of concrete with a delivery pipe secured
to it or sealed inside it. It takes pump pulsations from the delivery line.
Install a fixed point near to the concrete pump.The pump pulsations are reduced and the
delivery line is prevented from bending.

A520154_04_0903 6
Illustration 47: Elasticity of the delivery line using a fixed

point
Vertical or angled delivery lines leading upwards or downwards must always be fastened
to the structure or background so that they are selfsupporting. The delivery line must
not be supported by the lowest pipe bend.
11001100
Illustration 48: Fastening the delivery line
The lowest bend should be a thickwalled 90 cast pipe bend with a radius of 1 m.
The delivery line is called a riser if it is laid in such a way that the concrete is pumped
upwards.
The weight of the concrete in the riser exerts a force on the concrete pump
(approximately 30 kg per metre of continuous pipe) when the pump is switched off.
Install a gate valve at the start of the riser.The delivery line can be closed off so that the
pressure bears on the gate valve and not on the concrete pump.
A520154_04_0903 49
Travel and setup
The delivery line is called a downpipe if it is laid in such a way that the concrete is
pumped downwards.
The concrete flows down through the delivery line under its own weight when the pump
is switched off. This causes the concrete column to break off and the concrete can
segregate.
Install a gate valve at the end of the downpipe.The delivery line can be closed off so that
the concrete cannot flow out of the delivery line.
410 A520154_04_0903
5 Operation
In this chapter you will find information on the operation of the machine. You will learn
what operations are required for commissioning, for setting up the machine, in pumping
operations and for cleaning.

5.1 Preliminary Information 52
5.2 Hand signals for pumping 52
5.3 Setup 53
5.4 Start-Up 59
5.5 Maintenance During a Pour 517
5.6 Breaks in Pumping 522
5.7 Cleaning 525
5.8 Shutting Down 542
5.9 Pumping Concrete with the Emergency Stroke Change Kit 543
A520154_05_1001 51
Operation
5.1 Preliminary Information

Before attempting to place material with the machine, operators must be thoroughly
trained in its operation. Before using the machine, complete the following steps:
Completely inspect the unit for worn or damaged parts, loose bolts, missing parts, etc.
The delivery line is designed to withstand the relevant concrete pressure.
The delivery line is correctly laid.
Perform periodic maintenance on the unit, as outlined in the Maintenance section of this
manual.
Note
NOTICE Check in the Quick troubleshooting guide chapter first if a malfunction occurs
during pumping operations.Consult the Putzmeister Customer Service Group if
you cannot rectify the fault yourself.
WARNING
Read and comply with all safety rules, notes, and warnings contained in this
manual. This is absolutely essential to the safe, efficient operation of the unit.
5.2 Hand signals for pumping

It is particularly important that the machine operator at the concrete pump and the
concreting gang working at the placement site can communicate with each other if
accidents are to be avoided when pumping. Communication is particulary important in
longdistance and highrise pumping where the machine operator cannot see the site of
concrete placement. Communication may be via unambiguous and noninterchangable:
acoustic signals such as a horn, twoway radio, field telephone etc.
optical signals such as light signals, hand signals etc.
a combination of optical and acoustic signals
Suggestions for hand signals are based on guidelines issued by the American Concrete
Pumping Association. The direction of movement is specified from the machine
operators direction of view.
52 A520154_05_1001
Operation
Illustration 51: ACPA Hand Signals
Note
NOTICE For further reference please refer to the ACPA (American Concrete Pumping
Association) Safety Manual included with this manual.
5.3 Setup
5.3.1 Pre-Operation Inspection

Prior to operating the machine, perform a pre-operation inspection by checking the
following items:
Note
NOTICE Performing a pre-operation inspection prevents downtime and helps maintain the
machine in proper working condition between scheduled maintenance checks.
WARNING
Defective components, structural damage, missing parts or equipment
malfunctions, jeopardize the safety of the operator and other personnel and can
cause extensive damage to the machine. A poorly maintained machine could
become the greatest operational hazard you may encounter. It should be a
common practice that the operator perform a thorough walk-around inspection
before each days operation of the machine.
A520154_05_1001 53
Operation
WARNING
If any discrepancy is noted during the pre-inspection, perform Lock OutTag Out
procedure and attach a sign at the control panel stating DO NOT OPERATE and
repair the discrepancy before operating the machine.
Overall machine condition:

External structural damage
Wheel lug nuts (missing or loose)
Wiring and brake lines
Condition of tires (tears, cracks or cuts, inflation)
Missing decals, placards, warning signs
Missing, broken or damaged parts, bolts and nuts
Control panel, switches, gauges, volume control
Electrical system for frayed or broken wires or loose connections
Engine
Fuel level
Oil level
Mounting (bolts, wiring, hoses)
Fuel or oil leaks
Belts (fan, alternator)
Battery
Battery condition
Cables and connections (ground connection)
Battery hold down security
Hydraulic System
Hydraulic leaks
Loose or damaged hoses, tubing
Fluid level, hydraulic tank breather cap. Refill only with an appropriate hydraulic fluid
listed in the Recommended Lubricants section in the Maintenance chapter.
Hydraulic valves and control levers
Cleanliness of hydraulic fluid. Non-milky, bright in color
Hydraulic cylinders, Stube shift and delivery cylinders
Hopper
Grate, grate safety cut-out are in place, not damaged
Stube
Remixer paddles, drive motors
Outlet cleanliness
Lubrication
54 A520154_05_1001
Operation
5.3.2 Trailer Setup

To set up a machine, perform the following steps:
Note
NOTICE The unit should be located on level ground as near as possible to the placement
site.
1. Check the condition of the soil or flooring where the machine will be positioned. Keep
sufficient distance from excavations and slopes that could breakaway due to support
loads. Place chocks behind wheels on inclines and slopes.
2. After a location has been determined level the trailer by performing the following
steps:
Lower front leveling jack post, placing foot pad under the post. Depending on soil
condition, it might be necessary to place wooden blocking under foot pad.
Disconnect safety chain, hitch, and electrical cable from towing vehicle.
Lower rear outriggers and place additional blocking under pads. Pin manual legs in
place.
Level the machine using the front jack, raising or lowering as necessary.
During the pumping operation, periodically check the levelness of the machine and
blocking pads.
5.3.3 Filling the Machine with fuel

Your machine is driven by a diesel engine. The fuel tank is built into the superstructure,
its filler pipe is on the top. You may refuel the machine, once it is switched off, through
the filler pipe.
Note
NOTICE Refill the fuel tank in good time, as otherwise you will have to bleed the fuel line to
the diesel engine.Fill the fuel tank with commercially available branded diesel fuel
only, as otherwise the diesel engine can be damaged.Use summer or wintergrade
diesel fuel according to the outside temperature.
CAUTION
Only fill the machine with fuel with the engine switched off.Pay attention to
accuracy when filling the machine with fuel.Do not spill a single drop of fuel.
A520154_05_1001 55
Operation
5.3.4 Considering Concrete Properties

Properties of the concrete such as its consistence and grading curve are decisive factors
for the optimum fill level of the delivery cylinders. The fill level influences the level of
efficiency of the pump, i.e. the output per stroke.
2
1
11000401
Illustration 52: Saturated Mix
1 Aggregate 3 Boundary layer

2 Cement paste
Note
NOTICE A low fill level will be achieved in the delivery cylinder if the consistence is too
stiff and the grading curve of the aggregates is unfavourable (low sand content,
broken material). In such cases, reducing the speed of pumping can increase the
output.
56 A520154_05_1001
Operation
5.3.5 Delivery System Setup

When setting up the delivery system, observe the following recommendations:
Note
NOTICE The delivery system is all the components used from the pump discharge to the
placement site. This could consist of delivery hose, steel piping, clamps,
couplers, and reducers.
Set up the delivery line using a minimum length of rubber delivery hose. Rubber hose
offers three times the resistance to the flow of concrete as compared to steel pipe.
Concrete will flow with less back pressure through pipe than through hose. Bends in
hose or pipe elbows will also require more pressure. The operator should take these
facts into consideration when laying out the delivery line.
The most direct line feasible should be used from the machine to the placement site.
If the delivery line will cross rebar, supports must be considered for the pipe so that it
does not contact the rebar mat.
The steel pipe, elbows, reducers, and hoses should be equipped with high pressure
heavy duty ends.
Note
NOTICE Putzmeister has available a complete stock of hoses, pipe, elbows, clamps,
couplers, and reducers to fit your needs.
A520154_05_1001 57
Operation
CAUTION
If the delivery system has not been furnished by Putzmeister then it will be
necessary to contact the manufacturer for the maximum pressure capability of the
delivery components to be used.
The concrete delivery system must be capable of withstanding the machines concrete
working pressure listed on the machine rating plate (refer to page 38). If a hose is
used, it must have a burst pressure that is at least 3 times the working pressure.
It is important to size the inside diameter of the delivery system based on the size
aggregate being used. The general rule is the inside diameter should be 3 to 4 times the
size of the largest aggregate in the mix to be pumped. Here are several examples:
11/2 inch (38 mm) rock (8 to 10% maximum content by weight) requires a 5 inch
(127 mm) diameter concrete delivery system.
1 inch (25mm) rock (10 to 15% maximum content by weight) requires a 4 inch
(100mm) diameter concrete delivery system.
3/4 inch (19mm) or smaller rock (10 to 15% maximum content by weight) requires a 3
inch (76 mm) diameter concrete delivery system.
The hoses or pipe should be placed to the farthest point from the hopper discharge
outlet first. It is easier to remove than to add lines.
Only couplings or clamps that are clean and seals that will retain the slurry in the delivery
line should be used.
WARNING
Dirty couplings leak, and inevitably causes blockage. Do not use any worn or
damaged hoses, pipes or couplings.
Note
NOTICE If your pumping job requires a vertical concrete delivery system:
The vertical pipe line should be anchored every 10 feet (3m)
Pumping up requires higher pumping pressure
Pumping down can cause separation of the mixture which can cause
blockages. Maintaining back pressure in the delivery system will help to
reduce separation and blockages.
If the machine is stopped during vertical pumping, then the back pressure
created by the weight of the material may push the pumping delivery cylinder
towards the water box. It is then necessary to use the Pressure Test/Stroke
Change switch (refer to page 312 or 316; item 5, Ill. 310 or item 9, Ill. 311 in
the General Technical Description section) to correct the cylinder at the restart
of pumping.
58 A520154_05_1001
Operation
5.4 Start-Up
WARNING
To avoid damage to engines with turbochargers, when starting engine, DO NOT
run up the engine immediately to high idling speed or proceed to full load
operation from the cold state. Let engine warm up at low idling speed for about 30
seconds. Then idle up to high idling speed and proceed to full load operation.
Cold starting with immediate runup to high idling speed or full loading may
cause bearing damage to occur in the turbocharger.
5.4.1 Start-Up of Concrete Pump Powered by a Diesel Engine

To start a concrete pump powered by a diesel engine, perform the following steps:
1. Fill water box with water.
2. Prime the fuel system using the manual pump on the fuel prefilter.
8 5 8 5
6 11 3 4 11 3 2 4
2 6
9
9
1 7 1 7
10 10
BSA100D BSA120D
A520154_05_1001 3
Illustration 53: Electric Control Cabinet
1 Power key switch (engine start) 7 Local/Remote toggle switch

2 Alternator fault light (red) 8 Hour meter
3 Engine fault light (red) 9 EMERGENCY STOP pushbutton
4 Estop indicator (red) 10 Engine throttle
5 Pump direction toggle switch (push down for
11 Engine preheat indicator
Forward direction)
6 Engine tachometer (digital display)
3. At the control panel, start the pump as follows:
A520154_05_1001 59
Operation
A. Turn the engine key switch (item 1, Ill. 53) clockwise to the run position.
Check that the Emergency Stop indicator (item 4, Ill. 53) is not lit. Reset Emergency
Stops and/or hopper grate switch as necessary.
The Engine Fault (item 3, Ill. 53) and Alternator Fault (item 2, Ill. 53) indicators will
light.
The Engine Preheat indicator (item 11, Ill. 53) will light. If it is below 32F (0C), it
will remain lit for 12 seconds. Wait until this indicator goes out before starting the
engine.
B. Turn the engine key switch (item 1, Ill. 53) clockwise against the spring pressure to the
start position.
C. Release the key as soon as the engine starts.

Check that the Engine Fault (item 3, Ill. 53), Alternator Fault (item 2, Ill. 53), and
Engine Preheat (item 11, Ill. 53) indicators are not lit.
Do not actuate the starter for more than 20 seconds. If the engine does not start up,
wait for one minute and the repeat the starting process.
D. Allow the engine to warm up. Do not run the engine immediately to high speed / full load
operation.
E. Engine speed is controlled by the engine throttle switch (item 10, Ill. 53).
4. At the control panel, verify that the pump controls are ready by:
A. Having the local/remote switch (item 7, Ill. 53) in local () for operation at the panel or in
remote () for operation using a cable or radio remote control.
B. Verify the forward/reverse switch (item 5, Ill. 53) is in forward (down).
510 A520154_05_1001
Operation
5.4.2 Emergency Stop Button Locations

In the event of an emergency, the diesel engine or electric motor can be shut down by
pushing on the Emergency stop button on the electric control cabinet:
2 2
1
1
BSA100 BSA120
A520154_05_1001 4
Illustration 54: Emergency Stop Button on Electric Control Cabinet

1 Emergency Stop button
2 Emergency Stop indicator (red)
At the electric control cabinet, pushin Emergency Stop button (item 1, Ill. 54) the red
Emergency Stop indicator will illuminate (item 2, Ill 54).
To release the Estop button, twist the knob clockwise

To restart the pump, the pump on switch needs to be activated twice
In the event of an emergency, the pump will be shut down by pushing on the Emergency
stop button on the cable remote control unit or radio remote control transmitter.
Note
NOTICE Pushing the Emergency Stop button on the cable remote control unit or the radio
remote control transmitter will not stop the diesel engine.
A520154_05_1001 511
Operation
5.4.3 StartUp of Concrete Pump Powered by an Electric Motor

To start a concrete pump powered by an electric motor, perform the following steps:
1. Fill water box with water or water soluble oil.
2. Connect motor starter control box to 3-phase AC input (please refer to electrical schematic in
the Technical Data section of this manual).
2
ON
3 OFF
ON
OFF
4 RUN
START
5
6 STOP
A520154_05_1001 6
Illustration 56: Electric Motor Start Box (460V 60Hz YDelta)

1 Electric motor starter control box
2 Main power circuit breaker lever Position this lever to ON to close the main power circuit breaker
(power supply On) or to OFF to open the main power circuit breaker (power supply Off)
3 Main power ON/OFF switch Turns on or off 460V 60Hz input power. When switch is turned to ON
position, the red light on this switch illuminates.
4 Pump RUN light This green pilot light illuminates when the electric motor is running.
5 Electric motor START pushbutton Push this green button to start the electric motor.
6 Electric motor STOP pushbutton Push this red button to stop the electric motor.
DANGER
Electrocution hazard. Line voltage present with machine power off.
3. At electric motor starter control box, start the electric motor as follows:
Close main power circuit breaker (item 2, Ill. 56) using lever on outside of motor starter control
box.
Turn CONTROL PWR switch (item 3, Ill. 56) to ON. Verify that red light on control power
switch is illuminated.
512 A520154_05_1001
Operation
Press motor START push button (item 5, Ill. 56). Verify that 3-phase AC motor starts and
accelerates to rated speed. Also verify that green PUMP RUN light (item 4, Ill. 56)is
illuminated.
4. At the electric control cabinet, perform the following steps:
3 4 3 4
2 2
5 1 5
1
BSA100 BSA120
A520154_05_1001 4
Illustration 57: Electric Control Cabinet
1 Power key switch 4 Forward/Reverse pumping toggle switch

2 Pump On/Off toggle switch 5 Local/remote control switch (locks when in
local position
3 Pump running indicator (green)
Turn power key-switch (item 1, Ill. 57) to ON.

Place pump On/Off toggle switch (item 2, Ill. 57) to ON position.
Check that pump direction switch (item 4, Ill. 57) is in FORWARD position.
If using cable or radio remote control:
Turn local/remote toggle switch (item 5, Ill. 57) to Remote position.
Place toggle switch (item 3, Ill. 53) on cable remote control to FORWARD position.
Push FORWARD pushbutton (item 4, Ill. 53) on radio remote control transmitter
Note
NOTICE Before proceeding to cycle the pump it will be necessary to prime the pump and
delivery system. This is accomplished by pumping a coating of lubricating grout
through the Stube and into the delivery lines. This will enable the regular
concrete mix to flow smoothly.
A520154_05_1001 513
Operation
5.4.4 Checking the Hopper Grate Safety Cutout Device

This machine is fitted with a hopper grate safety cutout device. A pressure roller switch
is acted on as soon as you open the hopper grate. This stops the engine/motor.
WARNING
A defective agitator safety cutout can cause you to believe that the machine is
safe, even though this is not really the case. This can lead to the remixer
continuing to run or the transfer tube switching over when the hopper grate is
open.
You must therefore check the function of the hopper grate safety cutout device
before you start each pumping job. You must stop work if you open the hopper
grate and the electric motor or diesel engine continues to run.
A520154_05_1001 5
Illustration 55: Checking the Hopper Grate Safety Device
1. Open the hopper grate with the concrete pump running.

2. Verify that the switching cam acts on the pressure roller switch and the diesel engine
or electric motor turns off.
Note
NOTICE You must close the hopper grate to restart the diesel engine.
5.4.5 Filling the Agitator Hopper

Always fill the agitator hopper with concrete up to the mixer shaft.
514 A520154_05_1001
Operation
A520154_05_1001 6
Illustration 56: Hopper
DANGER
Entrapped air in the delivery line is dangerous as the compressed air is released
suddenly at the end of the delivery line and the concrete can be blown out
explosively. No air must be sucked in for this reason.You should therefore always
fill the agitator hopper with concrete up to the mixer shaft during pumping
operations.
Danger from escaping compressed air
A520154_05_1001 7
Illustration 57: Compressed Air
A520154_05_1001 515
Operation
5.4.6 Priming of Concrete Pump and Delivery System

Prime the concrete pump and delivery system, by performing the following steps:
Note
NOTICE The grout used for priming and lubrication should consist of two parts sand and
one part cement mixed to the consistency of thick soup. This mixture will coat the
delivery line ahead of the actual concrete mix to prevent packing when the line is
being filled during pumping operations.
1. Insert two sponge balls into the delivery line through the washout port.
2. Place the necessary amount of grout in the hopper. The amount of grout needed will
depend on the length and diameter of the delivery line. Normally it will take about 5
cu. ft. (.15 m3) to lubricate the system. Experience will eventually indicate the amount
required.
3. .With the necessary amount of grout in the hopper, pump it through the system by
performing the following steps:
A. Place PUMP switch (item 1, Ill. 58) to ON position.
4 1
BSA100
2 BSA120
5
6
3
BSA100
4
2 Cable Remote with VOL Radio Remote with VOL

BSA120 3
A520154_05_1001 8
Illustration 58: Volume Control
1 Pump on/off toggle switch 4 Engine throttle (diesel engine)

2 Local/remote control toggle switch 5 Volume control toggle switch (optional)
3 Volume control 6 Volume increase button (optional)
516 A520154_05_1001
Operation
Note
NOTICE Do not operate at full volume while priming and lubricating the system.
B. Turn VOLUME CONTROL knob (item 3, Ill. 58) counterclockwise to increase volume
slightly or leave at low volume BSA100. (BSA120 only uses the vol+/ switch)
Ensure local/remote toggle switch (item 2, Ill. 58) is in remote position if you wish to use
the optional cable or radio remote control.
On cable remote control with optional volume control toggle switch (item 5, Ill. 58), push
toggle switch to the right to increase volume slightly.
On radio remote control transmitter with optional volume control buttons, push button 10
(item 6, Ill. 58) to increase volume slightly.
Prime the pump with thin concrete is completed when the two sponge balls and a solid
concrete stream exit from the delivery line.
Note
NOTICE You must begin pumping with a cementwater mixture (grout) if the delivery lines
are new, or if the delivery line has not been used for a long time.
Note
NOTICE After you have lubricated the concrete delivery system, you can proceed to pump
the concrete.
5.4.7 Pumping
Correct mixing of the concrete influences pumping performance.
Mix the concrete vigourously in the truck mixer at maximum speed. Ensure that the
concrete mix is uniformly prepared.
Concrete additives (deflocculants, set retarding admixtures) must be mixed in for at least
4 minutes after they are added.
Pour the concrete from the truck mixer, silo, etc into the agitator hopper.
Switch the agitator on.
Begin delivery.
Note
NOTICE Start with a low output and increase this continuously after several cubic
metres.A machine driven by a diesel engine can be run more economically by
selecting engine speed and output regulation such that the engine does not rev
too highly when under low load.
A520154_05_1001 517
Operation
5.4.8 Transfer tube damping (BSA120)

The damping valve is used to control the switching speed of the transfer tube.
20203903
Illustration 59: Label

Hare: damping valve switch position open
Snail: damping valve switch position closed
Note
NOTICE You must close the damping valve when you are pumping soft consistency
concrete (snail symbol) as otherwise the transfer tube switches over too
harshly.You must open the damping valve (hare symbol) when you are pumping
stiff consistency concrete as the concrete has a damping effect.
518 A520154_05_1001
Operation
A520154_05_1001 10
Illustration 510: Emergency Stop Button Location Cable & Radio Remote Control
1 Emergency stop button cable remote control
2 Emergency stop button radio remote control transmitter
At the cable remote control, pushin Emergency Stop button (item 1, Ill. 510).
At the radio remote control, pushin Emergency Stop button (item 2, Ill. 510).
To release the Estop button, twist the knob clockwise.
5.5 Maintenance During a Pour
5.5.1 Monitoring
The displays of the monitoring instruments must be kept under observation during
pumping operations.
A520154_05_1001 519
Operation
1 3 2
Y R
G 6
Suction Gauge Pressure Gauge

50_F300_F (10_C150_C)
4
1 5
BSA120 BSA100 Engine Display

A520154_05_1001 11
Illustration 511: Monitor Gauges During Pumping
1 Suction gauge 4 Engine display (diesel engine models only)

2 Hydraulic oil temperature gauge 5 Return filter condition indicator gauge
3 Pressure guages 6 High pressure filter
" Check all displays for the monitoring instruments:

Return filter condition indicator gauge (item 5, Ill. 511): Indicates the differential
pressure across the hydraulic return oil filter assembly. Normal condition is the green
range (029 PSI) and the filter bypasses at 43 PSI (red range). Elements should be
changed if the pressure is in the yellow range (2943 PSI) with the hydraulic fluid at its
normal operating temperature (BSA100 only).
Hydraulic oil temperature gauge (item 2, Ill. 511): the temperature of the hydraulic oil
must not exceed 194_F (90_C) (BSA100/120).
Hydraulic pressure gauges (item 3, Ill. 511): Value indicated must not exceed the
maximum value specified on the machine rating plate, or hydraulic schematic
(BSA100/120).
Diesel engine display (item 4, Ill. 511): Provides a digital display of engine status:
engine RPM, engine coolant temperature, operating hours, and voltage (for more
information, please refer to the Technical Enclosure Deutz Display included with this
manual)(BSA100/120).
Suction Gauge (item 1 Ill. 511) normal condition is green range and the filter requires
replacement when in the red range (BSA120 only)
520 A520154_05_1001
Operation
High pressure filter indicator (item 6, Ill. 511). The filter element is OK if the red button
remains depressed. The filter element must be replaced if the red button pops out again.
(BSA120 only)
Note
NOTICE You must repeat these checks at regular short intervals all the time the machine is
running.
WARNING
The machine must be switched off every time a fault is indicated. All faults must
be rectified immediately, otherwise the warranty will be invalidated.
" Check the bearings and seals on the switching shaft, the pressure connection and the
agitator shaft at regular intervals.
" Lubricate the machine as required.
Note
NOTICE The bearings and seals must be replaced as soon as a cementcolored fluid and
grease mixture or slurry begins to escape.
5.5.2 Operational Tips and Precautions

Prior to and during a concrete pour, follow these tips and precautions:
Always maintain the hopper material level to at least the height of the remixer shaft or
1/2 full during pumping operations. If allowed to drop below this level, air will be sucked
into the delivery cylinders and the continuous smooth flow may be interrupted.
Always have the hopper grate mounted firmly in place and never stand on the grate.
Never place any body part into the hopper while the machine is in operation.
Prevent kinking of the end hose during concrete placement. Kinks can stop the material
flow, allowing pressure to build up in the system. When this occurs the pump must be
turned OFF. Place pump direction switch to REVERSE. Turn pump on for 2 or 3 reverse
strokes in order to relieve the pressure in the concrete delivery. Turn pump off once
again and return pump direction switch to FORWARD. Straighten out kinked hose, then
resume pumping.
A520154_05_1001 521
Operation
During concrete placement it may be necessary to stop pumping for a period of time
possibly due to lack of concrete or other job site problems. During these periods, the
concrete in the delivery system should be moved every 1015 minutes. This can be
accomplished by pumping backwards for 23 strokes then turning off pump and after
another 1015 minutes pump forward 23 strokes. If the problem continues for too long,
it may be necessary to clean out the delivery system and concrete pump. Determine this
from your experience with the material being pumped.
If shutdown periods exceed 23 minutes with material in hopper, it is recommended that
the engine be shut down to prevent separation of the mixture in the hopper due to
vibration from the operating engine.
5.5.3 Blockages
The following faults can lead to blockages:
Delivery line is insufficiently wetted.
Transfer tube is leaking.
Lines are leaking.
Leavings in the transfer tube and delivery line.
Unsuitable concrete composition.
Segregated concrete.
Set concrete.
2
1
3 11000601
Illustration 512: Blockages
1 Wedged aggregate 3 Boundary layer

2 Cement paste
CAUTION
In the event of blockages, pump the concrete immediately back into the agitator
hopper and mix it up. You can switch over to forwards pumping when the delivery
cylinders and the transfer tube are switching over automatically again without
problem. Begin pumping again with care.
522 A520154_05_1001
Operation
5.5.4 Avoiding Blockages

Water leaking from the coupling gaskets can cause separation of the mix in the delivery
line and subsequent blockage at that point.
Damaged hoses with internal restrictions can cause blockages.
When using snap joint coupling with gaskets to join hoses, wash and clean after each
job. Dip both couplings and gaskets into water prior to use for easier installation.
A slight pulsation of the delivery hose near the pump will always be noticeable.
Excessive pulsation near the pump is normally due to higher than average line pressure
caused by stiff, harsh mixes or extremely long pumping distances. The use of hoses
having larger internal diameter will reduce the line pressure.
The line pressure can be reduced by adding a small amount of water to the mix. The use
of certain admixtures may also help.
Be alert to the fact that if the delivery system is blocked or kinked at start up or during
the pump operation, the pump could straighten out the kink or force out the blockage.
The rapid surge of material could cause the line to whip or move in such a manner that it
may cause injury to personnel.
If a blockage in the hose occurs, walk along the hose until you find the point of trouble.
The hose will be soft immediately past the blockage. Elevate the hose at that point with
the blockage hanging down. Shake the hose until blockage loosens and the concrete
flows freely again.
Downhill pumping can be difficult on some jobs. When the pump is stopped, the material
can flow slowly in the delivery line causing the hose to collapse. As a result when
pumping is resumed a blockage will no doubt occur at the point of the hose collapse.
This can be prevented by kinking off the hose at the discharge while the pump is
stopped. Also the use of stiffer mixes when pumping down hill will lessen gravity flow.
During vertical pumping up the side of a building:
Above 40 feet (12m), use steel pipe that is securely fastened every 10 feet (3m).
Install long radius 90_ pipe sweeps at top and bottom of steel pipe.
Use a 25 feet (7.5m) section of hose off the pump discharge.
Use steel pipe for the balance of the horizontal run.
5.5.5 Clearing a Blockage

To clear a blockage, perform the following steps:
1. When a blockage occurs in the delivery system, the pumping pressure can reach its
maximum. When the maximum pressure occurs, immediately switch off the concrete
pump.
2. Change the pump direction switch to REVERSE. Turn PUMP switch to ON allowing
the pump to stroke 2 or 3 times in reverse. This will assist in relieving the pressure
from the delivery line blockage back to pump outlet.
A520154_05_1001 523
Operation
3. Switch the pump off.
WARNING
Extreme caution must be exercised and eye protection is required when opening
clamping devices on any part of the delivery system. It is possible that pressure is
still trapped in the line. Never attempt to clear a blockage in the delivery system
using pump pressure or compressed air.
4. Warn all persons in the immediate area of this danger and clear the area. Then
disconnect the clamping device and remove the blockage.
5. After the blockage has been cleared, turn the pump on and stroke the unit at low
volume until a steady flow of material is being pumped.
6. Stop the pump and reconnect the clamping device. Turn the pump on at low volume.
When material flows steadily out the discharge, then the volume can be increased.
5.6 Breaks in Pumping

You should avoid breaks in pumping as far as possible, as the concrete in the delivery
line can start to set, or can become segregated due the the vibrations of the machine.
Note the following points if breaks are unavoidable:
Never leave the delivery line under pressure.
Relieve the delivery line during short breaks in delivery by reverse pumping briefly (23
strokes). Move the concrete at short intervals by forward and reverse pumping.
You should avoid breaks when pumping concrete with a low water retentivity (tendency
to bleeding) as the vibrations can segregate the concrete. You must always leave the
pump switched to reverse pumping when you begin pumping again and wait for the
transfer tube to switch across fully on both sides. Only then can you switch over to
forwards pumping again.
Pump the concrete back into the agitator hopper before long breaks in pumping. You
must mix the concrete again before you recommence pumping.
Note
NOTICE Reverse pumping is only possible for a few pump strokes, otherwise the hopper
overflows.
524 A520154_05_1001
Operation
CAUTION
Never use force to pump segregated concrete or concrete that has become lumpy
because it is beginning to set into the delivery line. Blockages can very easily be
caused in this way.
5.6.1 Engine
Do not exceed the permissible engine speed specified in the machine card and on the
machine rating plate. Always set the engine speed higher than the vibrating speed. Do
not shut down the engine immediately after periods of heavy engine loading, but first
allow it to cool down at idling speed.
5.6.2 Overheating
During normal pump operation, the temperature of the hydraulic fluid is between 70 _C
and 80 _C. The following may cause the hydraulic fluid to overheat, particularly if several
factors coincide:
Continuous operation under high load.
High ambient temperatures.
Too little fluid in the hydraulic system.
Dirty hydraulic fluid radiator.
Insufficient radiator ventilation.
Hydraulic fluid radiator sucking in hot exhaust gases.
Excess pressure as a result of a blockage.
Too little water in the water box.
All pumps have a thermoelectrical cutout. The pump is automatically shut down if the
fluid heats up to over 90 _C. The engine keeps running to provide cooling and a red
indicator lamp lights up on the control cabinet. Proceed as follows to prevent a
shutdown in the middle of pumping when a fault is indicated:
Reduce the output.
Fill the water box with fresh water as soon as the fluid temperature rises above 80_C.
Change the water frequently if the temperature continues to rise.
Trace the cause of fluid overheating and rectify it.
A520154_05_1001 525
Operation
10600200
Illustration 513: Water Box
If necessary, you can cool the drive cylinders with a water jet if the measures described
above are not adequate.
10600400
Illustration 514: Cylinders

Direct the water jet at the drive cylinders and piston rods for the drive cylinders.
CAUTION
Never use sea water or salt water for cooling. Otherwise the chrome layer on the
delivery piston rods and delivery cylinders will be destroyed.
5.6.3 Restarting
Proceed as follows if the pump has nevertheless switched off because of overheating:
Set the output controller to min.
Refresh the water in the water box.
Wait until the fluid has cooled if you are not able to find the fault immediately.
Once the red indicator lamp has extinguished, switch the pump back on and continue
pumping slowly at reduced output
Determine the cause of the fluid overheating once pumping operations have been
completed and rectify the fault.
526 A520154_05_1001
Operation
Note
NOTICE Never switch the engine/motor off, as the radiator must remain in operation.
5.7 Cleaning
Concrete leavings that are left inside the delivery line or transfer tube can deposit and
continue to accumulate, thus reducing the crosssection. A clean delivery line and
transfer tube is therefore indispensable if you wish to be able to start pumping without
problems on the next job.
Concrete leavings deposited around the wear ring can impair its function. For this
reason, thorough flushing of the wear ring is required at the end of a job, unless the next
pumping job follows within 30 60 minutes.
Note
NOTICE When the pumping operation has been concluded, it will be necessary to clean
the machine by removing all the rest of the concrete from the hopper, swing tube,
and delivery system. Prior to performing this cleaning procedure, please note the
following:
The flushing or cleaning operation should only be done with low RPM and low
output of the pump.
For good wear parts and sealing conditions, the clean out of the system can be
accomplished through water pressure (i.e., pumping water).
If the wear parts of the pump are not in the best operating condition and do not
seal precisely, the system cannot be cleaned out with water pressure. It will be
necessary to clean the unit manually. Prior to manual clean out, pump as much
concrete out of the system as possible keeping a minimum level of concrete or
water in the hopper for lubrication of the piston cups.
Do not try to suck concrete from the pipeline with the machine. This could
damage the piston cups.
Note
NOTICE In the first six weeks of operation, clean all painted surfaces with cold water only
at a maximum water pressure of 73 psi (5 bar). Do not use any aggressive
cleaning additives. Only after this length of time has the paint hardened
completely allowing you to use steam jets or similar tools.
A520154_05_1001 527
Operation
Note
NOTICE The leavings should be used on the construction site. If this is not possible, the
leavings should be used as building rubble or be recycled.We recommend that
you use the Putzmeister Leavings sheet to allow you to make use of the
concrete leavings. You can lay this down under the hopper before opening the
hopper flap. The concrete then flows out into the sheet and can be transported to
the site of concrete placement using a site crane.If the concrete is not to be used,
you should bend a length of reinforcing steel into a hook and insert it in the
concrete. Once the concrete has cured, you can transport the lump of concrete
away using a site crane.
DANGER
Leave the agitator grille closed during all cleaning operations, since you could be
trapped by the agitator.
A520154_05_1001 15
Illustration 515: Do not reach into Hopper
DANGER
There is an increased risk of accident when cleaning with compressed air. The
cleaning operation must only be carried out by a subject expert or under his
supervision. Putzmeister accepts no liability for damage caused by incorrect
implementation of compressed air cleaning. All persons participating in the
cleaning operation must be instructed in the safety regulations.
528 A520154_05_1001
Operation
5.7.1 Preparations for cleaning
2
4
10003401
Illustration 516: Sponge
1 Sponge pig 3 Sponge ball

2 Sponge cube 4 Washout pig
You will need sufficient numbers of sponge balls and other cleaning accessories to clean
the machine properly.
You must use the catch basket if you wish to force the concrete out of the end of the
pipe using water pressure or compressed air. It must be designed such that the concrete
can flow out unhindered, but that the sponge ball (cube, pig) is trapped and that this
simultaneously seals off the delivery line.
WARNING
A catch basket on the end of the delivery line is an absolute requirement if you are
forcing the concrete out using compressed air, as otherwise there is a risk of
injury from the washout sponge and concrete as they are expelled.The use of the
catch basket is recommended when water is used to force out the concrete to
ensure that the delivery line is sealed off and no water can escape.
A520154_05_1001 529
Operation
4
31201501
Illustration 517: Catch Basket
1 Coupling 3 Spring pin (on both sides)

2 Catch basket (closed pipe section) 4 Catch bracket
The washout adaptor is used when the machine is cleaned using water under pressure
or compressed air.
DANGER
The washout adaptor must not be fitted to the delivery line while pump is
running as the washout connections and shutoff valves are not designed to
withstand the pressure of the concrete pump. The cleaning connection can only
be used for cleaning up to a maximum water or air pressure of 10 bar (145psi).A
catch basket on the end of the delivery line is an absolute requirement if you are
forcing the concrete out using compressed air, as otherwise there is a risk of
injury from the washout sponge and concrete as they are expelled.
530 A520154_05_1001
Operation
5 4 3
31201503
Illustration 518: Washout Adaptor
1 Pressure gauge 4 Shutoff valve for connection

2 Guard bracket 5 Pressure dump bend
3 Connection for water under pressure or
6 Dump cock
compressed air
The Tdelivery pipe with washout port can be used when cleaning with water under
pressure. It allows the the washout sponges to be inserted quickly. It traps the
washout sponge in suction cleaning.
2
1
A520154_05_1001 20
Illustration 519: TDelivery Pipe
1 Tdelivery pipe with washout port 4 Washout port lid
WARNING
Make sure that the Tdelivery pipe is also designed for the pressure stated on the
pump rating plate.You must only open the washout port lid once the pressure in
the delivery line has been dumped.
A520154_05_1001 531
Operation
Cement bags soaked in water and rolled up have proved useful when cleaning the
delivery line using water under pressure. The cement bags prevent the washing water
penetrating the concrete, flushing the concrete out and causing blockages.
10003501
Illustration 520: Rolledup Cement Bags

Roll up 1 2 empty cement bags together.
Immerse the rolledup cement bags in water for about 5 minutes before starting the
cleaning operation.
Note
NOTICE You may also prepare a short pipe section containing the cement bags and a
washout sponge before you start the cleaning operation.
10003502
Illustration 521: Cement Bag and washout sponge
The best way to clean the wear ring and seal ring on the transfer tube is to rinse this
area with water for some time from close up. You must mark the water hose as
described below to ensure that the hose does not get cut by the switching transfer tube
during cleaning.
WARNING
The machine must be switched off and the hydraulic system, including the
accumulator, fully depressurized when you are measuring the hose length
required, as otherwise there is a risk of injury as the transfer tube switches over.
532 A520154_05_1001
Operation
TAPE
A520154_05_1001 22
Illustration 522: Adhesive tape marking

Measure the hose length required on the outside of the transfer tube. The nozzle on the
hose should be located shortly before the seal ring so that concrete leavings are washed
away from the area around the wear ring and seal ring when the nozzle is set to spray.
Mark the measured length on the hose with adhesive tape, or similar.
5.7.2 Delivery Line

There are a number of options for cleaning a delivery line. Some of the factors affecting
which cleaning method you use include how the concrete pump has been used and
what equipment you have available.
5.7.3 How to Clean which Delivery Line

Overleaf you will find a summary showing which cleaning method is recommended for
the delivery lines listed. The symbols used in the summary are explained below. The
cleaning procedures are described in the following sections.
The delivery line is connected to the concrete pump. The

leavings are pumped by the concrete pump out of the
hopper and onwards to the site of concrete placement.
Cleaning is from the hopper onwards to the site of concrete
placement.
The delivery line is connected to the concrete pump. The

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

pump. The leavings are forced forwards from the start of the
delivery line to the site of concrete placement using an ex-
ternal force (compressed air or water under pressure).
Cleaning is from the start of the delivery line to the site of
concrete placement.
A520154_05_1001 533
Operation
The delivery line has been disconnected from the concrete

pump. The leavings are forced backwards from the the site
of concrete placement to the start of the delivery line to
using an external force (compressed air or water under pres-
sure). Cleaning is from backwards from the site of concrete
placement to the start of the delivery line.
Recommended method of cleaning
Method of cleaning not recommended
Prohibited method of cleaning
Method of cleaning not possible
534 A520154_05_1001
Operation
Overview of the cleaning procedures for the stationary delivery line
Leavings
from
Delivery line to
Method of
cleaning
Compressed air
Horizontal line Water under pressure
Suction cleaning
Compressed air only with

special
Riser Water under pressure equipment
Suction cleaning
Compressed air only with

special
Downpipe Water under pressure equipment
Suction cleaning
5.7.4 Suction Cleaning

Suction cleaning is the simplest and least hazardous method of cleaning a riser. The
method is described below.
Pump the agitator hopper out until the concrete is at the level of the top of the delivery
cylinder tubes.
Then switch the pump off.
12500100
Illustration 523: Inserting Washout Sponge
A520154_05_1001 535
Operation
Push a watersoaked washout sponge (cube) into the end of the delivery line at the site
of concrete placement.
Switch the pump to reverse pumping.The concrete and the washout sponge are
pumped back through the delivery line.
Check for the washout sponge
A520154_05_1001 25
Illustration 524: Tapping on the Delivery Line

Tap on the delivery line with a piece of hardwood (hammer handle) just ahead of the
cleaning eye during the washing out process.
Note
NOTICE Tapping produces deep dull noises there is concrete in the delivery line. Tapping
will yield high, clear sounds as soon as the concrete and washout sponge have
passed the point at which you are tapping.Use only a hammer handle to tap on the
delivery line, as otherwise the pipe may be damaged.
Switch the pump off as soon as the washout sponge has passed the point at which you
are tapping.
Trapping the washout sponge
A520154_05_1001 26
Illustration 525: Turn the Washout Lid around

Open the washout port on the Tdelivery pipe, turn the washout port lid round and
close it again with the pin pointing inwards.
536 A520154_05_1001
Operation
Switch the pump back to reverse pumping.The washout sponge will be trapped on the
pin of the washout port lid.
Then switch the pump off.
Open the washout port lid and remove the washout sponge.
Repeat the washing out procedure, as a single reverse pumping pass of a washout
sponge is not sufficient.
5.7.5 Highpressure Water Cleaning

Highpressure water cleaning, which is more thorough, but more timeconsuming than
suction cleaning, is described below.
Pump out the agitator hopper as far as possible.
Switch the pump over to Reverse pumping and relieve the pressure on the delivery line
by 1 or 2 strokes of reverse pumping
Switch the pump off.
Introducing the Washout Sponge
1 2
A520154_05_1001 27
Illustration 526: Washout Sponge
1 Prepared pipe section for cleaning 2 Washout Sponges being introduced
Push two or three watersoaked washout sponges into the washout port and close the
port or fit the pipe section prepared for cleaning into the delivery line.
Hose down the hopper with water.
Fill the agitator hopper with water.
Switch the pump to Forwards pumping.The water forces the concrete in the delivery
line towards the end of the delivery line.
Top up the water in the hopper in good time (on longer delivery lines) before air is
sucked in.
Pump until the washout sponges exit at the end of the delivery line. Take care to ensure
that the water flowing behind it does not run into the formwork.
A520154_05_1001 537
Operation
Then switch the pump to reverse pumping so that the washing water can flow out of the
delivery line.
5.7.6 Cleaning with Auxiliary Pump

The principle of this method of cleaning is similar to that for highpressure water
cleaning. This involves, however, separating the delivery line from the concrete pump
and replacing this with an auxiliary pump such as a high density solids pump (KOV) or a
washout adaptor with highpressure water pump.
Note
NOTICE Any highpressure water pump you might be using must have a sufficient
volumetric flow rate of water.
Pump out the agitator hopper as far as possible.

Switch the pump to Reverse pumping and relieve the pressure on the delivery line by 1
or 2 strokes of reverse pumping.
Switch the pump off and then remove it from the delivery line.
Now attach the auxiliary pump to the delivery line or use the washout adaptor with
highpressure water pump.
Introducing the Washout Sponge
1 2
A520154_05_1001 27
Illustration 527: Washout Sponge
1 Prepared pipe section for cleaning 2 Washout Sponges being introduced
When using an auxiliary pump, push two or three watersoaked washout sponges into
the washout port and close the port or fit the pipe section prepared for cleaning into the
delivery line.
When using a highpressure water pump, push two or three watersoaked washout
sponges into the washout port and then connect it to the delivery line.
538 A520154_05_1001
Operation
Connect the water for the auxiliary pump or highpressure water pump.
Switch the pump to Forwards pumping.The water forces the concrete in the delivery
line towards the end of the delivery line.
Pump until the washout sponges exit at the end of the delivery line. Take care to ensure
that the water flowing behind it does not run into the formwork.
5.7.7 Hopper, Delivery Cylinder & Stransfer Tube

One possible method of cleaning the hopper, the delivery cylinder and the Stransfer
tube is described below.
Note
NOTICE If the machine is fitted with an agitator safety cutout, the agitator is halted and the
transfer tube no longer switches over as soon as you open the grille. In addition,
the delivery pistons return to the end position and the concrete pump halts. You
must close the grille to restart the concrete pump.
DANGER
In no event should you insert the water hose, the spray gun or other objects
through the grille into the hopper to spray out the delivery cylinders. Such objects
may be trapped by the transfer tube as it switches over and become damaged.
The objects may be caused to fly about, thereby causing an injury to you or other
persons.
Drain off the remaining concrete onto a suitable sized tarp (with grommets for hoisting)
beneath the hopper by performing the following steps (refer to diagram below):
Place the tarp beneath the hopper.

Open the hopper flap beneath the hopper and let the leavings flow out of the hopper.
Switch the pump over to reverse pumping. This pumps the leavings out of the delivery
cylinders into the hopper and thus out of the hopper opening.
A520154_05_1001 539
Operation

A520154_05_1001 28
Illustration 528: Drain off the Leavings
Hoist away the concrete in the tarp
30000500
Illustration 529: Hoisting the tarp
CAUTION
Ensure to follow tarp manufacturers instructions and weight limitation when
hoisting the left over concrete. Hoist concrete as close to ground as possible to
prevent damage
to equipment and/or personal injury to personnel from falling concrete.
540 A520154_05_1001
Operation
Spray out Delivery Cylinder

A520154_05_1001 30
Illustration 530: Spray out
Allow the concrete pump to run slowly in reverse.

Spray the transfer tube out carefully downwards from the pressure connection. Slowly
insert the hose up to the marking as you do this (see the Mark water hose section).
TAPE
A520154_05_1001 31
Illustration 531: Insert Water Hose
Hold the water hose in this position, introduced as far as the marking, for several
minutes, until only clean water runs out.This will flush out the two delivery cylinders
alternately.
Carefully spray out the hopper using a hose.
Hose down all components that have come into contact with concrete.
A520154_05_1001 541
Operation
Check Sealing Gap
You should check the seal gap between the transfer tube and wear ring following
cleaning. The gap S must be 1.5 to 2 mm (0.060.08 in.), if not the transfer tube must
be readjusted.
Maintenance card: Adjusting the Stransfer tube
1 2 3 4
A520154_05_1001 32
Illustration 532: Insert Water Hose
1 Transfer tube 3 Wear ring

2 Thrust ring 4 Spectacle wear plate
Check the gap S between the transfer tube and wear ring.
Note
NOTICE The gap between the transfer tube and the wear ring must be 1.5 to 2 mm.
5.7.8 Postwashing Operations

Once the delivery line, hopper, delivery cylinders and transfer tube have been washed
out, you must then rinse down thoroughly all parts of the machine that have come into
contact with concrete. Concrete that is not washed off immediately can attack the paint,
especially if aggressive concrete additives have been used.
542 A520154_05_1001
Operation
CAUTION
The delivery line, water box, water tank and water pump must be drained fully if
there is a risk of freezing. The water box must also be drained at normal
temperatures during longer breaks in pumping, e.g. overnight and at
weekends.Leave the water outlet open afterwards.
DANGER
Atomized preserving agents are highly explosive. Keep away from all sources of
ignition whilst spraying.
Clean all seals and the seal seats.

Grease the seals before replacing them.
Clean the remaining parts of the machine by rinsing down with a water hose.
DANGER
Cleaning agents, solvents or preserving agents sprayed in air can enter the lungs
and trigger serious damage to health. You should, therefore, always wear
respiratory protection during this work.
Note
NOTICE After all cleaning is complete, it is highly recommended that you spary all
concrete contacting parts and surfaces with Putzmeister STOP STIKt.
Putzmeister STOP STIKt is an advanced sprayon solution that prevents
concrete from sticking to equipment surfaces. For more information, please
contact the Putzmeister Customer Support Group or visit website at
www.putzmeister.com
A520154_05_1001 543
Operation
5.8 Shutting Down

If the concrete pump is put out of service or into storage, it is recommended to grease
the machine.
WARNING
To avoid damage when shutting down engine, DO NOT shut down the engine from
full load operation. Let the engine idle for about two minutes. Shutting down
engine from full load may cause a buildup of heat in the oil inside of the
turbocharger and cause failure due to blockages of the oil bores.
Note
NOTICE Greasing the concrete pump prevents corrosion and premature aging. It is
necessary if the machine:
is not used for long periods;
is exposed to corrosive atmospheres during storage or transportation.
" Apply grease to the concrete pump as described in the section Maintenance.
Maintenance card: Lubrication diagram
" Only close down the machine when it is disconnected from the power supply.
" Preserve the machine with a suitable agent.
544 A520154_05_1001
Operation
5.9 Pumping Concrete with the Emergency Stroke Change Kit
5.9.1 BSA100D
The BSA100D comes with an Emergency Stroke Change Kit. This kit enables you to
finish pumping concrete in the event of an emergency. The Emergency Stroke Change
kit consists of five wires and a toggle switch that are connected between the battery and
the hydraulic manifold assembly.
To pump concrete with the Emergency Stroke Kit (P/N A052274), perform the following
steps:
WARNING
THE EMERGENCY STROKE KIT SHOULD ONLY BE USED IN AN EMERGENCY
CONDITION. THE EMERGENCY STOP (E-STOP) BUTTON DOES NOT WORK
WHEN USING THE EMERGENCY STROKE KIT.
1. Stop engine and verify that shift circuit pressure is at zero.
2. Disconnect pump harness from the following valves on the hydraulic manifold
assembly:
S-tube valve (2 connections)
Main control valve (2 connections)
Accumulator dump valve (1 connection)
3. Connect Emergency Stroke Kit wiring harness to five connections disconnected in
Step 2 and battery (refer to Ill. 59 below):
Stube valve Y1 Blue and Y2 Red
Main control valve Y3 Yellow and Y4 Green
Accumulator dump valve Y5 White
A520154_05_1001 545
Operation
10 Amp Fuse
ON
Red
Black
OFF
Battery
Toggle Switch
Y3 (Yellow)
Main Y1 (Blue)
Control
Y4 (Green)
Y2 (Red)
STube
Y5 (White)
Shift
Accum.
Dump
A520154_05_1001 33
Illustration 533: Emergency Stroke Kit (P/N A052274)

(Connected Between Battery and Hydraulic Manifold Assembly)
4. Start engine.
5. Use toggle switch on Emergency Stroke Kit wiring harness to shift drive cylinders and
S-tube at end of each stroke.
6. During an emergency condition or when job has been completed, stop engine by
cutting off fuel supply or disconnecting battery (i.e., removing ground wire).
5.9.2 BSA120D
The BSA120D comes with an Emergency Stroke Change Kit. This kit enables you to
finish pumping concrete in the event of an emergency. The Emergency Stroke Change
kit consists of five wires and a toggle switch that are connected between the battery and
the hydraulic manifold assembly.
To pump concrete with the Emergency Stroke Kit (P/N AT134931), perform the
following steps:
546 A520154_05_1001
Operation
WARNING
THE EMERGENCY STROKE KIT SHOULD ONLY BE USED IN AN
EMERGENCY CONDITION. THE EMERGENCY STOP (E-STOP) BUTTON
DOES NOT WORK WHEN USING THE EMERGENCY STROKE KIT.
1. Stop engine and verify that shift circuit pressure is at zero.
2. Disconnect pump harness from the following valves on the

compact block:
Stroke changeover valve (Y5) (green tywrap)
Stroke changeover valve (Y4) (yellow tywrap)
Accumulator dump valve (Y165)
3. Connect Emergency Stroke Kit wiring harness to three
connections disconnected in Step 2 and battery (refer to diagram
below):
10 Amp Fuse
Re
d Black
12 to 24 Volt Toggle Switch ON

Transformer OF
F
Battery
Y5
Stroke
Y165 Change
Accumula Over Valve
tor Dump
Valve Y4
Stroke
ChangeOver
Valve A520154_05_1001 34
Illustration 534: Emergency Stroke Kit (P/N AT134931)

(Connected Between Battery and Hydraulic Manifold Assembly)
4. Start engine.
5. Ensure that engine RPM is greater than 900 RPM.
6. Use toggle switch on Emergency Stroke Kit wiring harness to

shift drive cylinders at end of each stroke.
7. During an emergency condition or when job has been completed,

stop engine.
A520154_05_1001 547
Operation
548 A520154_05_1001
6 Maintenance
In this chapter you will find information on maintenance work which is necessary for the
safe and efficient operation of the machine.Following the general maintenance
information, you will find the maintenance cards necessary for this machine. The table of
contents includes a summary of the maintenance cards in numerical order, you will find
an alphabetical summary in the Index of key words under the entry for Maintenance
cards.We should like here to emphasise expressly that all prescribed checks,
inspections and preventative maintenance work must be conscientiously carried out.
Otherwise, we will refuse to accept any liability or to honour the warranty. Should you
ever be in any doubt, our After Sales Department is always ready to give you advice and
assistance.

Lock Out Tag Out Procedure 62
6.1 Daily Tasks 63
6.2 Recommended Lubricants 69
6.3 Inspecting the Unit 612
6.4 Adding Hydraulic Fluid 613
6.5 Lubricating the Unit 614
6.6 Replacing the Return Oil Filter Element 616
6.7 Replacing the Suction Filter Element and the High Pressure Filter Element 617
6.8 Changing the Hydraulic Fluid; Cleaning the Hydraulic Tank 617
6.9 Checking and Adjusting Hydraulic System Pressures 619
6.10 Replacing Proximity Switch 627
6.11 Performing Maintenance on the Accumulator 628
6.12 General Tightening Torques 636
A520154_06_0903 61
Maintenance
Note
NOTICE The finest equipment manufactured is only as good as its maintenance. Costly
repair and loss of revenue can often be avoided if a good preventative
maintenance program is followed:
The maintenance and checks noted in this section are not intended to replace
any local or regional regulations which may pertain to this type of equipment,
nor should the list and schedule be considered all inclusive. Interval times may
vary due to climate and/or conditions, depending on the location and use of the
machine.
Always ensure that applicable safety precautions are strictly observed when
performing the maintenance inspections and checks. Make certain
adjustments, and repairs are done before operation.
Be sure accumulator circuit is discharged before doing any work in the hopper.
Contamination is a major cause of malfunction in hydraulic systems. Care must
be exercised to prevent dirt from entering the hydraulic system. Always cap or
plug open ports and hydraulic lines.
Lock Out Tag Out Procedure
1. Lock OutTag Out Procedure Where Contact With Moving Parts is Possible:
Switch engine off and remove the key. The key must be kept by the individual performing
the work
Put a notice near the ignition switch stating Under RepairDO NOT START
2. Lock OutTag Out Procedure Where Contact With Moving Parts is Not Possible:
The individual performing the work must engage the Estop on the remote control unit
The individual performing the work must maintain complete control of the remote control
unit until the work is completed.
6.1 Daily Tasks

You must carry out daily checks, function checks and maintenance tasks so that your
machine remains fully functional and is safe in operation. The tasks are described in
detail in the Cleaning sections of the Safety regulations and Pumping operations
chapters. The following tables summarize these once more. The criterion column briefly
describes the points you need to observe. The checks must be carried out at the
beginning of each new shift in the case of machines in continuous operation.
62 A520154_06_0903
Maintenance
CAUTION
You must rectify (or have rectified) any defects immediately you discover them
during your checks.
6.1.1 Daily Visusal Checks

You must lubricate your machine and check it each time before you start to use it.
Assembly Checking Criterion
Safety devices available and in a fully functioning

General condition
Lubrication points sufficient lubrication
Engine Oil level sufficient
Agitator gearbox Oil level sufficient
Oil level sufficient

Hydraulic system Condensation in the hydraulic fluid drain off if present
reservoir
Radiator Contamination sufficient cooling possible
Spacer flange securing wire undamaged securing wire
Water level The piston rods must be completely

Water box covered
Water contamination no hydraulic fluid or concrete in the

water box
Inner wall and wear ring no mechanical wear
Transfer tube
Spectacle wear plate no mechanical wear
Pipes no leaks or fractures

Centralized lubrica
lubrica
tion system Grease gun sufficient grease reserve
designed for the delivery pressure,

Delivery line Suitability and wear laid according to the rules of technol
ogy, wall thickness sufficient
A520154_06_0903 63
Maintenance
6.1.2 Function Checks

You must always check all the control and monitoring functions plus the stroke times of
the pump before using it.
Assembly Function checks and inspections Criterion

Measure stroke times compare against test reading
General Engine start up/engine off fully functional
All operating elements fully functional
Vacuum gauge for the suction filter in the green zone

Hydraulic system
BSA120 Red button for the pressure filter red button remains depressed
Hydraulic system Return filter gauge in the green zone

BSA100
Agitator cutout fully functional
Drive cylinders oiltight

Hydraulic system
Switch cylinders oiltight
Lines and threaded unions oiltight
Control cabinet All operating elements fully functional
Remote control All operating elements fully functional
6.1.3 When Pumping

You must monitor the operational status of your machine and lubricate it as required.

General All lubrication points lubricate as required
Switching shaft bearings and seal

Transfer tube t l
no cementcoloured d oilil and
d grease
Bearings and seal on the pressure
mixture or slurry cement may escape
connection
from the bearings
Hopper Mixer shaft bearings and seal
Instruments Monitor all in the normal range
64 A520154_06_0903
Maintenance
6.1.4 After every Job

You should carry out the following service operations and checks after every job.

General All lubrication points lubricate as required
Switching shaft bearings and seal

Transfer tube t l
no cementcoloured d oilil and
d grease
Bearings and seal on the pressure
mixture or slurry cement may escape
connection
from the bearings
Hopper Mixer shaft bearings and seal
Instruments Monitor all in the normal range
6.1.5 Maintenance Intervals

The following table shows the intervals for some of the maintenance tasks:
Every . . . Hours of
Page
Action Operation Comments
No
No.
daily 50 150 500
Use an appropriate
Check and Hydraulic oil tank fluid level hydraulic fluid listed in the
D 65
Fill to Mark (with sight gauge provided) Recommended
Lubricants section
See above for oil type
Change Hydraulic oil tank fluid D 614
Tank capacity = 35 gal.
Also clean tank after any
Hydraulic oil tank D 614
component replacement
Clean Remove from tank, clean
Hydraulic oil tank breather D
with solvent, and blow dry
Oil cooler fins D
Drain water from hydraulic oil tank bottom after Also drain if oil appears
D
machine has set idle for 1 to 2 days milky
Use an appropriate grease
Designated grease fittings or listed in the
areas Refer to Lubricating the Unit Recommended
Lubricate
procedure on page 69
6 9 Lubricants section
Repack with wheel bearing
Trailer wheels
grease
A520154_06_0903 65
Maintenance
Action Page
Operation Comments
BSA100 No
No.
daily 50 150 500
At normal operating
temperature, also replace
Hydraulic oil tank return filter after first 50 hours of
Replace D 613
element operation or if filter
indicator gauge is in red
gauge area
Refer to Deutz engine operating manual for maintenance intervals (e.g., replacing oil/fuel/air filters, changing oil, etc.)
Action Page
Operation Comments
BSA120 No.
daily 50 150 500
At normal operating
Suction filter D 613 temperature, also replace
after first 50 hours of
Replace operation or if filter
indicator gauge is in red
High Press filter D 613 gauge area
Note
NOTICE Cleanliness is of the utmost importance in the maintenance of hydraulic systems.
Prevent any type of dirt from entering the system. Even small particles of dirt may
cause valves to be scored, pumps to seize and throttle and control bores to
become blocked.
Hydraulic fluid barrels must stand for some time before the fluid is removed
from them. Never roll the barrels to where you will be drawing off the fluid.
Clean bungs and filler lids as well as the area around them before opening.
If possible, you should use a charging set to fill up the hydraulic system. Never
leave the reservoir lid open longer than necessary.
Note
NOTICE Environmental hazard. Dispose of used filter elements in accordance with the
relevant regulations.
66 A520154_06_0903
Maintenance
6.1.6 Hydraulic Oil Tank BSA100
2 7
Y R
6 G
7
3
4
High
Low
5
4
A520154_06_0903 1
Illustration 61: Hydraulic Oil Tank and Filters

1 Filler/breather cap
2 Tank fill strainer
4 Hydraulic oil tank fluid level indicator and thermometer Indicates the level, condition, and
temperature (50300_F/10150_C) of the fluid in the hydraulic oil tank. Do not operate pump when
oil level is below LOW level mark.
5 Tank access cover
6 Return element filter assembly with 10 micron replaceable elements.
7 Return filter condition indicator gauge Indicates the differential pressure across the hydraulic return
oil filter assembly. Normal condition is the green range (0 to 29 PSI) and the filter bypasses at 43 PSI
(red range). Elements should be changed if the pressure is in the yellow range (29 to 43 PSI) with
the hydraulic fluid at its normal operating temperature.
A520154_06_0903 67
Maintenance
6.1.7 Hydraulic Oil Tank BSA120
3
4
High
6
Low 5
7
A520154_06_0903 2
Illustration 62: Hydraulic Oil Tank and Filters

1 Filler/breather cap
2 Tank fill strainer
4 Hydraulic oil tank fluid level indicator and thermometer Indicates the level, condition, and
temperature (50300_F/10150_C) of the fluid in the hydraulic oil tank. Do not operate pump when
oil level is below LOW level mark.
5 Tank access cover
6 High pressure filter.
7 Suction filter.
8 Suction filter gauge.
68 A520154_06_0903
Maintenance
6.2 Recommended Lubricants

We have listed the suitable lubricants in the tables on the next page. Putzmeister
accepts no liability for the quality of the lubricants listed or for changes in quality made
by the lubricant producer without changing the grade designation.
CAUTION
Never mix hydraulic fluids of different types (i.e., do not mix biologically
degradable hydraulic fluids with mineral hydraulic fluids etc.).
CAUTION
Never use hydraulic fluids or lubricants with additives such as molybdenum. Such
additives can attack the bearings.
Note
NOTICE Please only use a hydraulic fluid complying with the requirements standard specified
in the lubricant recommendation for topping up or a full fluid change. Observe the
manufacturers information in doing so.
Putzmeister accepts no liability for damaged caused by mixing the oil from
different producers. When hydraulic fluids of different viscosity grades are mixed,
the new viscosity is determined by the mix ratio. Loss of quality is possible if
hydraulic fluids from different manufacturers are mixed. For this reason, you must
always consult the manufacturer before mixing fluids.
Approximately 2% of the old hydraulic fluid will remain in the lines and cylinders
after a full fluid change.
Please consult the Putzmeister After Sales Department should you discover that
the functioning of your machine is impaired with one of the lubricants or hydraulic
fluids used. We will carry out a lubricant analysis to determine the cause.
A520154_06_0903 69
Maintenance
6.2.1 Hydraulic Fluids
Hydraulic Oils
To assure efficiency and long component life of your Putzmeister product, always use
the correct hydraulic oil that has been tested and proven for your products application.
While there may be oil suppliers that can supply a similar oil, we strongly recommend
using only the hydraulic oil that has been tested and has a proven history of success.
Hydraulic components are expensive to replace. Components that become
prematurely worn or damaged from the using incorrect oil are not covered by
Putzmeisters warranty. Please provide your local oil supplier with the specific grade, i.e.
(HLP VG46) as well as the required specifications (from the following charts) that the oil
must contain. Request your supplier to provide written confirmation stating that their oil
meets these requirements.
Putzmeister installs HLP VG46 mineral based oil as the standard hydraulic fluid at the
factory. This oil meets the majority of temperature requirements in the vast majority of
applications. In extremely warm or extremely cool applications, approved HLP VG68 or
HLP VG32 oils may be used. In limited applications, biodegradable oil may be used.
However, caution should be used because of the reduced acceptable operating
temperature range. Contact the factory first before switching to biodegradable oil.
Oil / Filter Change Intervals
Maintaining clean hydraulic oil is critical to the performance and life of the equipments
hydraulic system. As oil is initially pumped through a new system and as hydraulic
components complete their initial wearin cycle, the fine impurities that result are
deposited in the oil and captured by the filters. For this reason, the hydraulic filter
vacuum meter should be monitored closely, and the filters should be changed as
required. The hydraulic oil should be changed every 500 hours of operation. Likewise,
using the correct hydraulic oil that has been designed for this unit will provide optimum
performance and long life. Using other than the recommended hydraulic oil may result
in poor performance and premature wear or failure to components.
Please refer to the following charts when replacing the hydraulic oil. The standard oil
installed at the factory is HLP VG32 Mineral oil. This oil has been proven to function well
in a wide variety of applications and temperature ranges. For units operating in
extremely cool, or extremely hot conditions, optional oils may be substituted during the
normal oil change intervals.
610 A520154_06_0903
Maintenance
Standard Hydraulic Oil (Installed at Factory)

Oil Operating Temperature Range: 14_F (10_C) 194_F (90_C)
Grade: HLP VG46 Mineral
Specifications:
Properties Putzmeister Spec
Demulsifying power < 20 min
Air release properties < 6 min
Viscosity index > 97
Pour point < 11_F (12_C)
FZG gear test SKS 12
Foaming power @75_F (24_C) < 100 / 0
Foaming power @199_F (93_C) < 50 / 0
Hot Climate Applications

Specifications:
Foaming power @75_F (24_C) < 100 / 0
Foaming power @199_F (93_C) < 50 / 0
Cold Climate Applications

Specifications:
Foaming power @75_F (24_C) < 100 / 0
Foaming power @199_F (93_C) < 50 / 0
A520154_06_0903 611
Maintenance
Biodegradable Oil (Contact Factory)

Grade: HEES 46
Specifications:
Iodine value < 10
Gear test SKS 12
Foaming power @75_F (24_C) < 100 / 0
Foaming power @199_F (93_C) < 50 / 0
6.2.2 Oils and Greases

Greasing Centralized
Engine oil1 Transmission oil2
(manual) lube system
Marking HD HYP K2K30 K1K30
Requirements API
API GL4 DIN 51825 DIN 51825
standard CH4/SJ
Characteristics mineral mineral, lithium soap
SAE 90 SAE 80
Viscosity grade, SAE 15W40 NLGI Class 2 NLGI Class 1
DIN 51512 DIN 51512
NLGI Class DIN 51511 DIN 51818 DIN 51818
Standard Winter
Part number 000173.005 000101.006 A026511 360001.008
1Refer to engine operating manual; 2 The transmission oil for rotor pumps is listed separately.
6.3 Inspecting the Unit

To ensure a good, safe unit performance prior to start-up operations, the following items
need to be inspected daily:
Note
NOTICE By accomplishing these inspections on a daily basis, any potential malfunction
will be identified and detected before it expands into a major problem.
Overall Machine Condition

Visual damage: Inspect frame and all supporting structures for weld cracks, dents or
bends. Inspect the condition of hitch, wiring, and brakes.
Truck springs, axles: Check for broken leaves, missing clamps, bolts, or brackets
Tires and wheels: Check for wear, cuts, loose or missing lug nuts, and inflation
pressure
Lights, wiring: Check that lights operate properly and wiring is not broken or frayed
Engine
Visual damage: Inspect mounting bolts, brackets
612 A520154_06_0903
Maintenance
Oil level: Check for leaks, and proper level

Fuel system: Inspect tank mounting, fuel level, filter condition, leaks, damaged lines
Battery: Check battery hold down, condition and tightness of cables
Radiator: Check for free air flow; check coolant level
Control Panel
Switches
: Inspect for damage and function
Electrical wiring: Inspect for fraying and cracked insulation
Electrical connections Check for corrosion, looseness, and good ground contact
Gauges: Check for damage, proper operation
Hydraulic System
Hydraulic tank: Check fluid level and breather cap
Hydraulic hoses: Check for leaks and damage
Hydraulic tubing: Check for leaks and damage
Pump, valves: Check mountings; check for leaks and damage
Filters: Check condition of gauge; check for damage
Oil cooler: Check for free air flow
Pump Flat Pack
Main cylinder: Inspect for damage, leakage of fittings, hoses, tubing
Material cylinder: Inspect for damage, tightness of the tie rods
Water box: Look for cracks, drain valve
Proximity switches: Check condition
Hopper
Shift cylinder: Inspect connections for leaks, mounting pins/bolts
Shift lever: Inspect for damage, connection to cylinder and Stube. Check tightness of
Stube nut, cotter pin
Grating: Inspect for damage, proper position
Grate safety cut-out: Inspect for proper operation
Stube: Inspect for damage of wear plate wear ring, connection to outlet
Agitator: Inspect hydraulic motor and control for leaks and damage
6.4 Adding Hydraulic Fluid

To add hydraulic fluid to the hydraulic oil tank, perform the following steps:
Note
NOTICE The hydraulic oil tank is located just forward of the hopper must be kept filled to
specified level at all times. Exercise extreme care when adding fluid to the oil
tank.
1. Clean area around filler opening of tank to prevent dirt and water from entering.
A520154_06_0903 613
Maintenance
2. Use fresh clean hydraulic fluid. Pour fluid through the tank fill strainer.
CAUTION
Do not use a cloth for straining fluid as lint is harmful to the system.
6.5 Lubricating the Unit

To properly lubricate the machine, perform the steps outlined in the diagram on the next
page:
Note
NOTICE Refer to the Recommended Lubricants section on page 66 for an appropriate
grease or hydraulic fluid to use.
Note
NOTICE Rapid wear and probable component breakdown will result if the unit is operated
with inadequate lubrication. Adhere to the following lubrication guidelines:
Do not attempt to start the equipment until lubrication points have been
checked and/or serviced.
Pre-use lubrication does not eliminate the requirement for the next scheduled
periodic lubrication.
Recommended lubrication intervals are based on normal use in normal
environmental conditions. The user is cautioned to adjust the lubrication
interval accordingly, to meet individual conditions and usage.
Equipment which has been stored in/or exposed to environmental conditions of
extreme low humidity and high dust level, elevated temperatures or heavy
rainfall, may require more frequent lubrication of components than under
normal conditions.
External non bearing surfaces shall be wiped clean of extruded or spilled
surplus grease and oil with a clean lint free cloth to prevent damaging dust and
abrasive accumulation on lubricant wet surfaces.
6.5.1 Lubrication Points

The lubrication points for the diesel engine powered trailer concrete pumps are shown in
Illustration 63. Refer to 6.2.2 Oils and Greases for the recommended grease to use or
as specified.
614 A520154_06_0903
Maintenance
1
1
5
6
4
7
3
8
4
A520154_06_0903 3
Illustration 63: Units with Diesel Engine Lubrication Points Lubricate daily with an appropriate grease, except as
noted:
1 2 @ remixer bearings
2 3 @ lube manifold for S-tube outlet
3 4 @ lube manifold (2 for S-tube shift cylinders; 2 for S-tube shaft bearing)
4 2 @ each S-tube shift cylinder block
5 Fill hydraulic tank to required level with an appropriate hydraulic fluid daily
6 Repack wheel bearings with wheel bearing grease quarterly
7 Fill engine oil to required level with an appropriate engine oil daily
8 Lubricate main pump shaft spline with Optimoly spline grease (or equivalent)
every 500 operating hours or 6 months (whichever comes first).
6.6 Replacing the Return Oil Filter Element

To replace the 10 micron hydraulic return oil filter element, perform the following steps:
A520154_06_0903 615
Maintenance
1 2
1
4
3
A520154_06_0903 4
Illustration 64: Return Oil Filter Assembly
1 Hydraulic tank 3 Return oil dualelement filter assembly with

dual filter elements
2 Return oil filter gauge 4 Return oil filter element with single filter
element
Note
NOTICE Return filter condition indicator gauge indicates the differential pressure across
the hydraulic return oil filter assembly. Normal condition is the green range (0 to
29 PSI) and the filter bypasses at 43 PSI (red range). Elements should be changed
if the pressure is in the yellow range (29 to 43 PSI) with the hydraulic fluid at its
normal operating temperature.
1. Shut off machine. De-energize accumulator pressure.
2. Place a drain pan underneath filter housing to receive fluid drainage.
3. Remove any grime or dirt from around filter.
4. Unscrew old filter element and discard.
5. Lightly smear a small amount of oil on gasket of new filter element (P/N AT311660).
6. Screw on to filter housing, hand tight plus one quarter turn.
7. Start up unit and inspect for leakage.
CAUTION
Do not attempt to wash out the old filter element. These are disposable and more
harm can be done than it is worth.
616 A520154_06_0903
Maintenance
6.7 Replacing the Suction Filter Element and the High Pressure Filter
Element
Refer to Maintenance Card 04012.
6.8 Changing the Hydraulic Fluid; Cleaning the Hydraulic Tank

To change the hydraulic fluid and clean the hydraulic tank, perform the following steps:
3
4
A520154_06_0903 5
Illustration 65: Hydraulic Oil Tank Components
1 Filler cap 3 Tank access cover

2 Hydraulic oil tank 4 Gasket
1. Stop engine. De-energize accumulator pressure.
2. Remove filler cap (item 1, Ill. 65).
A520154_06_0903 617
Maintenance
6.8.1 Draining the Hydraulic Oil Tank
A820090_06_08066
Illustration 66: Hydraulic Oil Tank Drain Plug

1 Hydraulic oil tank drain plug (7/814)
3. Place a suitably sized container under tank drain plug (item 1, Ill. 66) at bottom of
hydraulic oil tank (item 2, Ill. 65). Remove drain plug to drain tank.
4. With hydraulic tank empty, remove access cover (item 3, Ill. 65) located at back of
tank. Take care not to damage Oring/gasket (item 4, Ill. 65) while doing this.
5. Flush inside of hydraulic tank with clean solvent and wipe clean. Remove any
particles from tank bottom.
6. Install drain plug. Re-install access cover, and gasket. Refill hydraulic tank with new
clean hydraulic fluid.
618 A520154_06_0903
Maintenance
6.9 Checking and Adjusting Hydraulic System Pressures

This section contains procedures for checking and adjusting hydraulic system pressures.
A test gauge kit must be attached to the volume control valve test port while performing
some of these procedures:
2 1
A520154_06_0903 7
Illustration 67: Putzmeister Test Gauge Kit

1 Test gauge #1 This gauge consists of a small diameter hose having one end connected to a 060
BAR (0882 PSI) hydraulic pressure gauge and the other end containing a female adapter.
2 Test gauge #2 This gauge consists of same set up as test gauge #1 except a 0400 BAR
(05880PSI) hydraulic pressure gauge is used.
A520154_06_0903 8
Illustration 68: Test Port for Attaching Test Gauge #1 or #2 (BSA100 only)
1 Test port This test port is located on top of the volume control valve and is accessible from the top
of the tank enclosure
2 Volume control valve
Note
NOTICE The operational hydraulic pressures of the machine have been checked and set at
the factory prior to shipment. Also, replacement relief valves are preset to the
correct setting prior to shipment. However, it may be necessary occasionally to
check and reset the pressures.
A520154_06_0903 619
Maintenance
6.9.1 Checking Standby Pressure of The Main Hydraulic Pump BSA100

To check the standby pressure of the main hydraulic pump, perform the following steps:
1. With engine/motor shut off, remove cap from test port (on top of volume control valve)
and install Test Gauge #1.
2. Start engine and adjust THROTTLE CONTROL to maximum.
3. Adjust VOLUME CONTROL so that it is completely closed (turn clockwise).
4. Verify that pressure gauge reads 230290 PSI (16 to 20 BAR). If indicated pressure
does not fall within specified range, then an adjustment is necessary.
WARNING
Do not activate pump switch or pressure test switch. To do so will damage the
test gauge.
6.9.2 Adjusting Standby Pressure of The Main Hydraulic Pump BSA100

To adjust the standby pressure of the main hydraulic pump, perform the following steps:
5. Leave Test Gauge #1 installed in test port. Engine can remain running.
6. Remove cap from standby pressure adjustment screw on main hydraulic pump to
expose adjustment screw. Loosen locknut.
A520154_06_0903 9
Illustration 69: Location of Standby Pressure Adjustment Screw

7. Using a #3 metric Allen wrench, turn adjustment screw (item 1, Ill. 69) IN to increase
pressure and turn OUT to decrease pressure. After pressure has been adjusted,
tighten locknut and replace cap.
620 A520154_06_0903
Maintenance
8. Turn engine off, remove Test Gauge #1, and cap test port.
6.9.3 Checking Main System and Relief Pressure BSA100

To check main system and relief pressure, perform the following steps:
1. With engine/motor shut off, remove cap from test port (on top of volume control valve)
and install Test Gauge #2.
A520154_06_0903 10
Illustration 610: Location of Main System Pressure Compensator Adjustment Screw

2. Remove cap from pressure compensator adjustment screw on main hydraulic pump
to expose adjustment screw. Loosen locknut.
3. Start engine/motor and bring to maximum speed.
4. Turn VOLUME CONTROL open (counterclockwise) until volume is fully on.
5. Using a #3 metric Allen wrench turn pressure compensator adjustment screw (item 1,
Ill. 610) in one to one & half turns. This will increase pressure.
6. Actuate TEST PRESSURE switch and hold. Monitor hydraulic pressure gauge.
Gauge should read the main system relief pressure setting indicated in the
Hydraulic Schematic in the Technical Data section of this manual.
7. If pressure on gauge does not read as per main system relief pressure setting
indicated in table on previous page, then an adjustment is necessary.
A520154_06_0903 621
Maintenance
6.9.4 Adjusting Main System and Relief Pressure BSA100

To adjust main system and relief pressure, perform the following steps:
Hopper Side
2
4
Engine Side
A520154_06_0903 72
Illustration 611: Location of Main System Relief Valve Adjustment Screw
1 Main system relief valve 3 Lock nut

2 Adjustment screw 4 Control block
8. Leave Test Gauge #2 installed in test port. Engine can remain running with VOLUME
CONTROL fully on.
9. Set main system relief pressure by performing the following steps:
A. Using a 9/16 in. (14 mm) wrench, loosen lock nut (item 3, Ill. 611) on main system relief
valve (item 1, Ill. 611) and adjustment screw (item 2, Ill. 611) located on control block
(item 4, Ill. 611).
B. Using a #4 metric Allen wrench, turn adjust set screw IN to increase pressure and OUT
to decrease pressure.
A820090_06_0806D12
Illustration 612: Function Switches on Control Cabinet

1 Pressure test toggle switch Push up and hold to complete the pump stroke. At the end of the
stroke, the pump will pressure out to the maximum pressure. The maximum pressure can be read on
the main system hydraulic pressure gauge.
622 A520154_06_0903
Maintenance
C. Actuate PRESSURE TEST switch (item 1, Ill. 612) and hold while monitoring Test
Gauge #2 pressure. Adjust set screw until pressure is equal to main system relief
pressure setting indicated in Hydraulic Schematic in the Technical Data section of this
manual.
D. Release PRESSURE TEST switch, and tighten relief valve adjustment screw lock nut.
10. After setting main system relief pressure, it will be necessary to set main system
pressure by performing these steps:
A. Actuate PRESSURE TEST switch and hold while monitoring Test Gauge #2 pressure.
Adjust pressure compensator adjustment screw (item 1, Ill. 610) on main hydraulic
pump. Turn screw out to reduce pressure until Test Gauge #2 is equal to main system
pressure setting indicated.
B. Release PRESSURE TEST switch, tighten lock nut on set screw, and replace cap.
6.9.5 Checking S-Tube Shift Circuit Pressure BSA100

To check the S-tube shift circuit pressure, perform the following steps:
2 3 Engine Side
Hopper Side
A520154_06_0903 13
Illustration 613: Location of S-tube Shift Unload and Relief Valves

(Used to Set the S-tube Shift Circuit Pressure)
1 S-tube shift unload valve (Accumulator charge 4 S-tube shift relief valve
valve)
2 Lock nut 5 Control block
3 Adjustment screw
A520154_06_0903 623
Maintenance
2. Adjust VOLUME CONTROL so that it is completely closed (turn clockwise).
3. Using a 8 mm (5/16 in.) wrench, loosen lock nut (item 2, Ill. 613) on S-tube shift
unload valve (item 1, Ill. 613).
4. Using a #2.5 metric Allen wrench, turn shift unload valve adjustment screw (item 3,
Ill. 613) all the way in. This will increase pressure.
1 2
A820090_06_0806D14
1 Pump On/Off toggle switch push up to 4 Stroke change push up temporarily to change the
turn pump On. Push down to turn pump Off drive cylinder direction and shift the Stube (change from
pumping one cylinder to another)
5. Actuate PUMP toggle switch (item 1, Ill. 614) to ON and actuate STROKE CHANGE
toggle switch (item 2, Ill. 614).
6. Monitor accumulator pressure gauge, which indicates the shift relief valve setting.
Gauge should match the pressure setting on the Hydraulic Schematic in the Technical
Data section of this manual. If gauge reads otherwise, then an adjustment is
necessary.
624 A520154_06_0903
Maintenance
6.9.6 Adjusting S-Tube Shift Circuit Pressure BSA100

To adjust the S-tube shift circuit pressure, perform the following steps:
Engine Side
3
2
1 4
Hopper Side
A820011_06_0805L15
Illustration 615: Location of STube Shift Relief Valve(Used to Set the STube Shift Circuit
Pressure)
1 S-tube shift relief valve (Accumulator charge 3 Adjustment screw

valve)
2 Lock nut 4 Control block
7. Using a 9/16 in. (14 mm) wrench, loosen lock nut (item 2, Ill. 615) on shift relief
valve (item 1, Ill. 615) and shift relief valve adjustment screw (item 3, Ill. 615).
8. Using #4 metric Allen wrench, turn shift relief valve screw IN to increase pressure
and OUT to decrease pressure.
1 2
A820090_06_0806D16
1 Pump On/Off toggle switch push up to 4 Stroke change push up temporarily to change the
turn pump On. Push down to turn pump Off drive cylinder direction and shift the Stube (change from
pumping one cylinder to another)
9. Actuate PUMP toggle switch (item 1, IIl. 616) to ON and actuate STROKE CHANGE
switch (item 2, Ill. 616).
A520154_06_0903 625
Maintenance
10. Monitor accumulator pressure gauge, while making adjustments so that gauge
reading matches the pressure setting on the Hydraulic Schematic in the Technical
Data section of this manual. With adjustment made and proper setting reached,
tighten shift relief valve lock nut (item 2, Ill 615).
11. Shift unload valve (item 1, Ill. 613) will now require setting. Adjust shift unload
valve set screw (item 3, Ill. 613) out until pressure on gauge matches the pressure
setting on the Hydraulic Schematic in the Technical Data section of this manual. With
adjustment made, tighten unload valve lock nut (item 2, Ill. 613).
6.9.7 Adjusting Remixer Relief Pressure

To adjust the remixer relief pressure, perform the following steps:
4 5
1
5
2
3
Outrigger/Remixer Control Valve
A520154_06_0903 17
Illustration 617: Adjusting Remixer Relief Pressure
1 Remixer 4 Manual control valve lever for the remixer motor

2 Test gauge #2 that has a range of 0400 BAR 5 Remixer relief valve adjustment
(05880PSI)
3 Cap for plugging end of hose
1. Turn engine/motor off.
2. Slowly loosen hose fitting at remixer hydraulic motor (item 1, Ill. 617) and then
disconnect hose. Plug end of hose with cap (item 3, Ill. 617).
3. Install hose with pressure gauge 0400 BAR (item 2, Ill. 617) on to fitting at remixer
hydraulic motor where hose was removed.
5. Actuate remixer manual control valve lever (item 4, Ill. 617) in appropriate direction
to pressurize remixer motor.
626 A520154_06_0903
Maintenance
6. Monitor pressure gauge. Gauge should match the pressure setting on the Hydraulic
Schematic in the Technical Data section of this manual.
7. If gauge reads higher or lower, then adjust remixer relief valve (item 5, Ill. 617) as
follows:
A. Loosen lock nut on remixer relief valve adjustment.
B. Using a #4 metric Allen wrench, turn set screw IN to increase pressure and OUT to
decrease pressure. When correct pressure is reached, tighten lock nut.
8. Turn engine/motor off.
9. Disconnect pressure gauge hose and re-install remixer motor hose.
6.10 Replacing Proximity Switch

To replace a proximity switch located in the hydraulic cylinders, perform the following
steps:
Note
NOTICE The proximity switches are used to send an electrical signal to the solenoid
valves to cycle the pump cylinders and shift the S-tube. If the proximity switches
are not operating properly, erratic cycling and shifting could occur. You can
remove a switch from opposite side and install on side with problem. If cylinder
cycles, replace faulty switch.
A520154_06_0903 627
Maintenance
1
Rod Side Rod Side 2 Rod Side
Rod Side Cyl. 2 Cyl. 1 Cyl. 2
Cyl. 1 (3S65.1)* (3S65.1)*
3 (3S65)*
(3S65)*
Head Side
Head Side Cyl. 2
Cyl. 1 (3S65.2)*
(3S65.2)
Cyls. Powered Cyls. Powered
on Head End on Rod End

A520154_06_0903 18
Illustration 618: Location of Proximity Switches

*Refer to the Electrical and Hydraulic Schematic in the Technical Data section of this manual.
1 Connector plug with knurled nut
2 Magnetic switch
3 Seal ring
CAUTION
Proximity switches for changeover (Stube shift) are marked. Pump may not
operate properly or damage may occur if the identified connector plug is
connected to the wrong proximity switch.
1. Unscrew knurled nut and remove connector plug (item 1, Ill. 618) from magnetic
switch (item2, Ill. 618).
2. Remove magnetic switch and seal ring (item 3, Ill. 618) from delivery cylinder.
3. Install new switch or switch from opposite side and seal ring onto delivery cylinder
and tighten.
4. Connect connector plug to magnetic switch and tighten knurled nut.
5. Test pump for proper operation.
6.11 Performing Maintenance on the Accumulator

It is recommended that the accumulator be thoroughly inspected, including a pressure
test, every 5 to 10 years. To perform maintenance on the accumulator, perform the
following steps:
628 A520154_06_0903
Maintenance
WARNING
Adhere to the following safety regulations when performing maintenance on the
accumulator:
The hydraulic accumulator is a pressurized vessel and only qualified technicians
should perform the necessary repairs.
Never weld, braze, or perform any type of mechanical work on the accumulator
shell.
Never lift the accumulator by the gas valve.
The hydraulic oil must always be drained completely from the accumulator before
performing any work.
WARNING
Never use oxygen or air as an explosion can occur. Only use dry nitrogen or
other recommended gasses.
Note
NOTICE Precharge pressure should be a:
Minimum of 25% of maximum working pressure
Maximum of 90% of minimum working pressure
A520154_06_0903 629
Maintenance
1 7
8
8
9
7 10
2
9 3
11
5
12
13
6 14
15
16
A520154_06_0903 19
Illustration 619: Accumulator
1 Gas valve core 9 Oring

2 Lock nut 10 Name plate
3 Shell 11 Poppet
4 Bladder 12 Seal rings
5 Anti-extrusion ring 13 Spacer ring
6 Lock nut 14 Fluid port
7 Valve seal hex cap 15 Seal ring
8 Valve protection cap 16 Vent screw
630 A520154_06_0903
Maintenance
Note
NOTICE The following special tools are required to perform maintenance on the
accumulator:
Charging and Gauging Kit (Putzmeister #AT311803)
Gas Valve Core Tool
Spanner Wrenches
Bladder Pull Rod
Sockets 27 mm, 36 mm
Blunt Flathead Screwdriver
Soft Faced Hammer
Torque Wrenches
1 5
3 8
6 9
7
A520154_06_0903 20
Illustration 620: Charging and Gauging Kit
1 Thandle 6 Knurled cap nut

2 Manual bleed valve 7 Adapter FPK/SB (M28 x 1.5) (7/814UNF)
3 Check valve 8 Allen wrench (6 mm)
4 Gauge (0 3500 psi) (0 250 bar) 9 Adapter G4 (SW32)
5 Charging hose, including cap screw
connections G1, M (SW32)
A520154_06_0903 631
Maintenance
6.11.1 Checking Accumulator Pre-Charge Pressure

To check accumulator pre-charge pressure, perform the following steps:
Note
NOTICE The proper gas precharge pressure is set at the factory. It is suggested that the
pressure be rechecked approximately 34 months after placing unit in service and
every 12 months thereafter. Refer to the Hydraulic Schematic in the Technical Data
section of this manuel for the precharge pressure.
WARNING
Before checking the precharge pressure, be sure machine is shut down and all
hydraulic pressure and fluid in accumulator has been relieved.
1. Unscrew valve protection cap (item 8, Ill. 619) and valve seal hex cap (item 7, Ill.
619). Be careful not to damage Oring (item 9, 619) when removing cap.
2. To connect gauging unit to accumulator, perform the following steps:
Charging and
Gauging Unit
Adapter FPK/SB
N2
Hydraulic
Accumulator
A820090_06_080621
Illustration 621: Connecting Charging and Gauging Unit to Accumulator

Using the 6 mm Allen wrench (item 8, Ill. 619) unscrew the socket head cap screw in
adapter FPK/SB (item 7, Ill. 619) 3 full turns counterclockwise.
632 A520154_06_0903
Maintenance
NOTE: This is done to prevent gas valve damage and leakage upon installation.
Install adapter FPK/SB onto accumulator gas valve (item 1, Ill. 619), hand tight.
Close manual bleed valve on gauging unit (item 2, Ill. 619), hand tight.
Connect gauging unit to adapter FPK/SB by screwing knurled cap nut (item 6, Ill. 619)
onto the adapter, hand tight (as shown in Ill. 621).
Turn T-handle (item 1, Ill. 620) counterclockwise until resistance is felt.
Install adapter onto accumulator as shown in Ill. 621.
3. After gauging unit has been installed, turn T-handle counterclockwise a maximum of 3
full turns. The gauge should read the existing precharge pressure.
4. If gauge does not indicate the value shown in the hydraulic schematic or decrease
accumulator pressure:
If pressure reading is Then By performing this procedure

Schematic value Increase pressure Increasing Accumulator Pressure
Schematic value Decrease pressure Decreasing Accumulator Pressure
5. If gauge indicates proper pre-charge pressure, remove charging and gauging unit by
Turn Thandle counterclockwise until resistance is felt to close gas valve.
Open manual bleed valve to relieve pressure in gauging unit.
Disconnect gauging unit by unscrewing knurled cap nut from adapter.
Re-install valve seal hex cap and tighten to 20 lb. ft. (27 Nm).
Re-install valve protection cap, hand tight.
6.11.2 Decreasing Accumulator Pressure

To decrease pressure in accumulator, perform the following steps:
1. Install charging and gauging unit as per Checking Accumulator Pre-Charge

Pressure procedure on previous page.
2. Carefully open manual bleed valve, allowing gas precharge pressure to release
slowly.
3. Monitor gauge until desired gas pressure is reached.
4. Close manual bleed valve and allow pressure to stabilize.
5. After 510 minutes, recheck pressure and adjust accordingly.
A520154_06_0903 633
Maintenance
6. When correct pressure is reached, remove charging and gauging unit by performing
the following steps:
Disconnect gauging unit by unscrewing cap from gas valve.
6.11.3 Increasing Accumulator Pressure
DANGER
Only use dry nitrogen gas. Never use oxygen or air because it could cause an
explosion.
WARNING
The hydraulic accumulators is a pressurized vessel and only qualified technicians
should perform the necessary repairs.
Never weld, braze or perform any type of mechanical work on the accumulator
shell.
Always drain the hydraulic oil completely from the accumulator before
performing any work.
CAUTION
It is recommended that the commercial nitrogen bottle be equipped with a
regulator to adjust pressure. Full pressure may damage the gauge.
To increase accumulator pressure to specified pressure (per hydraulic schematic in the

Technical Data section of this manual), perform the following steps:
634 A520154_06_0903
Maintenance
Pressure
Reducer Charging and
G1 hose M hose Gauging Unit
Connection Connection
Adapter FPK/SB
Adapter G4
Charging Check
Hose Valve
N2 N2
Nitrogen Hydraulic
Bottle Accumulator
A820090_06_080623
Illustration 622: Connecting Charging & Gauging Kit
1. Install charging and gauging unit as shown in Ill. 622.

Install adapter G4 (item 9, Ill. 620) onto the pressure regulator on nitrogen bottle
Connect the G1 cap screw on the charging hose (item 5, Ill. 620) to adapter G4
Connect the M cap screw on charging hose to the check valve (item 3, Ill. 620) of the
charging and gauging unit.
Connect the charging and gauging unit to the adapter and acccumulator as described in
6.11.1
2. Allow 510 minutes for the gas temperature to stabilize.
3. Turn T-handle clockwise until gauge begins to deflect, then turn it another full turn.
4. Open shutoff valve on nitrogen bottle and slowly fill accumulator with dry nitrogen
gas until the pressure in the accumulator reaches 100 psi. Once 100 psi is reached,
the charging rate can increase. Charging too quickly may damage the accumulator.
Note
NOTICE The gauge on the gauging unit registers the line pressure and not necessarily the
accumulator pressure while charging.
5. Check accumulator pressure as follows:

Close shut-off valve on nitrogen bottle.
Allow gas temperature and pressure to stabilize.
Check accumulator pressure.
6. Fill or release pressure as required until required pressure is reached.
A520154_06_0903 635
Maintenance
7. When correct pressure is reached, remove nitrogen bottle and gauging unit by
Close shutoff valve on nitrogen bottle.
Disconnect charging hose and remove gauging unit from accumulator.
NOTE: It may be necessary to loosen the connection between the cap nut and adapter
to remove the charging and gauging unit.
Check for leaks.
6.11.4 Replacing Accumulator Bladder

To replace the accumulator bladder, take the accumulator to a qualified hydraulic shop.
6.12 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
You must always use bolts of the same size and property class when you have to
replace bolts. Bolts with adhesive in the locking threads and selflocking nuts must
always be replaced after removal.
6.12.1Set Screws and Nuts

The following tables contain the maximum tightening torques MA in Nm for set screws of
strength class 8.8 and nuts of strength class 8, with a coefficient of friction of tot = 0.14,
threads lightly oiled or lightly greased.
Note
NOTICE All tightening torques are multiplied by a factor of 1.1 for bolts with adhesive in
the locking threads (MK).
636 A520154_06_0903
Maintenance
MA [Nm] MA [Nm]
tot 0.14 x1.1 (MK) tot 0.14 x1.1 (MK)
M4 3.1 3.4 M 20 430 473

M5 6.1 6.7 M 20x1.5 480 528
M6 10.4 11.4 M 22 580 638
M7 17 19 M 22x1.5 640 704
M8 25 28 M 24 740 814
M 8x1 27 30 M 24x1.5 830 913
M 9x1 40 44 M 24x2 810 891
M 10 51 56 M 27 1100 1210
M 10x1 57 63 M 27x1.5 1200 1320
M 10x1.25 54 59 M 27x2 1190 1309
M 12 87 96 M 30 1500 1650
M 12x1.25 96 106 M 30x1.5 1670 1837
M 12x1.5 92 101 M 30x2 1610 1771
M 14 140 154 M 33 2000 2200
M 14x1.5 150 165 M 33x2 2250 2475
M 16 215 237 M 36 2600 2860
M 16x1.5 230 253 M 36x2 2950 3245
M 18 300 330 M 39 3400 3740
M 18x1.5 350 385 M 39x2 3720 4092
M 18x2 330 363
6.12.2Flared Screwed Joint

After each time the joint is undone, the union nut must be tightened again securely
without excessive force.
Flared screwed joints

RAD* / Type MA [Nm] RAD* / Type MA [Nm]
6 L 20 18 L 120
8 L 40 20 S 250
L 55 25 S 400
12
S 80 30 S 500
A520154_06_0903 637
Maintenance
15 L 70 38 S 800
16 S 130
* RAD = pipe external diameter
Note
NOTICE Hold threaded connection fast against turning with wrench.
10400100
Illustration 623: Tighten Flared Screwed Joint
638 A520154_06_0903
Maintenance Cards
In this section you will find the maintenance cards necessary for this machine. The table
of contents includes a summary of the maintenance cards in numerical order, you will
find an alphabetical summary in the Index of key words under the entry for Maintenance
cards.
BPUS09_013_0806EN 639
640
Maintenance card
03002
Page 1 of 2
6.13 Function Checks
This maintenance card describes the inspection of machine functions. The inspections
are carried out with the machine running. You will find the service intervals in the
maintenance summary at the start of this chapter.
No further maintenance cards required.
The following special tools are required:

Pressure gauge and connections for the tapping points shown in the hydraulic circuit
diagram
Note
NOTICE Only qualified personnel authorized by us may carry out work on the hydraulic
system. Notify the Putzmeister After Sales department or the dealer/agent who
looks after you immediately should you find any irregularities.
" Measure the pressures generated by the pumps, using the measuring equipment speci-
fied directly on the pumps, and compare your results with the values specified in the test
reading.
" Check the proper functioning of the pressurerelief valves in the high pressure circuit
and the pressure accumulator.
WKUS03_002_0806 641
Maintenance Card
03002
Page 2 of 2
642 WKUS03_002_0806
Maintenance Card
04002
Page 1 of 4
6.14 Hydraulic Hose Inspection and Replacement
This maintenance card describes how to check and replace the hydraulic hoses. You will
find the maintenance intervals in the maintenance summary at the start of this chapter.
No special tools required.
Note
NOTICE Check all hoses (including hose fittings) with the machine running.
You must replace the hoses at the slightest sign of damage or even mere
indications of threatened damage.
Leaking hoses
6.221
Illustration 6.221: Check hydraulic hoses
Dark and moist patches on the fitting are external signs of damage. Check:
the hoses for kinks, cracks or a porous surface and
whether the hoses have been laid without restrictions.
Note
NOTICE Beware of strong sunlight, the action of heat and the effects of chemicals.
WKUS04_002_0806 643
Maintenance Card
04002
Page 2 of 4
6.222
Illustration 6.222: Tighten until

there is a clearly perceptible
increase in force
" Check whether the flared screwed joints are tight.
Note
NOTICE You may only tighten leaking flared screwed joints with the permitted torque.
Tighten the joint until you clearly feel an increase in the force required if you do
not have a torque wrench available. You must replace these flared screwed joints
if leaking continues.

External Type Max. torque External Type Max. torque
diameter Md Ft Lbs[Nm] diameter Md Ft Lbs[Nm]
6 L 15 (20) 18 L 89 (120)
8 L 30 (40) 20 S 184 (250)
L 41 (55) 25 S 295 (400)
12
S 59 (80) 30 S 369 (500)
15 L 52 (70) 38 S 590 (800)
16 S 96 (130)
644 WKUS04_002_0806
Maintenance Card
04002
Page 3 of 4
Replacing hoses
The procedure for replacing hoses is as follows:
" Shut down the machine.
" Perform lock out tag out procedure and secure against unauthorized starting.
" Fully dump any (residual) pressure in the hydraulic system.
WARNING
Hydraulic hoses may be mechanically prestressed. There is a risk of injury from
whipping hoses.
" Take care when undoing the joints.
Note
NOTICE Catch escaping fluid in a container and dispose of in an environmentally friendly
manner.
" Close the connection points with a plug immediately once you have removed the old
hoses. No dirt may enter the hydraulic circuit and the hydraulic circuit must not run
empty.
CAUTION
Hoses should not be more than six years old, including a storage time of two
years. Take note of the date of manufacture on the hoses.
" Keep the hoses free from dirt.
" Fit the hoses to be free from bends or points of abrasion.
" Bleed the hydraulic system.
" Carry out a test run and inspect all hoses again after fitting new hoses.
" Make sure hydraulic oil level is at the Maximum level mark on oil level indicator. Top off
if necessary.
WKUS04_002_0806 645
Maintenance Card
04002
Page 4 of 4
646 WKUS04_002_0806
Maintenance Card
04012
Page 1 of 6
6.15 Changing the This maintenance card describes how to change the suction filter
Suction Filter element. You will find the maintenance intervals in the maintenance
summary at the start of this chapter.
Element
NOTICE Replace the filter element once the indicator on the vacuum meter is in the red
zone.
Cleanliness is of the utmost importance in the maintenance of hydraulic
systems. Prevent any type of dirt from entering the system. Even small
particles of dirt may cause valves to be scored, pumps to seize and throttle
and control bores to become blocked.
Hydraulic fluid barrels must stand for some time before the fluid is removed
from them. Never roll the barrels to where you will be drawing off the fluid.
Clean bungs and filler lids as well as the area around them before opening.
If possible, you should use a charging set to fill up the hydraulic system.
Never leave the reservoir lid open longer than necessary.
WKUS04_012_0805EN 647
Maintenance Card
04012
Page 2 of 6
CAUTION
Filter elements available on the market may have too low a flow rate. It
is therefore recommended, that you use original Putzmeister filter
elements in order to prevent damage to the machine.
You must never attempt to clean filter elements. These must always be
replaced.
NOTICE Dispose of used filter elements in accordance with the relevant regulations.
Preparation The following tasks must be carried out before changing the filter:
" Switch off the hydraulic pumps.
" Switch off the engine/motor.
" Dump the fluid pressure completely.
" Switch off the remote control.
CAUTION
The pressure accumulated in pressurized systems must be dumped.
" Perform Lock out Tag out procedure for diesel engine powered
units (start of this chapter).
648 WKUS04_012_0805EN
Maintenance Card
04012
Page 3 of 6
Changing
1. 3
2.
4.
3.
WKUS04_012_0805EN 1
No. 0 Designation
1 Lid
2 Hexagon nut
3 Plug
4 Drain cock
NOTICE Above illustration is for reference only to show how to remove the filter lid to
access the filter element. The filter configuration for your machine may be dif-
ferent.
" Place a container under the drain cock (4) to allow you to catch the
escaping hydraulic fluid.
" Unscrew the hexagon nuts (2) as far as the stop and remove the
filter element without turning it to the stop [1.].
WKUS04_012_0805EN 649
Maintenance Card
04012
Page 4 of 6
A shutoff valve automatically interrupts the hydraulic fluid sup-

ply.
" Open the upper plug (3) to provide an air supply [2.].
" Open the drain cock (4) and allow the hydraulic fluid to run out of
the filter housing [3.].
" Turn the lid (1) anticlockwise and remove the filter element com-
pletely [4.].
WKUS04_012_0805EN 2
No. 0 Designation
1 Hexagon nut
2 Filter element
3 Magnetic rod
" Unscrew the hexagon nut (1) from the magnetic rod (3).
" Turn the filter element (2) to the left and withdraw it from the mag-
netic rod (3).
" Wipe the magnetic rod (3) lengthways with a clean rag.
NOTICE Before fitting new filter elements, you must check all Orings and other seals
on the filter elements and replace them if damaged.
" Fit a new filter element and screw the hexagon nut (1) back on.
650 WKUS04_012_0805EN
Maintenance Card
04012
Page 5 of 6
NOTICE Any hydraulic fluid which escapes must be disposed of in accordance with the
relevant regulations.
WKUS04_012_0805EN 651
Maintenance Card
04012
Page 6 of 6
Correction dimension The filter element must be adjusted to the correct length so that the filter
element opens to the rear after the filter housing has been fitted. Use the
length (correction dimension) given on the spare parts sheet. If no
correction dimension is specified, the length of the filter element is as
designed.
NOTICE The correction dimension is measured from the lower edge of the lid to
the tip of the filter element.
10400401
K = Correction dimension
" Check and, if necessary, adjust the filter element to the correction
dimension.
CAUTION
The filtering process causes dirt particles to accumulate in the filter
housing. You must therefore clean the filter housing thoroughly before
refitting the new filter element, as otherwise the new filter element will
rapidly become clogged again.
" Clean the filter housing thoroughly with a clean rag.
" Install a new filter element. The installation procedure is the re-
verse of the procedure for removing a filter element.
652 WKUS04_012_0805EN
Maintenance card
04013
Page 1 of 6
6.16 Changing the This maintenance card describes how to change the pressure filter
Pressure Filter element. You will find the maintenance intervals in the maintenance
summary at the start of this chapter.
Element
Note
NOTICE Cleanliness is of the utmost importance in the maintenance of hydraulic systems.
Prevent any type of dirt from entering the system. Even small particles of dirt may
cause valves to be scored, pumps to seize and throttle and control bores to become
blocked. Hydraulic fluid barrels must stand for some time before the fluid is removed
from them. Never roll the barrels to where you will be drawing off the fluid. Clean
bungs and filler lids as well as the area around them before opening. If possible, you
should use a charging set to fill up the hydraulic system. Never leave the reservoir lid
open longer than necessary.
CAUTION
Filter elements available on the market may have too low a flow rate. It is therefore
recommended, that you use original Putzmeister filter elements in order to prevent
damage to the machine.You must never attempt to clean filter elements. These must
always be replaced.
Note
NOTICE Dispose of used filter elements in accordance with the relevant regulations.
WKUS04_013_0701EN 653
Maintenance card
04013
Page 2 of 6
Preparation The following tasks must be carried out before changing the filter:
" Switch off the hydraulic pumps.
" Switch off the engine/motor.
" Dump the fluid pressure completely.
" Switch off the remote control.
CAUTION
The pressure accumulated in pressurized systems must be dumped.
" Perform Lock out Tag out procedure for diesel engine powered
units (start of this chapter).
654 WKUS04_013_0701EN
Maintenance card
04013
Page 3 of 6
Checking Replace the filter element if the red button on the contamination indicator
pops out again after being pressed in at operating temperature.
WKUS04_013_0701EN 1
Checking and changing the pressure filter
" Bring the machine up to operating temperature (> 122F/50C).
" Set the maximum engine/motor speed.
" Press the red button on the pressure filter.
Note
NOTICE The filter element is OK if the red button remains depressed. The filter element must
be replaced if the red button pops out again.
WKUS04_013_0701EN 655
Maintenance card
04013
Page 4 of 6
Changing
Tighten to:
3540 ft. lbs. (50 Nm)
WKUS04_013_0701EN 2
No. 0 Designation
1 Filter element
2 Filter housing
CAUTION
The filtering process causes dirt particles to accumulate in the filter housing. You
must therefore clean the filter housing thoroughly before refitting the new filter
element, as otherwise the new filter element will rapidly become clogged again.
656 WKUS04_013_0701EN
Maintenance card
04013
Page 5 of 6
" Undo the filter housing (2) and remove the filter element (1).
" Clean the filter housing (2) thoroughly with a clean rag.
" Install a new filter element.
Note
NOTICE Before fitting new filter elements, you must check all Orings and other seals on the
filter elements and replace them if damaged.
" Screw the filter housing back on (see the spare parts sheet for the
tightening torque).
" Tighten filter housing using hex nut on bottom to 3540 ft. lbs. (50
Nm).
Note
NOTICE Check the level of the contamination indicator. Always refit the protective lid on the
contamination indicator each time this is checked.
WKUS04_013_0701EN 657
Maintenance card
04013
Page 6 of 6
658 WKUS04_013_0701EN
Maintenance Card
06023
Page 1 of 6
6.17 Delivery Piston Replacement
This maintenance card describes how to replace the delivery pistons. You will find the
maintenance intervals in the maintenance summary at the start of this chapter.
Note
NOTICE Always repair damage to the delivery pistons immediately.
Putzmeister accepts no warranty claims for damage to the machine resulting from
failure to properly observe the maintenance recommendations.
CAUTION
Follow lock out tag out procedures and secure the working area.
You will have to start and stop the machine a number of times as you replace the
delivery pistons. The operations necessary for this are described below and must be
carried out conscientiously.
Shutting down the machine
Proceed as follows to shutdown the machine:
" Set the output to zero.
" Ensure that the Reverse pumping toggle switch on the control cabinet is set to forwards
pumping.
" Stop the engine/motor.
" Check the highpressure gauge and wait until the fluid pressure in the hydraulic system
has discharged.
WKUS06_023_0806 659
Maintenance Card
06023
Page 2 of 6
CAUTION
Make sure the accumulator pressure is discharged completely on machines with
accumulators.
CAUTION
Do not switch the pump on until you are called upon to do so. You should also
start up the pump quite slowly each time, checking that the piston travel direction
is correct.
Starting the machine Diesel Models
" Set the throttle to onethird.
" Start the engine.
" Wait until the engine has reached a steady engine speed.
" Switch the pump on (at control cabinet or cable remote).
Starting the machine Electric Models
" Turn main power circuit breaker lever to On position.
" Turn main power On/Off switch to On position.
" Push the green Start button to start the motor.
660 WKUS06_023_0806
Maintenance Card
06023
Page 3 of 6
6.17.1 Piston replacement
Pistons are replaced from the water box.
WARNING
Always shutdown the machine before you reach into the water box.
1 2 3 2 4
5
6.23.11
Illustration 6.23.11: Replacing the Piston
1 Piston rod flange 4 Delivery piston

2 Fastening bolts 5 Spacer flange
3 Securing wire
" Shutdown the machine.
" Drain the water from the water box and remove the water box cover.
" Start the machine.
" Switch the machine on and allow the hydraulic piston of the delivery piston to be re-
moved to travel slowly to its end position.
" Switch the pump off once the transfer tube has switched over.
The spacer flange will now be visible in the water box.
WKUS06_023_0806 661
Maintenance Card
06023
Page 4 of 6
Removing a piston
1
6.23.12
Illustration 6.23.12: Piston removal

1 Fastening bolts
" Remove the wire clips from the fastening bolts and remove the bolts from the spacer
flange.
" Shift the unbolted delivery piston away from the spacer flange, which is still held fast,
with an iron bar or by striking it carefully with a hammer.
" Remove the spacer flange, and store it in such a way that it is protected against damage
until it is reinstalled.
" Switch the concrete pump on at a very low output.

The piston rod flange approaches the delivery piston slowly.
" Bolt the delivery piston to the piston rod flange.
" Set the toggle switch on the control cabinet to reverse pumping.

The delivery piston is withdrawn completely from the delivery cylinder.
" Undo the bolted connection on the piston rod flange and remove the old delivery piston.
" Thoroughly clean the delivery piston edge at the end of the water box.
662 WKUS06_023_0806
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CAUTION
Do not use any hard objects or caustic cleaning agents to clean the delivery
cylinder. These could damage the chrome layer.
Fitting a piston
A piston is fitted in the reverse order of the operations required to remove a piston as
follows.
" Grease the new delivery piston heavily with acidfree grease (e.g., Vaseline).
" Bolt the new delivery piston to the piston rod flange.

The new delivery piston is pushed very slowly into the delivery cylinder.
" Switch the pump off before the fastening bolts for the delivery piston disappear into the
delivery cylinder.
" Undo two fastening bolts on the delivery piston.
" Set the toggle switch on the control cabinet to reverse pumping.

The piston rod flange is drawn back.
" Switch the pump off once the spacer flange fits between the piston rod flange and the
delivery piston.
" Insert the spacer flange and fasten all the bolts.
" Tighten the bolts with the specified tightening torques and secure them with a stainless
steel wire.
Note
NOTICE Replace the second delivery piston in the same way.
" Fasten the water box cover on the water box and fill the water box with water.
" Then carry out a test run.
WKUS06_023_0806 663
Maintenance Card
06023
Page 6 of 6
664 WKUS06_023_0806
Maintenance Card
07014
Page 1 of 18
6.18 Replacing the STransfer Tube
This maintenance card describes how to replace the Stransfer tube and its wear parts.
You will find the maintenance intervals in the maintenance summary at the start of this
chapter.
Refer also to the maintenance cards:

07015 Adjusting the Stransfer tube
10007 Measuring the wall thickness

Normal tools including standard pullers for bearings, crane/lifting equipment of me-
dium loadbearing capacity and standard lifting tackle
Torques
The tightening torques can be found in the General Tightening Torques section at the
start of the Maintenance chapter. Torques differing from these are specified in the spare
parts sheets.
CAUTION
Shut the machine down and perform lock out tag out procedure and secure it
against unauthorized or accidental starting. Dump the accumulator pressure.
Use only suitable lifting equipment for lifting components.
Note
NOTICE The wear parts must be replaced if visual inspection reveals wear or if there is
insufficient pressure buildup in the delivery line.
6.18.1 Dismantling the Stransfer tube bearing
The Stransfer tube is mounted in the Stransfer tube bearing in the rear wall of the
hopper.
" Disconnect the pump from the delivery line.
" Open the grille on the hopper and secure it.
" Suspend the Stransfer tube from suitable lifting equipment.
" Remove the lubrication lines from the Stransfer tube bearing.
WKUS07_014_0806 665
Maintenance Card
07014
Page 2 of 18
" Undo the hexagon head bolts and nuts (item 1, Ill. 6.24.1) on the pressure flange (item 2,
Ill. 6.24.1).
" Remove the pressure flange and withdraw the pressure connection (item 3, Ill. 6.24.1)
and the Stransfer tube bearing.
3
2
6.15.1
Illustration 6.15.1: Remove pressure flange and pressure

connection
1 Hexagon head bolts / hexagon nuts 3 Pressure connection

2 Pressure flange 4 Hopper
" Check the seal rings and Orings on the Stransfer tube bearing for wear and replace
these as required.
6.18.2 Stransfer tube bearing gasket set
6.15.2
Illustration 6.15.2: Bend the seal rings to make installation

easier
666 WKUS07_014_0806
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Page 3 of 18
CAUTION
Take note of the installation drawing shown in Spare Parts Sheet 7.313467,
particularly the mounting position of the grooved rings.
" Grease the new gasket set and insert.
Note
NOTICE Clean the Stransfer tube bearing before refitting and grease the seals. Check the
lubricant bores, in particular, for proper functioning. Do this by connecting the
lubrication lines and forcing the lubricant through the bores.
6.18.3 Removing the Stransfer tube shaft bearings
The switching shaft of the Stransfer tube is mounted in the switching shaft bearing
(flanged bearing) in the front wall of the hopper.
Summary
3
2
4 5
1 6
10
7 8 8
9 6.15.31
Illustration 6.15.31: Removal of Switching Shaft Bearings
1 Switch cylinder 7 Fastening bolt for flanged bearing (10)

2 Retaining plate 8 B fastening bolts for wear plate
3 Retaining plate fastening bolts 9 A fastening bolts for wear plate
4 Clamping bolts with nuts 10 Flanged bearing
5 Switch lever 11 (not shown) Two pulling bolts on the upper
edge of the hopper
6 Hexagon nut on the switching shaft
WKUS07_014_0806 667
Maintenance Card
07014
Page 4 of 18
" Remove any lubrication lines from the retaining plate (item 2, Ill. 6.24.31) and flanged
bearing (item 10, Ill. 6.24.31).
1
2
6.15.32
Illustration 6.15.32: Unbolting the retaining plate

1 Fastening bolt
2 Retaining plate
" Undo the fastening bolts (item 1, Ill. 6.24.32) on the retaining plate (item 2, Ill. 6.24.32)
and remove the retaining plate. (You will have to replace the locking plates on the fasten-
ing bolts with new ones on reassembly).
Note
NOTICE Catch the escaping hydraulic fluid in a suitable container and dispose of it in
accordance with the disposal regulations applicable for your region.
" You may disconnect the hydraulic hoses leading to the switch cylinders at the bulkhead
unions if necessary for reasons of space. Then close off the hydraulic line with plugs.
6.15.33
Illustration 6.15.33: Removing the switch cylinders
668 WKUS07_014_0806
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07014
Page 5 of 18
Note
NOTICE You may push the switch cylinders back as illustrated, or you may screw a bolt
into the jacking bores for the ball cups and force the switch cylinders out with the
ball cups.
" Force the pistons of the switch cylinders back and remove the switch cylinders with the
hydraulic hoses.
" Undo the hexagon nuts on the switching shaft and remove the spacer ring.
6.15.34
Illustration 6.15.34: Loosen the clamping bolts
" Loosen the clamping bolts on the switch lever.
" Spread the switch lever apart by screwing the two jacking bolts supplied into the two
bores.
" Withdraw the switch lever from the switching shaft.
WKUS07_014_0806 669
Maintenance Card
07014
Page 6 of 18
1
2
6.15.35
Illustration 6.15.35: Removing flanged bearing
1 Fastening bolt 3 Flanged bearing

2 Retaining plate
" Unscrew the fastening bolt (item 1, Ill. 6.24.35)) from the flanged bearing (item 3, Ill.
6.24.35)).
" Force the flanged bearing off by screwing the two jacking bolts into the pulling bores
(item 2, Ill. 6.24.35).
" Check the seal rings and Orings on the flanged bearing for wear and replace these as
required.
6.18.4 Stransfer tube shaft bearing gasket set
6.15.41
Illustration 6.15.41: Removing the retaining ring
" Remove the retaining ring.
670 WKUS07_014_0806
Maintenance Card
07014
Page 7 of 18
6.15.42
Illustration 6.15.42: Removing old gasket set
" Remove the old gasket set. It may be necessary to cut the seal rings to do this.
6.15.43
Illustration 6.15.43: Fit the new gasket set
Note
NOTICE A fitting illustration may be found in Spare Parts Sheet 7.313467.
CAUTION
Note the mounting position of the grooved ring illustrated in Spare Parts Sheet
7.313467.
WKUS07_014_0806 671
Maintenance Card
07014
Page 8 of 18
Note
NOTICE Clean the Stransfer tube shaft bearing before refitting grease the seals.
" Check the sleeve for wear and replace if necessary.
" Grease and fit the new gasket set.
" Fit the retaining ring.
6.18.5 Removing the wear plate
6.15.51
Illustration 6.15.51: Pushing the Stransfer tube to one side
" Push the Stransfer tube away from the wear plate.
672 WKUS07_014_0806
Maintenance Card
07014
Page 9 of 18
2
1
3
6
7
4
8
5
B B
A
6.15.52
Illustration 6.15.52: Removing wear plate (5 bolt style)

AFastening bolts (item 5)
BFastening bolts(item 5)
1 Wear plate 5 Socket head capscrew (A & B fastening bolts)

2 Oring (2) 6 Wear ring (2)
3 Nylock nut (5) 7 Thrust ring (2)
4 Washer (5) 8 Spacer ring (2)
1
5
6
7
3
2
2 2
6.15.53
Illustration 6.15.53: Removing wear plate (2 bolt style)
1 Wear plate 5 Nylock nut (2)

2 Flat head screw (fastening bolts) 6 Wear ring (2)
3 Washer (2) 7 Oring (2)
4 Rubber buffer(5)
WKUS07_014_0806 673
Maintenance Card
07014
Page 10 of 18
" Remove the nylock nuts and fastening bolts.
" Remove the wear plate.
6.18.6 Removing the Stransfer tube
Replace the Stransfer tube if the wall thickness has fallen below the minimum.
Note
NOTICE You may skip this procedure and continue with the Fit the wear plate operation
if you do not need to replace the Stransfer tube or the wear sleeve on the
Stransfer tube outlet.
6.15.61
Illustration 6.15.61: Removing the agitator shaft
" Remove the agitator shaft.
6.15.62
Illustration 6.15.62: Lifting out the Stransfer tube
674 WKUS07_014_0806
Maintenance Card
07014
Page 11 of 18
" Unbolt the scratch bar from the bottom of the Stransfer tube.
" Push the Stransfer tube forwards until the transfer tube outlet is free.
" Lift the Stransfer tube outlet opening first upwards and out.
Note
NOTICE If you wish only to replace the wear sleeve, you must also carry out the operations
on the next page and only then replace the Stransfer tube.
If you are replacing the complete Stransfer tube, fit the new tube in the reverse
sequence to disassembly.
" Fit the new Stransfer tube.
6.18.7 Replacing the wear sleeve on the Stransfer tube
You can replace a heavily worn wear sleeve without having to replace the Stransfer
tube. The Stransfer tube must be removed to do this.
WARNING
There is a risk of burning during heating and fitting of the new wear sleeve. Use
suitable protective equipment.
CAUTION
Do not damage the transfer tube when cutting off the wear sleeve.
6.15.7
Illustration 6.15.7: Wear sleeve

1 Wear sleeve
WKUS07_014_0806 675
Maintenance Card
07014
Page 12 of 18
" Carefully cut the wear sleeve at two opposing places using an angle grinder and remove
the two parts.
Note
NOTICE The wear sleeve is chromeplated and therefore must not be heated locally or to
too great a temperature.
" Heat the new wear sleeve uniformly to a maximum of 284_F (140_C).
" Push the heated wear sleeve over the transfer tube end and let the wear sleeve cool.
" Replace the Stransfer tube.
6.18.8 Fitting the wear plate
To make positioning of the wear plate easier during fitting, screw two short threaded rods
into the two upper threaded bores in the wear plate and insert these into the upper holes
in the hopper wall.
" Check the Orings in the spacer ring on which the wear plate is placed.
" Clean the mounting surfaces and grease them with a multipurpose grease.
CAUTION
The wear plate lies only against the Orings of the spacer rings. There is a small
clearance between the wear plate and the hopper wall. You should therefore only
tighten the sockethead capscrews fingertight, as otherwise the wear plate will
break up.
6.15.81
Illustration 6.15.81: Fitting the wear plate
676 WKUS07_014_0806
Maintenance Card
07014
Page 13 of 18
" Install the new wear plate.
Note
NOTICE Ask our Customer Support Group for the tightening torques if a ceramic spectacle
wear plate is fitted to your machine.
Machines with 5bolt wear plate
1
0.02 in.
max. 0.5 mm
6.15.82
Illustration 6.15.82: Maximum distortion of the wear plate: 0.5 mm (0.02 in.)
1 Wear plate
2 Spacer ring
" Install the new wear plate and fasten it with the B
fastening bolts (outer fastening bolts; item 5, Ill. 6.24.52) and nylock nuts (item 3, Ill.
6.24.52). Tighten these fingertight.
" Bolt down the wear plate with the A fastening bolts (top and bottom; item 5, Ill. 6.24.52)
and tighten the (top and bottom) nylock nuts with a torque wrench.
WKUS07_014_0806 677
Maintenance Card
07014
Page 14 of 18
" Then tighten the B fastening bolts (outer fastening bolts) and outer nylock nuts with the
torque wrench. The wear plate may only be distorted by a maximum of 0.5 mm (0.02 in.)
when the bolt and nuts are tightened.
Machines with 2bolt wear plate
1
2
4
6.15.83
Illustration 6.15.83:
1 Fastening bolt 3 Rubber buffer

2 Wear plate 4 Nylock nut
" Install the new wear plate in place and fasten it with the fastening bolts.
" Tighten the nylock nuts so that the rubber buffer is compressed by approximately 0.2 in.
(5 mm).
678 WKUS07_014_0806
Maintenance Card
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Page 15 of 18
6.18.9 Replacing the seal ring
Replace the seal ring in the event of heavy visible wear, if concrete is leaking or if there
is inadequate pressure buildup in the delivery line.
2
1
6.15.9
Illustration 6.15.9: Replacing the seal ring

1 Thrust ring
2 Seal ring
" Remove the old seal ring (item 2, Ill. 6.24.9) and the thrust ring (item 1, Ill. 6.24.9).
" Clean the thrust ring seat thoroughly. Dirt and concrete residue must be removed from
the seat.
" Fit a new thrust ring and a new seal ring in the Stransfer tube.
WKUS07_014_0806 679
Maintenance Card
07014
Page 16 of 18
6.18.10 Fitting the Stransfer tube bearing
3
2
6.15.10
Illustration 6.15.10: Fitting Stransfer tube bearing
1 Hexagon head bolts / hexagon nuts 3 Pressure connection

2 Pressure flange 4 Hopper
Note
NOTICE Pay attention to the location of the lubrication openings when fitting the
Stransfer tube bearing.
" Replace the Stransfer tube bearing and the pressure connection and bolt them both in
place with the pressure flange.
6.18.11 Wear sleeve and collared washer
6.15.11
Illustration 6.15.11: Locating the collared washer
" Bend the tab on the collared washer downwards.
680 WKUS07_014_0806
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Page 17 of 18
" Place the collared washer on the Stransfer tube shaft casing such that the tab is in-
serted in the bore and the washer is thus secured against turning.
" Insert the wear sleeve in the Stransfer tube shaft casing.
Note
NOTICE Note the position of the lubricant bores when fitting the Stransfer tube shaft
bearing.
" Grease the inside of the wear sleeve with AntiSeize AS 450 assembly paste or similar
assembly grease.
" Place the complete Stransfer tube shaft bearing on the switching shaft and bolt it in
position.
Note
NOTICE The rolled pin ensures that the wear sleeve rotates with the switch lever.
The topmost tooth of the switching shaft is slightly flattened and may be used as
a marker.
6.18.12 Mounting the switch lever
6.15.121
Illustration 6.15.121: Inserting the rolled pin
" Insert the rolled pin into the bore in the switch lever.
" Grease the teeth on the switch lever and the switching shaft with AntiSeize AS 450 As-
sembly Paste or an equivalent assembly grease.
WKUS07_014_0806 681
Maintenance Card
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Page 18 of 18
6.15.122
Illustration 6.15.122: Aligning the switch lever
" Fit the switch lever. The flattened tooth on the switching shaft must be seated in the
notch in the switch lever and the rolled pin must be located in the hole in the wear
sleeve.
" Fit the switch cylinder.
" Complete the remaining assembly operations and adjust the Stransfer tube.
Maintenance card: Adjusting the Stransfer tube.
Note
NOTICE The hydraulic system must be bled once assembly is complete if you have
removed the hydraulic hoses on the switch cylinders. Do this by starting up the
pump slowly and switching the transfer tube across slowly a few times.
682 WKUS07_014_0806
Maintenance Card
07015
Page 1 of 12
6.19 Adjusting the STransfer Tube
This maintenance card describes how to adjust the Stransfer tube.
CAUTION
Secure the working area. Affix warning notices to the blocked control and setting
devices.
Keep the grille on the hopper closed during adjustment operations.
You will have to shutdown and restart the machine a number of times. The operations
necessary for this are described below and must be carried out conscientiously. As far
as possible, you should execute all machine functions from the cable remote control.
6.19.1 Shutting down the machine
Proceed as follows to shutdown the machine:
" Set the output to the minimum.
" Switch off the pump.
" Stop the engine/motor.
" Dump the pressures completely.
CAUTION
Dump the accumulator pressure completely in systems with pressure
accumulators.
WKUS07_015_0806 683
Maintenance Card
07015
Page 2 of 12
CAUTION
Do not switch the pump on until you are called upon to do so. You should also
start the pump slowly each time, checking that the piston travel direction is
correct.
6.19.2 Starting the machine
Proceed as follows to start a diesel engine model:
" Set the throttle to onethird.
" Start the engine.
" Wait until the engine has reached a steady engine speed.
Proceed as follows to start an electric motor model:
" Turn main power circuit breaker lever to On position.
" Turn main power On/Off switch to On position.
" Push the green Start button to start the motor.
6.19.3 Set the gap
The first part of this maintenance card describes how to adjust the gap (clearance
between the wear ring and the transfer tube).
" shutdown the machine.
Note
NOTICE The switch lever is not normally centered and vertical during disassembly as is
shown in the illustration below.
The switch cylinders do not need to be removed, as is shown in some
illustrations, for the purposes of setting the gap.
The disassembly steps described below are unnecessary if you have already
fitted the S transfer tube following the instructions in the Replacing the
Stransfer tube maintenance card.
684 WKUS07_015_0806
Maintenance Card
07015
Page 3 of 12
6.16.31
Illustration 6.16.31: Unbolting the retaining plate
" Remove any lubrication lines from the retaining plate.
" Undo the fastening bolts on the retaining plate and remove the retaining plate. (You will
have to replace the locking plates on the fastening bolts with new ones on reassembly).
1 2 3
6.16.32
Illustration 6.16.32: Loosen hexagon nuts on switching shaft

1 Spacer ring
2 Switching shaft
3 Hexagon nut
" Undo the hexagon nuts on the switching shaft.
WKUS07_015_0806 685
Maintenance Card
07015
Page 4 of 12
6.16.33
Illustration 6.16.33: Loosen the clamping bolts
" Loosen the clamping bolts on the switch lever.
1 2 3 4 6.16.34
Illustration 6.16.34: Setting the clearance (S) between

seal ring and transfer tube
1 Transfer tube 3 Seal ring

2 Thrust ring 4 Wear plate
" Tighten the hexagon nuts on the switching shaft until the collar of the wear ring is flush
against the transfer tube.
686 WKUS07_015_0806
Maintenance Card
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Page 5 of 12
NOTICE The gap (clearance between seal ring and transfer tube) must be set to en-
sure that the transfer tube switches correctly.
" Undo the hexagon nuts on the switching shaft by to of a turn. Line up the hexagon
nut as you do this so that the retaining plate can be fitted without problems.
The gap S is now set automatically and is 0.0591 to 0.0789 inch. (1.5 to 2 mm).
NOTICE Use only new nuts for the clamping bolts.
" Remove the old nuts on the clamping bolts and fit new nuts. Tighten the clamping bolts
to 155 ft. lbs. (210 Nm).
6.16.35
Illustration 6.16.35: Tighten clamping bolts
" Further assembly is carried out in the reverse sequence to disassembly.
" Check that all covers and other safety equipment have been refitted and are fully func-
tional.
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Maintenance Card
07015
Page 6 of 12
6.19.4 Set the switching overlap
The switching overlap is set to the optimum if the wear ring is central to the relevant hole
in the wear plate for both switch positions of the Stransfer tube.
Wear plate with wear ring
1 2
6.16.41
Illustration 6.16.41: Transfer tube swing angle setting...

1 is too great
2 is too small
3 is correct
The lefthand side switching overlap is corrected by replacing the packing washer
behind the ball cup on the righthand switch cylinder with a thicker or thinner washer
respectively. The righthand switching overlap is corrected on the left in the same way.
1 2
3
6.16.42
Illustration 6.16.42: Replacing packing washer

1 Switch cylinder
2 Ball cup
3 Packing washer
688 WKUS07_015_0806
Maintenance Card
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Page 7 of 12
6.16.43
Illustration 6.16.43: Extended switch cylinder
" Allow one switch cylinder to retract fully.
6.16.44
Illustration 6.16.44: Marking the wear plate
" Mark the location of the seal ring on the wear plate with a felttip pen or wax crayon.
" Allow the other switch cylinder to retract.
" Determine to which side and by how far the circle you have drawn is offset against the
circle of the wear plate.
WKUS07_015_0806 689
Maintenance Card
07015
Page 8 of 12
Wear plate with sample markings
1 2
6.16.45
Illustration 6.16.45: The packing washer...

1 is too thin
2 is too thick
3 is correct
If too thin
The packing washer fitted must be replaced by a packing washer 0.078 Inch
(2 mm) thicker to reduce the swing angle of the transfer tube by 0.157 inch
(4 mm).
If too thick
The packing washer fitted must be replaced by a packing washer 0.076 Inch
(2 mm) thinner to increase the swing angle of the transfer tube by 0.157 Inch
(4 mm).
If correct
The packing washer does not need to be replaced.
690 WKUS07_015_0806
Maintenance Card
07015
Page 9 of 12
1 2
6.16.46
Illustration 6.16.46: Locking plate removal

1 Switch cylinder
2 Locking plate
" Remove the locking plate of the extended switch cylinder.
6.16.47
Illustration 6.16.47: Removing the switch cylinders
Note
NOTICE You may push the switch cylinders back as illustrated. You may, however, also
screw a bolt into the jacking bores for the ball cups and force the switch cylinders
out with the ball cups.
" Force the piston of the extended switch cylinder back a little and remove the switch cylin-
der with the hydraulic hoses.
WKUS07_015_0806 691
Maintenance Card
07015
Page 10 of 12
1
2
6.16.48
Illustration 6.16.48: Removing ball cup and packing washer

1 Ball cup
2 Packing washer
" Remove the ball cup and packing washer.
CAUTION
No packing washers may be inserted in the switch lever, as otherwise the switch
cylinder can run over the edge of the ball cup and break it.
" Fit a thicker or thinner packing washer, as required, with the ball cup.
" Fit the switch cylinder and locking plate.
" Allow the transfer tube to switch over a few times. Stop the machine when the transfer
tube is over the side of the wear plate that has not been marked.
" Check the switching overlap of the other side of the wear plate and correct accordingly.
6.19.5 Switching overlap on fully hydraulic control (VHS)
The two switch cylinders must extend to the same extent on machines with fully
hydraulic control (VHS) and active signal tapping in the switch cylinders.
" First set one switching overlap of the wear ring and the wear plate.
" Allow the switch cylinder (1) to extend to its end position.
692 WKUS07_015_0806
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Page 11 of 12
6.16.5
Illustration 6.16.5: Extended switch cylinder
" Measure how far the switch cylinder has extended. (Measurement E1)
" Allow the switch cylinder (2) to extend to its end position.
" Measure how far the switch cylinder has extended. (Measurement E2)
" Compare the two measurements.
The two measurements E1 and E2 should be identical. You will have to change the
packing washers as described below if the two measurements are not equal:
" Swap the packing washer on the switch cylinder with the greater measurement for a
washer (E1E2):2 thinner.
" Swap the packing washer on the switch cylinder with the smaller measurement for a
washer (E1E2):2 thicker.
Note
NOTICE This setting must be checked after a runningin period of approximately 100
operating hours.
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6.20 Measuring the Wall Thickness (Machines with Stransfer tube)
This maintenance card describes how to measure the wall thickness of delivery lines.
You will find the maintenance intervals in the maintenance summary at the start of this
chapter.

Wall thickness measuring device
Note
NOTICE Delivery lines are subject to constant wear. Measurement of the wall thickness is
particularly important before starting on large jobs.
You will obtain reliable results for your measurements if you carry out the test
with the measuring device recommended by Putzmeister.
DANGER
The delivery line can burst once it reaches a high delivery pressure if the wall
thickness of the delivery line has decreased below the minimum required,
particularly if a blockage has built up.
CAUTION
Only tap the delivery line with a piece of hardwood (hammer handle). Otherwise,
dents may be created and these will lead to more rapid wear. In addition, the
hardened lining of high wear resisting pipes may flake off the inside of the pipe.
The pipe can burst at points that have suffered heavy wear.
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6.18.1
Illustration 6.181: Tapping the delivery line

with a hammer handle
Straight pipes
Uniform wear can be achieved by regularly rotating the straight delivery pipes through
120.
The minimum wall thickness for straight pipes is shown in the graph below.
Bends
Uniform wear can be achieved by regularly rotating the bends through 180. The wear
on the external radius of a bend is greater than that on the internal radius or on straight
pipes. You should, therefore, take special care when measuring the wall thickness of
the external radius of a bend.
The minimum wall thickness for bends is shown in the graph below.
6.18.2
Illustration 6.182: Rotate delivery pipes

and bends regularly
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6.20.1 Stransfer tube
The minimum wall thickness for the Stransfer tube depends on the maximum possible
operating pressure. Furthermore, the fact that the transfer tube is subject to greater
stress at the point at which the torque is applied (switching shaft transfer tube) must be
taken into consideration.
6.18.1
Illustration 6.18.1: X = Area of heavy loading
Operating pressure up to Guide value for wall thickness

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

Area B 0.236 0.315 in. [6 8 mm]
Note
NOTICE We should draw your attention to the fact that the transfer tube is subject to
varying loading as a result of the dynamic loading during pumping. There is no
general method for calculating the minimum wall thickness for this loading, which
depends on the individual circumstances, and so the transfer tube can also burst
at an operating pressure which is assumed still to be permissible.
You should also note that the operating pressure can rise to the maximum
pressure in the event of a blockage, and in this case the wall thickness may no
longer be adequate.
If the operating pressure is higher than 1885.5 psi (130 bar), consult the
Putzmeister Customer Support Group what the minimum wall thickness is.
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6.20.2 Measuring
Follow the Operating Instructions supplied with the measuring device when carrying out
measurements. Do not measure the wall thickness of the delivery line at just one point,
but around the entire circumference of the delivery pipes.
The minimum wall thickness is shown in the graph below.
CAUTION
Pipes and bends must be replaced as soon as the wall thickness has declined to
the value for the minimum wall thickness.
Putzmeister accepts no liability if the wall thickness is less than the minimum wall
thickness.
Note
NOTICE As a rule it is possible to continue pumping with an operating pressure lower than
that shown in the graph.
We should, however, draw your attention to the fact that the delivery line is
subject to varying loading as a result of the dynamic loading during pumping.
There is no general method for calculating the minimum wall thickness for this
loading, which depends on the individual circumstances, and so the delivery line
can also burst at an operating pressure which is assumed still to be permissible.
Furthermore, the operating pressure can rise to 1233 psi (85 bar) in the event
of blockages, meaning that the wall thickness will no longer be adequate and the
delivery line will burst.
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Graph Minimum wall thickness as a function of operating pressure

Psi (Bar)
3625 (250)
3480 (240)
3335 (230)
3191 (220)
3045 (210)
2900 (200)
2755 (190)
2610 (180)
2465 (170)
2320 (160)
2175 (150)
2030 (140)
1885 (130) 1
1740 (120)
1595 (110)
1450 (100)
1305 (90)
2
1160 (80)
1015 (70)
870 (60)
725 (50)
580 (40)
435 (30)
290 (20)
145 (10)
0
Inch 0.0 .020 .039 .059 .079 .098 .118 .138 .157 .177 .197 .217 .236 .256 .276 .295 .236 .335 .354 .374.394
(mm) (0.5) (1.0) (1.5) (2.0) (2.5) (3.0) (3.5) (4.0) (4.5) (5.0) (5.5) (6.0) (6.5) (7.0) (7.5) (8.0) (8.5) (9.0) (9.5)(10.0)
6.18.2
Illustration 6.18.2: Minimum wall thickness of delivery pipe to operating pressure

1 High pressure
2 Maximum delivery pressure
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6100 WKUS10_007_0806
7 Troubleshooting Guide
The previous sections of this manual dealt with the various aspects of operation,
preventative maintenance, adjustments, and component replacement. This
troubleshooting section will assist you in recognizing and recovering from conditions that
cause equipment malfunctions.
The items listed are based on logical symptoms from our experience with the Thom-Katt
and from your calls to our Technical Support Department. We need your help to
continually up-grade this section. Perhaps you and your mechanic have come across a
situation not found here and have resolved the problem. Share it with us and others like
yourself. Just send it to the Putzmeister Technical Support Department.

7.1 Engine 72
7.2 Hydraulic Oil Cooler 73
7.3 Main Hydraulic Pump 73
7.4 Secondary Hydraulic Pump 74
7.5 Electrical System 74
7.6 Hydraulic Drive Cylinders 76
7.7 S-Tube Shifting 78
7.8 Hydraulic System 79
7.9 Remixer 710
7.10 Concrete Pump 711
A520154_07_0903 71
Troubleshooting Guide
7.1 Engine
Note
NOTICE Engine troubleshooting items noted in this section only pertain to general items
and those which may be caused by pump operation. For more serious items,
consult the Diesel Engine Manual.
Engine Cranks But Fails To Start

Possible Cause: Corrective Action:
No fuel BSA100/120 Fill up fuel tank with a good grade of diesel fuel
Dirty fuel filter BSA100/120 Replace fuel filter
Clogged fuel line BSA100/120 Disconnect and air blow clean or replace fuel line
Dirty injectors BSA100/120 Clean or replace injectors
Air leak in fuel connections BSA100/120 Check that all fittings are tight
Engine Does Not Crank

Battery cables loose BSA100/120 Clean and tighten cables; check grounding
Low battery BSA100/120 Check battery output, recharge, or replace
Ignition key switch or start button switch malfunctioning
Check power across contacts; replace if damaged
BSA100/120
Check for loose connections, power across contacts;
Starter solenoid BSA100/120
replace if malfunctioning.
Failed starter BSA100/120 Replace starter
Engine Bogs Down With Full Throttle, Full Volume, and Pump Switch On
Horsepower limiter on main pump Contact Putzmeister Service Department. Main pump horsepower limiter
misadjusted BSA100 needs to be readjusted during a full load condition.
72 A520154_07_0903
7.2 Hydraulic Oil Cooler
The Fan on the Oil Cooler No Longer Switches in Automatically

Thermal contact switch B2 Check terminal (and ground contact). Replace thermal contact switch (do not
defective (seat on the connecting forget copper gasket). Switch on cooler motor by the manual switch.
flange of the cooler) BSA120
10501100
Separate Oil Cooler Fan Fails To Operate

Loose electrical connections BSA120 Check for loose connections; tighten if loose
Check relay, contacts and connections.
Relay 2K2 malfunction BSA120
Fan works off ignition switch.
Fan motor burned out BSA120 Replace fan motor
Cooler Fails To Cool Hydraulic Fluid

Look for intake air restriction. Clean external dirt from oil
Blocked air flow BSA100/120
cooler.
Switch fan leads so that fan rotates in opposite direction
Incorrect rotation of separate oil cooler fan BSA120
(i.e., rotating fan draws air through oil cooler).
7.3 Main Hydraulic Pump
Pump Fails To Deliver Required Flow And Pressure

Adjust throttle control to full open; readjust maximum
Engine speed too low BSA100/120
engine no-load speed as per nameplate on unit.
Volume control set too low BSA100/120 Adjust control to full on (open)
A520154_07_0903 73

Check for contamination in load sensing valve or main
Load sense signal not working properly BSA100 hydraulic pump standby pressure adjustment (if necessary,
remove and clean); replace any defective items.
Main system hydraulic pressure gauge defective
Replace gauge
BSA100/120
Check the following pressures and adjust accordingly using
the Checking and Adjusting Hydraulic System Pressures
procedure, in the Maintenance section:
Pressure settings incorrect BSA100
Main hydraulic pump standby pressure
Main hydraulic pump compensator pressure
Main system relief pressure
High flow at case drain (i.e., defective pump) BSA100 Replace main hydraulic pump
7.4 Secondary Hydraulic Pump
Pump Fails To Deliver Required Flow And Pressure

Pressure settings incorrect BSA100 procedure, in the Maintenance section:
Defective pump BSA100 Replace secondary hydraulic pump
7.5 Electrical System
The Red Indicator Light for fluid overheating is Lit

The hydraulic fluid has Allow the hydraulic fluid to cool and, if necessary, top up or
overheated BSA120 replace the water in the water box.
The fan on the oil cooler is defective Check fan function and replace the fan motor if necessary.
BSA120
Temperature sensor is Replace temperature sensor. Hold temperature sensor connection to ground to
defective BSA120 check.
The connection cable to the Clean and fasten the connections on the temperature sensor.
temperature sensor is loose BSA120
74 A520154_07_0903
The Red Indicator Light for fluid overheating is Lit

The fan connection is corroded Clean the terminals on the fan motor and fasten the connection cables properly.
BSA120
Caution
Avoid contact with ground.
The Vibrator Fuse is Blown

The vibrator is defective or the Replace defective vibrator. Fasten the grate cover on the hopper and reduce the
hopper grate is loose BSA100/120 outofbalance of the vibrator, if necessary.
Vibrator cable is damaged Replace vibrator cable.

BSA100/120
Pump is Switched On, but will Not Start

The specified minimum engine Increase engine speed.
speed for pumping operations of 900
rpm is not achieved BSA120
Pumping rate too low Increase pumping rate, or turn knob.
BSA100/120
EMERGENCY SHUTDOWN is Unlock all EMERGENCY SHUTDOWN buttons.

activated (EMERGENCY
SHUTDOWN button pressed)
BSA100/120
10500200
A520154_07_0903 75
Hour Meter Does Not Function

Note: Hour meter operates only when pump is cycling.
Loose electrical connections BSA100/120 Check for loose connections; tighten if loose
Damaged wiring BSA100/120 Check for damaged wiring; replace if damaged
Improper ground connection BSA100/120 Check ground connection
Damaged hour meter BSA100/120 Replace hour meter
Emergency Stop Switch Does Not Function

Note: Emergency stop switch stops the diesel engine
K4 relay or contacts failure BSA100/120 Replace 1K4 relay
Emergency stop switch failure BSA100/120 Replace E-stop switch
Alternator Fault Light (LED) Remains On

Loose electrical connections BSA100/120 Check for loose connections; tighten if loose
Damaged wiring BSA100/120 Check for damaged wiring; replace if damaged
Loose alternator belt BSA100/120 Tighten alternator belt
Failed Alternator BSA100/120 Check alternator output; replace alternator if failed
7.6 Hydraulic Drive Cylinders
Hydraulic Cylinders Will Not Stroke With Correct Volume And Pressure
Emergency stop switch engaged BSA100/120 Release emergency stop switch
Faulty proximity switch; no signal to change over valve Remove switch from opposite side and install on side with
BSA100/120 problem. If cylinder cycles, replace faulty switch.
S Check control panel for 12V DC input
S Check main cycle pilot valve solenoid connection
Insufficient electrical voltage BSA100/120
S Check for 12 volts to solenoid
S Check interconnecting wiring for continuity
Faulty main cycle relay 3A23 BSA100/120 Check relay and contacts; replace relay if defective
Faulty PUMP ON toggle switch BSA100/120 Replace toggle switch
76 A520154_07_0903

Check coils by manually pushing on override button of the
Defective solenoid coils on main cycle pilot valve BSA100 solenoid. If cylinder strokes, replace coil. If spool cannot
be shifted, remove valve and clean or replace.
S Check for 12V DC current at accumulator discharge
solenoid valve
S Check solenoid coil; replace if faulty
S Check the following pressures and adjust accordingly
using the Checking and Adjusting Hydraulic System
Pressures procedure:
Improper S-tube shift circuit pressure BSA100/120
S Remove, disassemble, and clean main cycle valve,
checking for contamination or damage. Replace
damaged spools if necessary.
S Check S-tube cylinder seals and replace if necessary.
S Check accumulator gear pump and replace if defective.
S Check hydraulic cylinders and replace if defective.
Hydraulic Cylinders Do Not Fully Extend During Cycling (i.e., Short Stroking)
S Actuate test pressure switch and hold until cylinder being
extended bottoms out; resume normal operation
Too much hydraulic oil in loop between cylinders S Determine if check valve on barrel side of cylinder is
BSA100/120 faulty; clean or replace check valve
S Determine if orifice on rod side is blocked; clean orifice
S Check piston seals and replace if necessary
Malfunctioning hydraulic cylinders load-sensing valve
Clean or replace load-sensing valve
BSA100
Hydraulic Cylinders Stroke Very Slowly Even With High Pressure and Volume Open
Corrective Action:
Remove and clean pilot orifice. Caution: Exercise extreme
Clogged pilot orifice BSA120 care when removing and installing orifice so that it will not
fall into another passage in control block.
Slurry In Water Box

Damaged delivery cylinder piston cups BSA100/120 Replace with new piston cups
A520154_07_0903 77
7.7 S-Tube Shifting
S-Tube Does Not Shift Completely To Cover Delivery Cylinder

Corrective Action:
Obstacle in hopper (e.g., wear plate binding, concrete
Check for obstacle; clear obstacle
buildup, etc.) BSA100/120
S-Tube Not Shifting Properly

Concrete buildup near wear ring or wear plate in hopper
Remove concrete buildup
BSA100/120
Remove switch from opposite side and install on side with
Faulty proximity switch BSA100/120
problem. If cylinder cycles, replace faulty switch.
Check accumulator pre-charge pressure and adjust
accordingly using the Performing Maintenance on the
Accumulator pre-charge pressure too low BSA100/120
Accumulator procedure, in the Maintenance section,
replace bladder if pressure does not hold.
S-tube shift circuit pressure too low BSA100/120 procedure, in the Maintenance section:
Check seals by disconnecting one of the hoses from the
cylinder (i.e., with rod extended, disconnect rod side hose
S-tube shift cylinder seals leaking oil BSA100/120
and pressure barrel side; if oil comes out of rod side hose,
seals are leaking). If necessary, replace seals or cylinder.
S Check electrical connections to solenoid
Malfunctioning accumulator discharge solenoid valve S Check solenoid valve for 12V DC input
BSA100/120 S Actuate solenoid manually to shift spool
S Replace solenoid cartridge
Check coils by manually pushing on solenoid override
Defective solenoid coils on S-tube cycle valve BSA100/120 button. If cylinder strokes, replace coil. If spool cannot be
shifted, remove valve and clean or replace.
78 A520154_07_0903
Accumulator Is Not Working Properly (i.e., Pressure Builds Slow or Releases Fast)
Check accumulator pre-charge pressure and adjust
Insufficient pre-charge of bladder BSA100/120 accordingly using the Performing Maintenance on the
Accumulator procedure, in the Maintenance section.
S-tube shift circuit pressure too low BSA100/120 procedure, in the Maintenance section:
S Check electrical connections to solenoid
Malfunctioning accumulator discharge solenoid valve S Check solenoid coil for 12V DC input
BSA100/120 S Actuate solenoid manually to shift spool
S Replace solenoid cartridge
Replace bladder and pre-charge accumulator with dry
Ruptured accumulator bladder BSA100/120 nitrogen using the Performing Maintenance on the
Accumulator procedure, in the Maintenance section.
7.8 Hydraulic System
Hydraulic Fluid Temperature Is Abnormally High

Malfunctioning oil cooler BSA100/120 Refer to Hydraulic Oil Cooler section
Defective temperature gauge BSA100/120 Check temperature gauge and replace if defective
Clogged oil tank breather cap BSA100/120 Remove and clean breather cap
Too little cooling water in the water box at high output Top up the water.
BSA100/120
Cooling water too hot Replace with fresh water.

BSA100/120
A520154_07_0903 79

Too little fluid in the hydraulic system Top up hydraulic fluid.
BSA100/120
Pump is running in the maximum pressure range because Reduce pump delivery speed or ask for better concrete (composition).
of poor concrete and high delivery rate
BSA100/120
Constantly at maximum pressure in longdistance delivery Increase pipe size, eg from 4 (DN 100) to 5 (DN 125).
BSA100/120
Overpressure as a result of a blockage Remove blockage (by switching the pump over from delivery to reverse pum
BSA100/120 a number of times).
Oil cooler (132) dirty, oil cooler fan not running Clean BSA100/120
BSA100/120 Switch on.
Check voltage and ground contact of thermocouple 131F(55C)
(not on frontmounted radiator) BSA120.
7.9 Remixer
Remixer Will Not Rotate

Broken or missing bolt where agitator connects to drive Check agitator to drive shaft connection; replace any
shaft BSA100/120 broken or missing bolt.
Broken key in drive shaft coupling BSA100/120 Install new key or coupling
Check remixer relief valve setting and adjust accordingly
Relief valve set too low BSA100/120 using the Adjusting Remixer Relief Pressure procedure in
the Maintenance section.
No oil flow to remixer control valve BSA100/120 Check flow; if no flow, replace hydraulic pump
Malfunctioning remixer control valve BSA100/120 Check valve operation (i.e., spool shifts easily)
Malfunctioning remixer hydraulic motor BSA100/120 Replace hydraulic motor
710 A520154_07_0903
7.10 Concrete Pump This section describes the possible causes of defects which may
affect the concrete pump and how to rectify them. The numbers in
parentheses are the item numbers on the hydraulic schematic.
The Pump No Longer Switches Over on Every Other Stroke

One coil on the stroke change valve Replace stroke change valve (103a).
(103a) is defective BSA120
103a Stroke changeover switch control valve
103a
The Delivery Pistons do not Start

Pump not switched on BSA100/120 Verify the green pump running LED is illuminated
Lack of fluid in the hydraulic system Top up hydraulic fluid.

BSA100/120
A520154_07_0903 711
The Delivery Pistons do not Start

No accumulator pressure (see test Verify that hopper grate is closed and then manually push solenoid-operated
reading for required value) accumulator dump valve (184) to see if accumulator pressurizes. If accumulator
BSA120 pressurizes (when dump valve is pressed), problem is in the dump valve or its
circuitry.
121
113
184 120
113 Pressure gauge for accumulator 121 Shutoff valve with 5mm orifice
120 Accumulator 184 Safety cutout for accumulator
Suction gauge in the red zone Suction filter (140) dirty. Replace filter element (141), clean
BSA120 magnetic rod, observe maintenance intervals.
Main hydraulic system pump (127) Increase delivery rate regulation by:
not engaged for operation BSA120 (1) Using electric volume control switch (211), or
(2) Closing manual volume control valve (125)
Delivery piston blocked in the end Press reverse pumping switch or stroke change switch.
position
BSA100/120
10600100
Engine speed too low. The main Increase engine speed.

pump does not engage BSA120
712 A520154_07_0903
Pump has Insufficient Output

Main hydraulic system pump (127) Increase delivery rate regulation by:
not fully engaged BSA120 (1) Using electric volume control switch (211), or
(2) Closing manual volume control valve (125)
Pump is Not Running

Lack of fluid BSA100/120 Top up hydraulic fluid.
Stroke change valve (103a) sticks as Press stroke change valve manual operation button (103a) a number of times,
a result of fine dirt or defect BSA120 switch the pump over to reverse pumping for 2 3 strokes. Check solenoid coils
and their connections.
103a
A520154_07_0903 713
Pump Does Not Switch Over

Too little hydraulic fluid Top up hydraulic fluid.
BSA100/120
Fuse blown BSA100/120 Replace fuse.
Stepping relay in the switch cabinet Operate stroke change function. Verify that LED on the stroke change module
defective illuminates during cycle. If LED does not illuminate, check stepping relay.
BSA100/120
Stroke change valve (103a) sticks as Press stroke change valve manual operation button (103a) a number of times,
a result of fine dirt or defect BSA120 switch the pump over to reverse pumping for 2 3 strokes. Check solenoid coils
and their connections.
103a
714 A520154_07_0903
Transfer Tube does not Switch or Gets Stuck

Insufficient accumulator pressure, Verify that hopper grate is closed and then manually push solenoid-operated
accumulator circuit not pressurized accumulator dump valve (184) to see if accumulator pressurizes. If accumulator
(see test reading for required value), pressurizes (when dump valve is pressed), problem is in the dump valve or its
change-over pressure is too low, or circuitry.
accumulator dump valve (184) is
open.
121
BSA120
113
184 120
113 Pressure gauge for accumulator 121 Shutoff valve with 5mm orifice
120 Accumulator 184 Safety cutout for accumulator
Accumulations of aggregate in the Remove by repeated change-over and reverse pumping, if necessary, open
range through which the transfer hopper and clean. Request concrete complying with the standard BSA100/120.
tube swings, deposits in the hopper Set transfer tube hard/soft shift valve (121) to hard shift position (i.e., open)
BSA100/120 BSA120 only.
Accumulator Empties too Quickly or No Pressure

Hopper grate is open or Verify that hopper grate is closed and then manually push solenoid-operated
solenoid-operated dump valve (184) accumulator dump valve (184) to see if accumulator pressurizes. If accumulator
is not operating properly BSA120 pressurizes (when dump valve is pressed), problem is in the dump valve or its
circuitry.
A520154_07_0903 715
716 A520154_07_0903
Index
Cable remote with RPM/VOL, 333

A Centralized lubrication system, 35
Accumulator, 324 Changeover delay, 36
- Maintenance, 628, 630, 632
Decreasing accumulator pressure, 633 Changing the Hydraulic Fluid, 617
Increasing accumulator pressure, 634 Charging and gauging kit, 631
- Troubleshooting, 79, 715
Checking
Accumulator Dump Valve, BSA120, 325 - Accumulator precharge pressure, 632
Accumulator Hydraulic Pump, BSA120, 321 - Main system relief pressure, 621
- Stube shift circuit pressure, 623
Adjusting
- Standby Pressure of the main hydraulic pump, 620
- Main system relief pressure, 622
- Remixer relief pressure, 626 Checking accumulator precharge pressure, 632
- Stube shift circuit pressure, 625 Checking and adjusting hydraulic system pressures, 619
- Standby pressure of the main hydraulic pump, 620
Checking main system and relief pressure, BSA100, 621
Adjusting main system and relief pressure, BSA100, 622
Checking Stube shift circuit pressure, BSA100, 623
Adjusting remixer relief pressure, 626 Checking standby pressure of the main hydraulic pump,
Adjusting Stube shift circuit pressure, BSA100, 625 BSA100, 620
Adjusting standby pressure of the main hydraulic pump, Cleaning, 617
BSA100, 620 - Cleaning with Auxiliary Pump, 538
Autolube system, 331 - Delivery Line, 533
- Highpressure Water Cleaning, 537
- Hopper, Delivery Cylinder & Stransfer Tube, 539
- How to Clean which Delivery Line, 533
B - Hydraulic oil tank, 65, 617
Battery, 311 - Hydraulic oil tank breather, 65
Biodegradable hydraulic oil, 612 - Oil cooler fins, 65
- Postwashing Operations, 542
Blockages, 522
- Preparations for cleaning, 529
- Clearing, 523
- Suction Cleaning, 535
- Tips for avoiding, 523
Cleaning the Hydraulic Tank, 617
Breaks in Pumping
- Engine, 525 Control box, with engine display, 312, 314
- Overheating, 525 Control box with engine display
- Restarting, 526 - BSA100D, 312
BSA - BSA120D, 314
- Centralized lubrication system, 35 Cylinder stroke counter, 338
- Inspecting the unit, 612
- Lubricants (recommended), 69
- Lubrication points, 65, 614
- Setup, 53
D
- Startup, 59 Daily Tasks
- Trailermounted overview diagram, 34 - After every Job, 65
- Function Checks, 64
BSA100, Auxiliary system, 328
- Intervals, 65
BSA120, Auxiliary system, 328
- Visusal Checks, 63
- When Pumping, 64
Decreasing accumulator pressure, 633
C Delivery line, Measuring the wall thickness (Machines with
Cable remote 12V, 332 S transfer tube), 6 95
Cable remote control unit, 332, 333
Index i
Index
Delivery piston
- Piston replacement, 6 59
G
- Troubleshooting, 711 General
Dismantling the Stransfer tube bearing, 665 - BSA100, 317
Draining the hydraulic oil tank, 618 - BSA120, 317
General Tightening Torques
- Flared Screwed Joint, 637
- Set Screws and Nuts, 636
E
Electric motor start box, 316
Electrical System, 311 H
- Troubleshooting, 74
High Press. Filter, 66
Electrical system
High Pressure Filter, 68
- Battery, 311
- Cable remote control, 332 Hopper grate safety switch, 328
- Cable remote control with RPM/VOL, 333 - Operational check, 514
- Electric motor start box, 316 Hoses
- Hopper grate cutout device, 328 - Leaking, 643
- Radio remote control, 334 - Maintenance, 643
Element replacement, 66, 615, 617 - Replacing, 645
Emergency stop button locations, 511 Hydraulic circuit, 326
Emergency Stroke Change Kit - Auxiliary system, 328
- BSA100D, 545 - Delivery cylinder pump system, 326
- BSA120D, 546 - Stube shifting system, 327
Emergency stroke kit, 545 Hydraulic fluid, Troubleshooting, 74

Hydraulic oil
Engine, Troubleshooting, 72
- Biodegradable oil, 612
- Cold climate applications, 611
- Hot climate applications, 611
F - Standard hydraulic oil, 611
Filter, 68 Hydraulic oil tank, 67, 68
- Replacement, 617 - BSA100, 67
Filter (hydraulic system return oil), 67 - BSA120, 68
- Replacement, 615 - Draining, 618
Filter change, 6 47 Hydraulic oils, 610
- Pressure filter, 6 53 Hydraulic outriggers, 335
Fitting the Stransfer tube bearing, 680 hydraulic pump suction strainers, cleaning, 617
Fitting the wear plate, 676 Hydraulic system, 317, 617
Flat pack assembly, 33 - Abnormally high fluid temperature, 79
- Accumulator, 324
Foreword, 12
- Accumulator Dump Valve, 325
Function Checks, 641 - Accumulator hydraulic pump, 321
Function checks, 641 - Accumulator maintenance, 630
Fuse, Troubleshooting, 75 - Adding hydraulic fluid, 613
- Adjusting standby pressure of the main hydraulic pump, 620
- BSA100, 317
- BSA120, 318
- Charging and gauging kit, 631
- Checking and adjusting hydraulic system pressures, 619
ii Index
Index
- Checking Stube shift circuit pressure, 623 - Draining water from hydraulic oil tank, 65
- Checking standby pressure of the main hydraulic pump, 620 - Increasing accumulator pressure, 634
- Draining the hydraulic oil tank, 618 - Inspecting the unit, 612
- Filtration, 317, 318 - Lubricating, 65, 614
- General, 317 - Performing maintenance on the accumulator, 628
- Hydraulic circuit, 326 - Replacing accumulator bladder, 636
- Hydraulic drive cylinder malfunctions, 76 - Replacing proximity switch, 627
- hydraulic pump suction strainers, 317, 318 - Replacing return oil filter element, 66
- Main control block, 322, 323 - Stube shift circuit pressure adjustment, 625
- Main hydraulic pump, 73
BSA100, 319
BSA120, 320
- Main system pressure compensator adjustment screw, 621
I
- Main system relief pressure, 621 Icons, 13
Adjustment, 622
Increasing accumulator pressure, 634
Checking, 621
- Main system relief pressure adjustment screw, 622
- Oil cooler, 319, 73
- Oil tank, 65, 67, 68, 617 L
- Oil tank BSA100, 67
Leaking hoses, 643
- Oil tank BSA120, 68
- Oil tank filler cap, 67, 68, 617 Lock OutTag Out Procedure, 62
- Oil tank fluid level gauge, 67, 68 Lubricant recommendation
- Oil tank thermometer, 67, 68 - Hydraulic oils, 610
- Remixer, 336 - Oil/Filter change intervals, 610
- Remixer hydraulic pump, 321 Oil/Filter change intervals, 610
- Remixer malfunctions, 710
Lubricants (recommended), 69
- Remixer relief pressure adjustment, 626
- Return oil filter, 67 Lubrication Points, 614
- return oil filter, 317, 318 Lubrication points
- Return oil filter element replacement, 66, 615 - Remixer, 65, 614
- Stube shift circuit pressure adjustment, 623, 625 - Stube, 65, 614
- Stube shifting malfunctions, 78 - Trailer, 65, 614
- Secondary hydraulic pump, 320, 74
- Spool valves, 325
-
-
Suction and High Pressure filter element replacement, 617
System pressures, 317
M
- Test gauge kit, 619 Machine rating plate, 38
- Test port, 619 Main control block
Maintenance procedures - BSA100, 322
- Adding hydraulic fluid, 613 - BSA120, 323
- Adjusting main system and relief pressure, 622 Main hydraulic pump
- Adjusting remixer relief pressure, 626 - BSA100, 319
- Adjusting standby pressure of the main hydraulic pump, 620 - BSA120, 320
- Changing the hydraulic fluid, 65, 617 - Troubleshooting, 73
- Checking and adjusting hydraulic system pressures, 619 Maintenance
- Checking main system and relief pressure, 620, 621 - Intervals, 65
- Checking Stube shift circuit pressure, 623 - After every Job, 65
- Cleaning hydraulic oil tank breather, 65 - Daily Tasks, 62
- Cleaning hydraulic pump suction strainers, 617 - Daily Visusal Checks, 63
- Cleaning oil cooler fins, 65 - During a pour, 519
- Cleaning the hydraulic oil tank, 65, 617 - Flared Screwed Joint, 637
- Decreasing accumulator pressure, 633
Index iii
Index
- Function Checks, 64 - Cleaning with Auxiliary Pump, 538

- General Tightening Torques, 636 - Clearing a blockage, 523
- Set Screws and Nuts, 636 - Considering Concrete Properties, 56
- When Pumping, 64 - Delivery Line, 533
Maintenance cards - Delivery system setup, 57
- Adjusting the S transfer tube, 6 83 - Engine, 525
- Changing the pressure filter element, 6 53 - Filling the Agitator Hopper, 514
- Changing the suction filter element, 6 47 - Fuel, 55
- Delivery piston replacement, 6 59 - Highpressure Water Cleaning, 537
- Fitting the wear plate, 676 - Hopper, Delivery Cylinder & Stransfer Tube, 539
- Function checks, 641 - How to Clean which Delivery Line, 533
- Hoses, 643 - Maintenance during a pour, 519
- Measuring the wall thickness (Machines with S transfer tube), - Operational tips and precautions, 521
6 95 - Overheating, 525
- Replacing the Stransfer tube, 665 - Postwashing Operations, 542
Dismantling the Stransfer tube bearing, 665 - Preoperation inspection, 53
Fitting the Stransfer tube bearing, 680 - Preliminary information, 52
Mounting the switch lever, 681 - Preparations for cleaning, 529
Removing the Stransfer tube, 674 - Priming of concrete pump and delivery system, 516
Removing the Stransfer tube shaft bearings, 667
- Pumping, 517
Removing the wear plate, 672
Replacing the seal ring, 679 - Pumping concrete with the emergency stroke kit, 545
Replacing the wear sleeve on the Stransfer tube, 675 - Restarting, 526
Stransfer tube bearing gasket set, 666, 670 - Shutting down, 544
Wear sleeve and collard washer, 680 - Startup of concrete pump with diesel engine, 59
Measuring, Wall thickness, 6 98 - Startup of concrete pump with electric motor, 512
Measuring the wall thickness - Suction Cleaning, 535
- Trailer setup, 55
- Machines with S transfer tube, 6 95
- Transfer tube damping, 518
- Measuring, 6 98
- Stransfer tube, 6 97 Operating tips and precautions, 521
Monitoring, 519 Operation procedures, Emergency stop button locations,
511
Mounting the switch lever, 681
Optional, Radio remote control, RPM/VOL, 334
Optional equipment, 331
O - Autolube system, 331
- Cable remote control unit, 332, 333
Oil and Greases, 612 - Cable remote control with RPM/VOL, 333
Oil cooler, 319 - Cylinder stroke counter, 338
- Troubleshooting, 73 - Hydraulic outriggers, 335
Oil filter (hydraulic system return), 67 - Radio remote control, 334
- Radio remote control unit, 334
Oil tank (hydraulic system), 67, 68, 617
- Vibrator kit, 339
- Filler cap, 67, 68, 617
- Volume control kit, 340
- Fluid level gauge, 67, 68
- Water pump, 337
- maintenance, 65, 617
- Thermometer, 67, 68
Operating procedures
- Avoiding blockages, 523
P
- Blockages, 522 Performing maintenance on the accumulator, 628
- Breaks in Pumping, 524 Priming concrete pump and delivery system, 516
- Checking the hopper grate safety cutout device, 514
Pump
- Cleaning, 527
- Accumulator hydraulic, 321
iv Index
Index
- Autolube system, 331 safety regulations, 21

- Main hydraulic, 319, 320, 73 Secondary hydraulic pump
- Remixer hydraulic, 321 - BSA100, 320
- Secondary hydraulic, 320, 74 - Troubleshooting, 74
- Troubleshooting, 75, 711, 713
Setup site, 43
- Water, 337
- Accessibilty, 43
Pumping, 517 - Approach route, 44
Pumping operations, Monitoring, 519 - Clearance from pits, 44
- Connection, 45
- Danger Zone, 46
R - Fastening, 48
- Laying the line, 47
Radio remote control, 334 - Space for truck mixers, 44
Radio remote control unit, Optional, 334 - Stationary delivery lines, 45
- RPM/Volume, 334 - Supporting Ground, 44
Rating plate, Machine, 38 Setting up
Remixer, 336 - Considering Concrete Properties, 56
- Troubleshooting, 710 - Delivery system, 57
- Filling the Machine with fuel, 55
Remixer Hydraulic Pump, BSA120, 321
- Hand signals for pumping, 52
Removing the Stransfer tube shaft bearings, 667 - Trailer, 55
Removing the wear plate, 672 Shutting down, 544
Repair, Lock OutTag Out Procedure, 62 Spool valves, 325
Replacing Standard hydraulic oil, 611
- Accumulator bladder, 636
Startup of concrete pump with diesel engine, 59
- filter element, 617
- Proximity switch, 627 Startup of concrete pump with electric motor, 512
- Return oil filter element, 615 Starting up
Replacing proximity switch, 627 - Concrete pump with diesel engine, 59
- Concrete pump with electric motor, 512
Replacing the accumulator bladder, 636
Storing unit, 544
Replacing the seal ring, 679
Suction Filter, 66, 68
Replacing the wear sleeve on the Stransfer tube, 675
Suction Filter Gauge, 68
Symbols, 13
S Symbols for the control system, 39
- Concrete pump, 310
S transfer tube - Electrical system, 39
- Adjusting, 6 83 - Engine, 39
- Measuring the wall thickness, 6 95
- Minimum wall thickness, 6 97
Stransfer tube bearing gasket set, 666, 670 T
Stube
- Removal, 674 Test gauge kit, 619
- Replacing, 665 Test port, 619
- Wear parts, 665 ThomKatt, Principles of operation, 32
Stube shifting, Troubleshooting, 78 Towing of trailer, 42
Safety Regulations Trailer, Lubrication points, 65, 614
- Personnel Qualifications, 22
Trailermounted overview diagram, 34
- Safety Regulations, 22
Transfer tube, Troubleshooting, 715
Index v
Index
Transfer tube damping, 518

Transport, 42
Travel, 41, 42
- set up, 41
- Towing of trailer, 42
Troubleshooting
- Abnormally high hydraulic system fluid temperature, 79
- Accumulator, 79
- Concrete Pump, 711
- Electrical System, 74
- Engine, 72
- Hydraulic drive cylinders, 76
- Hydraulic oil cooler, 73
- Main hydraulic pump, 73
- Remixer, 710
- Stube shifting, 78
- Secondary hydraulic pump, 74
V
Vibrator kit, 339
Volume control kit, BSA120, 340
W
Water pump, 337
Wear sleeve and collared washer, 680
vi Index

ManualArchive 2106T3450 Operating Instructions

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Operating Instructions

Vehicle Series (VS) Vehicle Series Power Take-Off (VS PTO)

1 Guide to the Operating Instructions

1.2 Icons and Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

2.2 Safety Regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

3 General Technical Description

3.2 Flat Pack Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

3.3 Trailer-Mounted Overview Diagram . . . . . . . . . . . . . . . . . . . 34

3.4 Centralized lubrication system . . . . . . . . . . . . . . . . . . . . . . . 35

3.5 Changeover delay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

3.6 Machine Rating Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

3.7 Symbols for the Control System . . . . . . . . . . . . . . . . . . . . . . 39

3.8 Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 311

3.9 Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 317

3.9.3 System Pressures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 317

3.10 Hydraulic Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 326

3.11 Hopper Grate Cutout Device . . . . . . . . . . . . . . . . . . . . . . . . . 328

3.12 Optional Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 331

4 Travel and set up

4.2 Towing of Trailer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

4.3 Requirements for the setup site . . . . . . . . . . . . . . . . . . . . . 43

4.4 Clearance from pits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

4.6 Stationary delivery lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

5.2 Hand signals for pumping . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

A520154 A_TOC_1001 III

5.4.8 Transfer tube damping (BSA120) . . . . . . . . . . . . . . . . . . . . . . . . . 518

5.5 Maintenance During a Pour . . . . . . . . . . . . . . . . . . . . . . . . . . 519

5.6 Breaks in Pumping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 524

5.7 Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 527

5.8 Shutting Down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 544

5.9 Pumping Concrete with the Emergency Stroke

6.1.7 Hydraulic Oil Tank BSA120 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

6.2 Recommended Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

6.3 Inspecting the Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 612

6.4 Adding Hydraulic Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 613

6.5 Lubricating the Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 614

6.6 Replacing the Return Oil Filter Element . . . . . . . . . . . . . . . 615

6.7 Replacing the Suction Filter Element and the High

6.8 Changing the Hydraulic Fluid; Cleaning the

6.9 Checking and Adjusting Hydraulic System Pressures . 619

6.10 Replacing Proximity Switch . . . . . . . . . . . . . . . . . . . . . . . . . . 627

6.11 Performing Maintenance on the Accumulator . . . . . . . . . 628

6.12 General Tightening Torques . . . . . . . . . . . . . . . . . . . . . . . . . . 636

6.13 Function Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 641

6.14 Hydraulic Hose Inspection and Replacement . . . . . . . . . . 643

6.15 Changing the Suction Filter Element . . . . . . . . . . . . . . . . . . 6 47

6.16 Changing the Pressure Filter Element . . . . . . . . . . . . . . . . 6 53

6.17 Delivery Piston Replacement . . . . . . . . . . . . . . . . . . . . . . . . . 6 59

6.18 Replacing the STransfer Tube . . . . . . . . . . . . . . . . . . . . . . . 665

6.19 Adjusting the STransfer Tube . . . . . . . . . . . . . . . . . . . . . . . 6 83

6.20 Measuring the Wall Thickness

7.2 Hydraulic Oil Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

7.3 Main Hydraulic Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

7.4 Secondary Hydraulic Pump . . . . . . . . . . . . . . . . . . . . . . . . . . 74

7.5 Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

7.6 Hydraulic Drive Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

7.7 S-Tube Shifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

7.8 Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

7.9 Remixer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 710

7.10 Concrete Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 711

A520154 A_TOC_1001 VII

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Putzmeister America, Inc.

or the Distributor or Dealer that looks after you.