Putzmeister BSA 1006 D5 User manual

Operating Instructions
for machine operator and maintenance staff
always keep by the machine
Translation of the original instructions
Stationary concrete pump BSA 1006 D5
Machine no. 210111697
2021-08-09
The paper on which this document is printed is 100% chlorine-free © Putzmeister Concrete Pumps GmbH 2021

land
PM
Putzmeister Concrete Pumps GmbH
Max−Eyth−Straße10
D− 72631 Aichtal
+49−7127−599−0
+49−7127−599−520
[e-mail]
www.putzmeister.de
España
PME
Putzmeister Ibérica S.A.
Camino de Hormigueras 173
Pol. Ind. Vallecas
E− 28031 Madrid
+34−91−428 81 00
+34−91−428 81 43
[e-mail]
www.putzmeister.es
France
PMF Putzmeister France 3, rue Paul Henri Spaak
ZAE Jean Monnet
77240 Vert Saint Denis
+33−164 64 39 39
+33−164 64 39 29
[e-mail]
www.putzmeister.fr
Great
Britain
PMUK
Putzmeister Limited
Carrwood Road
GB−Chesterfield
Derbyshire S41 9QB
+44−1246−2642 00
+44−1246−26 00 77
[e-mail]
www.putzmeister.co.uk
Türkiye
PTR Putzmeister Makine Sanayi ve Tic. A.
G.O. Pa a Mah.
Nam kKemal Bulvar No: 6
59500 Çerkezköy / TEK
+90−282−735−1000
+90−282−738−1001
[e-mail]
www.putzmeister.com.tr
USA
PMA Putzmeister America 1733 90th Street
Sturtevant, WI 53177 USA
+1−262−886−3200
+1−262−886−3212
[email protected]
www.putzmeister.com
South
Africa
PMSA
Putzmeister S.A. (Pty) Ltd.
Cnr. Braam & Citrus St. Honeydew
P.O.Box 5146 ZA 2118 Cresta
South Africa
+27−11−794−37 90
+27−11−794−41 19
[email protected]
www.putzmeister.co.za
India
PCM Putzmeister Concrete Machines Pvt Ltd
Plot No. N4, Phase IV
Verna Industrial Estate, Verna Salcete
Goa−403722
[e-mail]
www.pmw.co.in
Putzmeister Japan Co. Ltd.
7-4 Misawa, Tomisato-shi
Chiba 286-0225, Japan
[phone]
[phone]
[email protected]
www.putzmeister.de/jp
Korea
PMK Putzmeister Korea Co. Ltd. 59 Huimanggongwon-ro,Chungwang−Dong
Shihwa Ind. complex 2MA707-1HO,
Shihung−city Kyunggi−Do, Korea
+82−31−433−4541
+82−31−498−7230
[email protected]
www.putzmeister.co.Kr
Russland
PMR OOO
Urgumskaja Straße 4, Geb. 31
129343 Moskau, Russia
+7−495−775−22−37
+7−495−775−22−34
[e-mail]
www.putzmeister.ru
Japan
PMJ

en Translation of the original instructions
ar 󰤕󰥥󰤠󰤯󰤘 󰥟󰥵󰥠 󰥟󰥵󰥑󰤹󰤙󰥠 󰥳󰥡󰤼󰥸
bg Превод на оригиналното „Ръководство за работа“
cs Překlad originálního návodu k obsluze
da Oversættelse af den originale driftsvejledning
de Übersetzung der Originalbetriebsanleitung
el Μετάφραση του πρωτότυπου των οδηγιών λειτουργίας
es Traducción del manual de instrucciones original
et Originaalkasutusjuhendi tõlge
fi Alkuperäisen käyttöohjeen käännös
fr Traduction de la notice originale
hr Prijevod originalnog priručnika za rad
hu Az eredeti üzemeltetési utasítás fordítása
it Traduzione delle istruzioni per l'uso originali
ja 取扱説明書原本の翻訳
lt Naudojimo instrukcijos originalo vertimas
lv Oriģinālās lietošanas instrukcijas tulkojums
nl Vertaling van de originele handleiding
no Oversettelse av original bruksanvisning
pl Tłumaczenie oryginalnej instrukcji eksploatacji
pt Tradução das Instruções de funcionamento originais
ro Traducere a instrucţiunilor de funcţionare originale
ru Перевод оригинальной инструкции по эксплуатации
sk Preklad originálneho návodu na obsluhu
sl Prevod originalnih navodil za uporabo
sr Prevod originalnog uputstva za upotrebu
sv Översättning av instruktionsbok i originalutförande
tr Orijinal kullanım kılavuzunun tercümesi
zh 原始操作说明翻译
210111697_2021-08-09_en Operating Instructions

Operating Instructions 210111697_2021-08-09_en

Table of contents
1 Guide to the Operating Instructions ........................................ 1 — 1
1.1 Foreword ......................................................................................................................... 1 — 3
1.2 Icons and symbols .......................................................................................................... 1 — 4
1.2.1 Layout of warning notices ............................................................................................... 1 — 5
2 Safety regulations ................................................................... 2 — 1
2.1 Definition of terms ........................................................................................................... 2 — 3
2.1.1 Machine ........................................................................................................................... 2 — 3
2.1.2 Concrete pump ................................................................................................................ 2 — 3
2.1.3 Arm assembly ................................................................................................................. 2 — 3
2.1.4 Placing boom .................................................................................................................. 2 — 3
2.1.5 Base structure ................................................................................................................. 2 — 3
2.1.6 Truck mixer ..................................................................................................................... 2 — 4
2.1.7 Delivery line systems ...................................................................................................... 2 — 4
2.1.8 End hose ......................................................................................................................... 2 — 4
2.1.9 Manufacturer ................................................................................................................... 2 — 4
2.1.10 Operator .......................................................................................................................... 2 — 4
2.1.11 Machine operator ............................................................................................................ 2 — 4
2.1.12 Hoseman ......................................................................................................................... 2 — 4
2.1.13 Signaller and other auxiliary personnel ........................................................................... 2 — 5
2.1.14 Truck mixer driver ........................................................................................................... 2 — 5
2.1.15 Subject expert ................................................................................................................. 2 — 5
2.1.16 Qualified personnel ......................................................................................................... 2 — 5
2.1.17 After Sales Service personnel ......................................................................................... 2 — 5
2.1.18 Maintenance .................................................................................................................... 2 — 5
2.1.19 Place of work, working area, danger zone ...................................................................... 2 — 6
2.2 Designated use ............................................................................................................... 2 — 10
2.2.1 Retesting (safety inspection) ........................................................................................... 2 — 11
2.2.2 Inspection intervals for retesting ..................................................................................... 2 — 11
2.3 Improper use ................................................................................................................... 2 — 12
2.3.1 Transporting goods ......................................................................................................... 2 — 12
2.3.2 Lifting loads ..................................................................................................................... 2 — 13
2.3.3 Removing obstacles ........................................................................................................ 2 — 13
2.3.4 Extending the reach ........................................................................................................ 2 — 13
2.3.5 Extending the placing boom and end hose ..................................................................... 2 — 13
2.3.6 Impermissible end hose .................................................................................................. 2 — 14
2.3.7 Impermissible working area ............................................................................................ 2 — 14
2.3.8 Climbing the placing boom .............................................................................................. 2 — 15
2.3.9 Highpressure delivery ..................................................................................................... 2 — 15
Table of contents
1.
2.
3.
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210111697_2021-08-09_en Operating Instructions A — 1

2.3.10 Accessories and attachments ......................................................................................... 2 — 15
2.3.11 Changes to the machine ................................................................................................. 2 — 15
2.4 Exclusion of liability ......................................................................................................... 2 — 16
2.5 Personnel ........................................................................................................................ 2 — 16
2.5.1 Requirements .................................................................................................................. 2 — 16
2.5.2 Qualifications ................................................................................................................... 2 — 17
2.5.3 Responsibility of the machine operator ........................................................................... 2 — 17
2.6 Operating Instructions, operating procedures and other regulations .............................. 2 — 17
2.6.1 Operating Instructions ..................................................................................................... 2 — 17
2.6.2 Operating procedures ..................................................................................................... 2 — 18
2.6.3 Other regulations ............................................................................................................. 2 — 19
2.7 Personal protective equipment ........................................................................................ 2 — 19
2.8 Before working with the machine .................................................................................... 2 — 21
2.8.1 Checking that the machine is ready for operation ........................................................... 2 — 21
2.8.2 Rendering the machine ready for operation .................................................................... 2 — 21
2.9 Danger due to high voltage ............................................................................................. 2 — 22
2.9.1 High-voltage lines ............................................................................................................ 2 — 22
2.9.2 Discharge voltage pattern ............................................................................................... 2 — 22
2.9.3 Clearances ...................................................................................................................... 2 — 22
2.9.4 Highvoltage warning devices .......................................................................................... 2 — 24
2.9.5 Procedure in the event of a flash over ............................................................................ 2 — 24
2.9.6 Earthing in the event of electrostatic charging ................................................................ 2 — 25
2.9.7 Earthing on construction sites with special installations .................................................. 2 — 25
2.10 Stationary machines ........................................................................................................ 2 — 25
2.10.1 Setup site ........................................................................................................................ 2 — 25
2.10.2 Stationary placing booms ................................................................................................ 2 — 26
2.10.3 Lifting machines and components ................................................................................... 2 — 26
2.10.4 Loading and transporting ................................................................................................ 2 — 26
2.11 Mobile machines ............................................................................................................. 2 — 27
2.11.1 Setup site ........................................................................................................................ 2 — 27
2.11.2 Supporting ground ........................................................................................................... 2 — 28
2.11.3 Corner bearing loads ....................................................................................................... 2 — 29
2.11.4 Supports .......................................................................................................................... 2 — 29
2.11.5 Driving ............................................................................................................................. 2 — 31
2.11.6 Towing ............................................................................................................................. 2 — 32
2.11.7 Loading ........................................................................................................................... 2 — 32
2.12 Placing booms ................................................................................................................. 2 — 33
2.12.1 Unfold placing boom ....................................................................................................... 2 — 33
2.12.2 End hose ......................................................................................................................... 2 — 35
2.12.3 Guiding the end hose ergonomically ............................................................................... 2 — 36
2.12.4 Connecting drills .............................................................................................................. 2 — 36
1.
2.
3.
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Table of contents
A — 2 Operating Instructions 210111697_2021-08-09_en

2.12.5 Procedure in storms ........................................................................................................ 2 — 36
2.12.6 Concreting in cold weather .............................................................................................. 2 — 37
2.13 Delivery line systems ...................................................................................................... 2 — 37
2.13.1 Suitable delivery lines ..................................................................................................... 2 — 37
2.13.2 Securing delivery lines .................................................................................................... 2 — 38
2.13.3 Leak tightness and blockages ......................................................................................... 2 — 38
2.13.4 Opening delivery lines ..................................................................................................... 2 — 39
2.13.5 Clearance to delivery lines .............................................................................................. 2 — 39
2.13.6 Securing the delivery lines .............................................................................................. 2 — 39
2.13.7 Continuation delivery lines .............................................................................................. 2 — 39
2.13.8 Devices for shutting off, diverting and cleaning ............................................................... 2 — 40
2.14 Pumping operations ........................................................................................................ 2 — 40
2.14.1 Place of work ................................................................................................................... 2 — 40
2.14.2 Safety .............................................................................................................................. 2 — 40
2.14.3 Remote control ................................................................................................................ 2 — 41
2.14.4 Moving machine components and hot surfaces .............................................................. 2 — 41
2.14.5 Constant observation of the machine .............................................................................. 2 — 42
2.14.6 Truck mixer ..................................................................................................................... 2 — 42
2.15 Cleaning .......................................................................................................................... 2 — 42
2.15.1 General ........................................................................................................................... 2 — 42
2.15.2 Cleaning agents .............................................................................................................. 2 — 43
2.15.3 Cleaning with compressed air ......................................................................................... 2 — 44
2.15.4 Protection against water .................................................................................................. 2 — 46
2.15.5 Post-cleaning procedure ................................................................................................. 2 — 46
3 General technical description ................................................. 3 — 1
3.1 Overviews ....................................................................................................................... 3 — 3
3.2 Safety equipment ............................................................................................................ 3 — 5
3.2.1 Overview ......................................................................................................................... 3 — 5
3.2.2 Safety components ......................................................................................................... 3 — 6
3.2.3 Safety-related parts (SRPs) ............................................................................................ 3 — 6
3.2.4 Plates .............................................................................................................................. 3 — 8
3.2.5 EMERGENCY STOP function ......................................................................................... 3 — 8
3.2.6 Agitator safety cutout ...................................................................................................... 3 — 11
3.2.7 Grille ................................................................................................................................ 3 — 16
3.3 General conditions for using the machine ....................................................................... 3 — 17
3.3.1 Service life ....................................................................................................................... 3 — 17
3.3.2 Site of use ....................................................................................................................... 3 — 18
3.3.3 Operating altitude ............................................................................................................ 3 — 18
3.3.4 Operating temperature .................................................................................................... 3 — 18
3.4 Machine rating plate ........................................................................................................ 3 — 19
Table of contents
1.
2.
3.
. . .
210111697_2021-08-09_en Operating Instructions A — 3

3.5 Sound pressure level/sound power level ........................................................................ 3 — 20
3.5.1 Sound pressure level ...................................................................................................... 3 — 20
3.5.2 Sound power level ........................................................................................................... 3 — 21
3.6 Electromagnetic compatibility (EMC) .............................................................................. 3 — 21
3.7 Putzmeister Connected Services .................................................................................... 3 — 21
3.7.1 Remote Service ............................................................................................................... 3 — 22
3.7.2 Machine Cockpit .............................................................................................................. 3 — 22
3.8 Exhaust after treatment ................................................................................................... 3 — 22
3.8.1 Function .......................................................................................................................... 3 — 22
3.8.2 Regeneration ................................................................................................................... 3 — 23
3.8.3 Starting regeneration ....................................................................................................... 3 — 23
3.9 Colour definition – LEDs in the button ............................................................................. 3 — 25
3.10 Control cabinet ................................................................................................................ 3 — 26
3.11 Core pump operating panel ............................................................................................. 3 — 27
3.12 Display ............................................................................................................................ 3 — 29
3.13 Software .......................................................................................................................... 3 — 30
3.13.1 Main menu ...................................................................................................................... 3 — 30
3.13.2 “User settings” menu ....................................................................................................... 3 — 34
3.13.3 “Core pump” menu .......................................................................................................... 3 — 35
3.13.4 “Motor” menu ................................................................................................................... 3 — 38
3.13.5 “Inputs and outputs” menu .............................................................................................. 3 — 41
3.13.6 “Operating data” menu .................................................................................................... 3 — 42
3.13.7 Messages ........................................................................................................................ 3 — 43
3.14 Cable remote control ....................................................................................................... 3 — 47
3.14.1 Structure .......................................................................................................................... 3 — 47
3.14.2 Safely using the remote control ....................................................................................... 3 — 48
3.15 Core pump ...................................................................................................................... 3 — 49
3.15.1 Structure .......................................................................................................................... 3 — 49
3.15.2 Function .......................................................................................................................... 3 — 50
3.15.3 Reversal .......................................................................................................................... 3 — 50
3.15.4 Water box ........................................................................................................................ 3 — 51
3.15.5 Agitator ............................................................................................................................ 3 — 54
3.15.6 Vibrator ............................................................................................................................ 3 — 56
3.15.7 Magnetic switch distributor casing .................................................................................. 3 — 57
3.15.8 Magnetic switch connector .............................................................................................. 3 — 59
3.16 Centralised lubrication system ........................................................................................ 3 — 61
3.16.1 Structure .......................................................................................................................... 3 — 61
3.16.2 Function .......................................................................................................................... 3 — 61
3.16.3 Maintaining the centralised lubrication system ................................................................ 3 — 62
1.
2.
3.
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Table of contents
A — 4 Operating Instructions 210111697_2021-08-09_en

3.16.4 Filling the lubricant reservoir ........................................................................................... 3 — 62
3.16.5 Additional lubrication procedure ...................................................................................... 3 — 63
3.17 Flushing water pump ....................................................................................................... 3 — 64
3.17.1 Structure .......................................................................................................................... 3 — 64
3.17.2 Function .......................................................................................................................... 3 — 64
3.17.3 Switching on the water pump .......................................................................................... 3 — 65
3.17.4 Switching off the water pump .......................................................................................... 3 — 66
3.17.5 Draining the flushing water pump .................................................................................... 3 — 67
4 Transport, support and connection ......................................... 4 — 1
4.1 Transporting .................................................................................................................... 4 — 3
4.1.1 Loading ........................................................................................................................... 4 — 3
4.1.2 Driving ............................................................................................................................. 4 — 5
4.2 Supporting the machine .................................................................................................. 4 — 5
4.2.1 Checking the setup site ................................................................................................... 4 — 5
4.2.2 Support structure ............................................................................................................. 4 — 10
4.2.3 Extend supports .............................................................................................................. 4 — 11
4.2.4 Retracting the supports ................................................................................................... 4 — 16
4.3 Connecting the water supply ........................................................................................... 4 — 16
5 Operation ................................................................................ 5 — 1
5.1 Test run ........................................................................................................................... 5 — 3
5.2 Starting up ....................................................................................................................... 5 — 3
5.2.1 Checking the machine for damage ................................................................................. 5 — 3
5.2.2 Draining the hydraulic fluid reservoir ............................................................................... 5 — 5
5.2.3 Checking functional fluids ............................................................................................... 5 — 6
5.2.4 Switching on the machine ............................................................................................... 5 — 7
5.2.5 Warming up the hydraulic fluid ........................................................................................ 5 — 8
5.2.6 Deactivating the EMERGENCY STOP ........................................................................... 5 — 8
5.2.7 Deactivating the agitator safety cutout ............................................................................ 5 — 9
5.3 Checking the functions .................................................................................................... 5 — 9
5.3.1 Checking the EMERGENCY STOP function ................................................................... 5 — 10
5.3.2 Checking the agitator safety cutout ................................................................................. 5 — 11
5.3.3 Checking the pump functions .......................................................................................... 5 — 13
5.3.4 Checking the hydraulic fluid filters ................................................................................... 5 — 14
5.4 Hand signals for pumping operations .............................................................................. 5 — 16
5.4.1 EMERGENCY STOP hand signal ................................................................................... 5 — 17
5.4.2 Hand signal for stopping ................................................................................................. 5 — 17
5.4.3 Hand signal for increasing output/start of delivery .......................................................... 5 — 18
5.4.4 Hand signal for reducing output ...................................................................................... 5 — 18
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3.
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210111697_2021-08-09_en Operating Instructions A — 5

5.4.5 Hand signal for reverse pumping .................................................................................... 5 — 19
5.4.6 Hand signal for stopping the pump ................................................................................. 5 — 19
5.5 Filling the water box ........................................................................................................ 5 — 19
5.6 Pumping .......................................................................................................................... 5 — 20
5.6.1 Dangers during pumping ................................................................................................. 5 — 20
5.6.2 Notes on correct pumping ............................................................................................... 5 — 21
5.6.3 Mixing together ................................................................................................................ 5 — 21
5.6.4 Operating the agitator ..................................................................................................... 5 — 22
5.6.5 Starting to pump .............................................................................................................. 5 — 22
5.6.6 Starting the pumping process ......................................................................................... 5 — 24
5.6.7 Checking the condition of the machine ........................................................................... 5 — 24
5.6.8 Breaks in pumping .......................................................................................................... 5 — 24
5.6.9 Rectify any faults ............................................................................................................. 5 — 25
5.7 Cleaning .......................................................................................................................... 5 — 29
5.7.1 Observe the notes on cleaning ....................................................................................... 5 — 31
5.7.2 Cleaning preparations ..................................................................................................... 5 — 31
5.7.3 Using concrete residue ................................................................................................... 5 — 36
5.7.4 Switching on the water pump .......................................................................................... 5 — 37
5.7.5 Clean the delivery line ..................................................................................................... 5 — 39
5.7.6 Cleaning the core pump .................................................................................................. 5 — 52
5.7.7 Cleaning the remote control ............................................................................................ 5 — 60
5.7.8 Cleaning other machine components .............................................................................. 5 — 60
5.7.9 Switching off the water pump .......................................................................................... 5 — 61
5.8 Storing the machine ........................................................................................................ 5 — 61
5.8.1 Document the measures taken to preserve value ........................................................... 5 — 62
5.8.2 General measures to preserve value .............................................................................. 5 — 62
5.8.3 General measures to preserve the value of the electrical system assembly .................. 5 — 62
5.8.4 General measures to preserve the value of the water assembly .................................... 5 — 64
5.8.5 General measures to preserve the value of the engine assembly .................................. 5 — 64
5.8.6 General measures to preserve the value of the concrete pump assembly ..................... 5 — 64
5.8.7 General measures to preserve the value of the hopper assembly .................................. 5 — 64
Glossary .................................................................................. B — 1
Symbols for concrete pumps in accordance with German Mechanical Engineering
Association Standard (VDMA -24119) ............................................................................
B — 3
Abbreviations and technical terms .................................................................................. B — 10
Index ........................................................................................ C — 1
1.
2.
3.
. . .
Table of contents
A — 6 Operating Instructions 210111697_2021-08-09_en

1 Guide to the Operating Instructions
In this chapter you will find notes and information that will help you
use this document. If you have any queries, please write to us in
confidence at the address given below, or contact the relevant
branch or works agency.
Putzmeister Concrete Pumps
Abteilung Kundendienst
Max-Eyth-Straße 10
72631 Aichtal, Germany
Telephone: [phone]
Fax: [phone]
E-mail: [email protected]
You can contact the relevant branch or works agency by calling the
following service hotline from a landline in Germany or from any Ger‐
man mobile phone network.
Service hotline tel.: [phone] / 30 18 30
210111697_2021-08-09_en Operating Instructions 1 — 1

1 — 2 Operating Instructions 210111697_2021-08-09_en

1.1 Foreword
These Operating Instructions aim to help you to familiarise yourself
with the machine and make use of its intended 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 ma‐
chine.
The operator undertakes to supplement the Operating Instructions
with the relevant national rules and regulations for accident preven‐
tion and environmental protection.
The Operating Instructions must always be available wherever the
machine is in use.
The Operating Instructions must be read and applied by anyone who
will be carrying out the following work with/on the machine:
●Operation, including setting up, fault rectification in the course of
work, removal of production waste, maintenance and disposal of
fuels and auxiliary materials
● Maintenance (service, inspection, repair)
● Transport
The generally recognised rules of technology for safe and proper
working must be observed in addition to the Operating Instructions
and mandatory rules and regulations for accident prevention in the
country and place of use of the machine.
If you have any questions after reading the Operating Instructions,
you can contact:
● The branch serving you
(or its agents)
● Aichtal Works
You will make it much easier for us to answer any questions if you
can give us the details of the machine model and the machine num‐
ber.
For the purpose of continuous improvement, changes are made at
certain times, meaning that these changes may in some circumstan‐
ces not yet have been taken into account by the time these Operating
Instructions are sent to print.
Guide to the Operating Instructions
210111697_2021-08-09_en Operating Instructions 1 — 3

In the event of any amendment, the copy of the Operating Instruc‐
tions intended for the machine will be replaced in full.
The reproduction, distribution and utilisation of this document as well
as the communication of its contents to others without explicit authori‐
sation is prohibited. Violations will result in a claim for damages. All
rights reserved in the event of the grant of a patent, utility model or
design.
© Putzmeister Concrete Pumps GmbH 1994
1.2 Icons and symbols
The following icons and symbols are used:
Icon/symbol/
designation
Meaning
▶ Individual instruction or alternative step
1. 2. 3. Instructions to be carried out as described in the
specified sequence.
⇒ Intermediate result of multiple steps.
➙ End result of an individual instruction or of multi‐
ple steps.
● Bullet point list – Key words or short sentences
that provide comprehensive information. This in‐
cludes the various options available, enumera‐
tions, lists of components, etc.
Operating ele‐
ment
Operating elements are written in small capitals to
make it immediately clear which operating ele‐
ment should be used. The designation is only
written in small capitals in continuous text and in
instructions. Tables and headings are not inclu‐
ded.
Link/cross ref‐
erence:
(Icons and
symbols
P. 1 — 4)
A link/cross reference to related topics. Cross ref‐
erence with page number and heading. If the
cross reference is displayed digitally, it acts as a
direct link to a related topic area.
Guide to the Operating Instructions
1 — 4 Operating Instructions 210111697_2021-08-09_en

Icon/symbol/
designation
Meaning
Fault rectification – Instructions to be carried out
in accordance with fault messages.
View additional steps. For example, “Contact a
qualified electrician”.
✓
The requirements or tools outlined below must be
met or available.
Tests or inspections have been passed.
This indicates a tip, helpful note or additional in‐
formation regarding machine maintenance, envi‐
ronmental protection, etc.
1.2.1 Layout of warning notices
WARNING
Type and cause of risk
Consequences of not observing the risk.
▶What to do in order to provide a remedy or avoid the risk.
Signal words
The signal word is chosen in accordance with the ANSI Z535.6:2011
safety standard.
The following signal words are used:
DANGER
Indicates a dangerous situation in which an accident resulting in se‐
rious injuries and/or death may occur. Highest level of risk.
▶After identifying the risk, instructions are set out which are inten‐
ded to avoid or remedy the risk.
Guide to the Operating Instructions
210111697_2021-08-09_en Operating Instructions 1 — 5

WARNING
Indicates a dangerous situation in which an accident resulting in se‐
rious or fatal injuries may occur.
▶After identifying the risk, instructions are set out which are inten‐
ded to avoid or remedy the risk.
CAUTION
There is a risk of injury to the entire body, however there is no risk
of serious or fatal injuries.
▶After identifying the risk, instructions are set out which are inten‐
ded to avoid or remedy the risk.
NOTICE
Risk of damage to the machine. There is no risk of injury.
▶After identifying the risk, instructions are set out which are inten‐
ded to avoid or remedy the risk.
Guide to the Operating Instructions
1 — 6 Operating Instructions 210111697_2021-08-09_en

2 Safety regulations
These safety regulations correspond to the “Terms, definitions, re‐
quirements” and “Starting up and working with the machine” sections
in the VDMA (German Engineering Federation) brochure “Safety
manual for concrete delivery and placing machines”.
Here you will find a summary of the most important safety regulations.
This chapter is therefore particularly useful for providing initial and ba‐
sic instruction for new employees.
Special safety regulations may be necessary for some tasks.
These special safety regulations will only be found in the descrip‐
tion of the particular task.
We include here a listing of regulations and safety standards for
your information:
●DIN EN 12001:2012, Conveying, spraying and placing ma‐
chines for concrete and mortar
● DIN EN 60204-1:2014, Safety of machinery – electrical equip‐
ment on machines
● DIN EN ISO 12100:2011, Safety of machinery
210111697_2021-08-09_en Operating Instructions 2 — 1

2 — 2 Operating Instructions 210111697_2021-08-09_en

2.1 Definition of terms
The terms used in this Safety Manual are explained below, along with
descriptions of the requirements placed on specific groups of people.
2.1.1 Machine
For the purposes of this Safety Manual, concrete delivery and placing
machines are defined as:
●Truck-mounted concrete pumps (an ensemble of truck and con‐
crete pump with and without placing boom). The safety regulations
issued by the truck manufacturer also apply to the truck.
● Truck mixer concrete pump (an ensemble of truck mixer, concrete
pump and placing boom). The safety regulations issued by the
truck mixer manufacturer and by the truck manufacturer also apply
to truck mixer concrete pumps.
● Stationary concrete pumps
● Stationary placing systems (an ensemble of placing boom and
base structure)
2.1.2 Concrete pump
For the purposes of this Safety Manual, concrete pumps are defined
as devices which are designed to deliver concrete to placement sites
via pipes or hoses.
2.1.3 Arm assembly
Arm assembly is a synonym for placing boom and can be used inter‐
changeably.
2.1.4 Placing boom
For the purposes of this Safety Manual, placing booms are defined as
powered, slewable devices consisting of one or more swinging or
folding sections for guiding the delivery line.
2.1.5 Base structure
For the purposes of this Safety Manual, base structures are defined
as equipment which is designed to hold a stationary placing boom to
give the latter the required stability.
Safety regulations
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2.1.6 Truck mixer
For the purposes of this Safety Manual, truck mixers are defined as
vehicles with mixing equipment for transporting concrete.
2.1.7 Delivery line systems
For the purposes of this Safety Manual, delivery line systems are de‐
fined as self-contained pipes or hoses in which concrete is pumped
from the concrete pump to the placement site. Devices for shutting
off, diverting or cleaning delivery lines can be integrated into delivery
line systems.
2.1.8 End hose
For the purposes of this Safety Manual, end hose is defined as the
hose that is fitted on the placing boom at the end of the delivery line
for distributing the concrete. There must be no couplings, spouts, dis‐
charge stops or other items fixed to the outlet end of the end hose un‐
less they are approved by the manufacturer.
2.1.9 Manufacturer
Any natural or legal person that markets a machine or incomplete ma‐
chine that is dealt with in this Safety Manual.
2.1.10 Operator
Authorised representative of the owner of the concrete pumps and/or
placing booms. The operator is responsible for the use of these ma‐
chines.
2.1.11 Machine operator
Persons trained in and charged with the operation of concrete pumps
and placing booms.
2.1.12 Hoseman
Persons instructed by the site management in how an end hose is
guided. Hosemen must be able to independently evaluate all danger‐
ous situations which may occur in the area of the end hose and react
according to the situation.
Safety regulations
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