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user manual-42R4XXT

1. Bi Notes Er Bi Notes Er Concept Layout G amp 5 DOKUMENTATION 85521 Ottobrunn
2. 2 15 2 9 4 AgitatOr u nenne doo RR Fa LA PG ee 2 16 2 10 Safety instructions at concrete pressures in excess of 85 2 16 2 11 Safety instructions for maintenance and repair 2 16 2 12 High tension overhead electric cables 2 17 2 12 1 Saly distance ete dee are EGRE a de ee ee eee ERE 2 18 2 12 2 High tension contacts sie dee dE RE reelle REESE eS 2 19 2 12 2 1 Automatic reconnection 2 0 ce eee 2 20 2 12 3 Static disch rge five au su cd Pama de in nn E RES Ei ade ne eRe den 2 20 2 12 4 Immediate measures 2 vs vrl Phe nasser wee ee haha 2 21 2 12 4 1 Actions after contacting a high tension overhead cable 2 21 THP 94 42 R 4 XXT THP 125 42 R 4 XXT THP 140 H 42 R 4 XXT GB 07 2005 0 1 C Sat 2 13 Operation Po Ta a ee 2 20 2 14 Storms and thunderstOrtms tee eae ewe dee aceon ee EA GER ed 2 21 2 15 Noise emission 2 21 2 16 Environmental protection 2 21 2 17 First ald WEE 2 21 2 18 Responsible persons nennen 2 22 2 18 1 Personnel is ag T LETT 2 22 2 18 2 Een ue 2 22 2 18 3 MEE 2 2
3. THP 94 42 R 4 XXT THP 125 42 R 4 XXT 8 2 GB 07 2005 THP 140 H 42 R 4 XXT TROUBLE SHOOTING 2 CHAPTER 8 amk Fault Cause Pressure relief valve defective Controls defective Pumping or sucking does not at maximum pressure Blockage in the conveying pipework Defective sensor on drive cylinder Spool valve defective Concrete delivery from the pump is too little or is irregular Incorrect gear or stage engaged in the vehicle gearbox Vehicle engine speed too low Concrete pump sucking in air Concrete mixture unsuitable for pumping Remedy Check valve and solenoid and have part replaced if necessary by WAITZINGER customer service Check fuses F9 to F12 and replace if necessary Set back up function to position A Immediately on finishing work have the fault rectified by WAITZINGER customer service Suck back and establish the cause of the blockage see section 7 6 1 1 Set back up function to position B Replace the defective sensor at the earliest opportunity Check valve and solenoid and have fault rectified if necessary by WAITZINGER customer service Engage the correct gear Increase the speed Check the settings Inform the mixer truck driver that the hopper must always be filled to the agitator shaft at least see section 7 6 2 Check the conveying piston for wear Use only pumping co
4. 140 42 R 4 GB 07 2005 9 CHAPTER 9 MAINTENANCE amp INSPECTION Qa 9 2 7 Safety precautions when charging batteries N WARNING Around batteries there is an explosion hazard due to short CITIT circuits sparks or naked flames Batteries on charge release explosive gas Switch off the charging power before disconnecting the charging lead plug gt When charging in enclosed spaces ensure good ventilation Continue to ventilate the room up until an hour after completing the charge No smoking Do not place tools on the battery Disconnect the battery terminals before working on the electrical system Electric arcs can be life threatening and cause fires Do not place anything metallic on the battery Sulphuric acid is corrosive When working on the battery always wear safety glasses and protective gloves y Battery fluid contains sulphuric acid Remove splashes from the skin immediately with soap and water Immediately summon a doctor is acid splashes the eyes or mucous membranes 9 2 8 Safety instructions for welding work N CAUTION gt Whenever carrying out welding work on the truck mounted concrete pump disconnect the battery and unplug all electrical control equipment r Attach the earth connection immediately adjacent to the welding location In addition observe all safety instructions set out in C
5. Fault Cause Remedy Emergency Stop indicator lamp flashing Emergency Stop button has been pressed Selector switch set to remote control Broken cable or defective Emergency Stop switch Pumping or sucking does not start no pressure available Selector switch in position Desk Grill open Pump ON was selected when the controls were switched on using the horn Engine not running Vehicle gearbox in neutral Stroke rate potentiometer at 0 Emergency Stop button has been pressed Hydraulic oil too hot Spool valve defective Establish why the Emergency Stop button was pressed and remedy the cause Release the Emergency Stop and restart the controls with the horn see section 7 2 2 Release remote control Emergency Stop or change over the selector switch on the desk and start the controls with the horn Move selector switch to position Remote control operate horn Close grill Check limit switch Switch the pump off and restart it Start the engine Select a gear see section 7 2 1 Set a higher value see section 7 2 1 Establish why the Emergency Stop button was pressed and remedy the cause Release the Emergency Stop and restart the controls with the horn see section 7 2 2 Let the hydraulic system cool down see section 7 6 4 Check valve and solenoid and have part replaced if necessary by WAITZINGER customer service
6. Fig 7 21 Operation Pump Suck desk NOTE Opening the safety grill or pressing an Emergency Stop button whilst the Pump Suck switch is activated will deactivate the Pump Suck function NOTE If the hydraulic oil temperature exceeds 80 C the pump function is stopped and the indicator lamp Item 4 Fig 7 21 on the control panel desk will light Sucking the concrete back remains available The hydraulic system must be cooled down as quickly as possible by appropriate means see section 7 6 4 THP 94 42 R 4 XXT THP 125 42 R 4 XXT 7 16 GB 07 2005 THP 140 H 42 R 4 XXT STARTING UP AND OPERATING f CHAPTER 7 7 5 3 Pump Suck control by radio remote control cable remote control The operating mode selection switch Item 14 Fig 7 6 must be set to Radio remote control The rocker switch Item 12 Fig 7 21 on the remote control pendant is pre set to Pump or Suck Select Pump or Suck using the rocker switch Item 13 Fig 7 21 The stroke rate depends on the setting of the stroke rate en ege potentiometer Item 11 Fig 7 22 and the engine speed Fig 7 22 Operation Pump Suck radio remote control NOTE Opening the safety grill or pressing an Emergency Stop button whilstthe Pump Suck switch is activated will deactivate the Pump Suck function which must then be restarted by switching the rocker switch Item 13 F
7. e Each operator should enter here in a clear manner all maintenance and modification work performed and present the list to the supervisor for confirmatory signature e This maintenance and modifications list should be made available on request to the Employers Liability Insurance Association or the TUV properly filled in and signed Maintenance Modification Date Operator Confirmed by on on signature person responsible THP 94 42 4 XXT THP 125 42 R 4 XXT THP 140 H 42 R 4 XXT GB 07 2005 12 1 MAINTENANCE AND MODIFICATIONS LIST 12 Make further copies if required Maintenance Modification Date Operator Confirmed by on on signature person responsible THP 94 42 4 XXT THP 125 42 R 4 XXT 12 2 GB 07 2005 THP 140 H 42 R 4 XXT A MAINTENANCE AND MODIFICATIONS LIST CHAPTER 12 Make further copies if required Maintenance Modification Date Operator Confirmed by on on signature person responsible THP 94 42 4 XXT THP 125 42 R 4 XXT THP 140 H 42 R 4 XXT GB 07 2005 12 3 Notes Er
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9. c Engine braking must be disengaged c The handbrake must be applied THP 94 42 R 4 THP 125 42 R 4 XXT 7 4 GB 07 2005 THP 140 H 42 R 4 XXT STARTING UP AND OPERATING f CHAPTER 7 The Controls ON indicator lamp 3 remains on as long as the ignition is on and the gearbox is set for pump drive This function is independent of any Emergency Stop indication The vehicle engine must be running Fig 75 Indicator lamp Controls On 7 2 2 Emergency Stop The machine is fitted with 4 illuminated Emergency Stop buttons plus an Emergency Stop button on each remote control pendant Each Emergency Stop button immediately switches off all functions and movements optionally the engine can be switched off by an Emergency Stop The Emergency Stop buttons are located as follows Control panel desk Item 1 Fig 5 2 Boom control block Item 3 Fig 5 4 Left hand outrigger controls Item 2 Fig 5 5 Right hand outrigger controls Item 2 Fig 5 6 Radio remote control Item 9 Fig 5 12 Cable remote control Item 9 Fig 5 12 The activated Emergency Stop button is indicated n the control panel by the flashing Emergency Stop indicator lamp Item 12 Fig 5 2 and at the activated Emergency Stop button itself except for remote control After the reason the activating the Emergency Stop button has been rectified the activated Emergency Stop button can be released by pulling or twistin
10. We expressly draw to your attention that we accept no liability for damage and operating failures that arise due to disregard of this user manual gt This section contains safety instructions which must be complied with at all times when the machine is in operation These instructions are highlighted in the text by particular symbols 2 1 Warranty and liability After the machine has been delivered check the completeness of the scope of supply against the delivery note gt If anything is missing or damage has occurred in transport please report this immediately to WAITZINGER The machine as delivered is in accordance with current technology and complies with the mandatory safety standards The machine should be operated only when it is in good technical condition and in a proper manner see section 4 2 Proper use Any use other than this or beyond this is deemed to be improper use If the machine is used inappropriately or improperly risks to life and limb can arise and or damage to the machine or other property WAITZINGER accepts no liability for damage that arises under such circumstances The risk is borne solely be the user of the machine t Proper use of the machine also requires compliance by the user with national regulations for accident prevention and environmental protection with recognised professional rules for good and safe working practice and with this user manual
11. aitzinger Baumasc hinen GmbH WAITZINGER CONCRETE PUMP THP 94 42 R 4 XXT THP 125 42 R 4 XXT THP 140 H 42 R 4 XXT Waitzinger Baumaschinen GmbH Lessingstra e 4 89231 Neu Ulm Phone 49 0 7 31 7 29 05 0 Fax 49 0 7 31 7 29 05 30 e mail info waitzinger de Internet www waitzinger de Waitzinger Baumaschinen GmbH All rights reserved This user manual is copyright to Waitzinger Baumaschinen GmbH This document contains instructions and technical drawings and may therefore not be copied and released to third parties in whole or in part Errors and omissions excepted This user manual is part of the supply of the following Your appointed Waitzinger Service Office Waitzinger concrete pump Customer Service is The machine number is shown on the serial plate on the vehicle frame behind the cab Issue July 2005 CONTENTS CHAPTER 0 J 0 Contents 1 FOreWOrd u aa a d EE nen 1 1 2 Safety instructions and information nun nennen nn nn 2 1 2 1 Warranty liability EE 2 1 2 2 Safety symbols i zum SEIN Pade hd eee edad eee we a 2 3 2 3 Safety SGuipMment Has aan het oe Fats Bee iene MURDER 2 4 2 4 Personal safety equipment 0 000 cee ee 2 4 2 5 Ensuring safe working and lt 2 4 2 6 Information on risks Of injury summ LER x EY na ae 2 6 2 7 Safety informatio
12. gt No changes additions or modifications of any sort may be made to the machine without express permission from WAITZINGER Original spare parts and approved accessories from WAITZINGER contribute to safety No liability is accepted for the consequences arising from use of other parts c Persons working on or with the machine must have read and understood the user manual before starting work and have appropriate physical and mental capabilities c Disregard of these instructions and information can lead to risks to life and limb and or damage to the machine or other property THP 94 42 R 4 XXT THP 125 42 R 4 XXT THP 140 H 42 R 4 XXT GB 07 2005 2 1 SAFETY INSTRUCTIONS AND INFORMATION CHAPTER 2 gt If due to disregard of failure to comply with the instructions and information in this user manual or the operating and maintenance handbook for the overall system accidents leading to personal injuries and or damage to property occur this circumstance releases WAITZINGER from any liability for direct or consequential damages such as personal injuries damage to property not covered by the contract loss of profits and interruption to production that comes under the heading Product liability to WAITZINGER THP 94 42 R 4 XXT THP 125 42 R 4 XXT 2 2 GB 07 2005 THP 140 H 42 R 4 XXT SAFETY INSTRUCTIONS AND INFORMATION A A CHAPTER 2 2 2 Safety symbols DANGER This symbol indicates an immediate
13. 1350 13 070 Fig 3 1 Leading dimensions of the truck mounted concrete pump 3 2 Truck Information regarding the truck can be found in the separate user manual supplied by the truck manufacturer THP 94 42 R 4 XXT THP 125 42 R 4 XXT THP 140 H 42 R 4 XXT GB 07 2005 3 1 TECHNICAL DATA CHAPTER 3 3 3 Distributor boom 42 R 4 XXT Horizontal reach mm 38 000 Vertical reach mm 42 000 Slewing range degrees 370 1 A element rotation degrees 100 2 B element rotation degrees 180 3 C element rotation degrees 180 4 D element rotation degrees 235 Concrete pipeline diameter mm 125 Front outrigger setup mm 8 500 Rear outrigger setup mm 8 000 Length of discharge hose mm 4 000 Voltage V 12 24 Max slope of ground degrees 3 Front outrigger pressure kN 220 Rear outrigger pressure 220 Max concrete pressure bar 85 Max weight of pipework kg m 12 Max weight of elbow kg 13 Max density of concrete kg m 24 Hydraulic pressure for distributor boom bar 330 Hydraulic pressure for outriggers bar 200 Secondary settings Element 1 up bar 300 Element 2 up bar 320 Element 3 up bar 280 Element 4 up bar 280 Rotate bar 160 Telescopic extension bar 100 100 Slew out front outrigger bar 50 Slew in front outrigger bar 80 Time element 1 up down 100 sec 90 Time element 2 up down 180 sec 115 Time element 3 up down 180 sec 76 Ti
14. Deploy boom element C and D Item 1 Fig 7 18 to deploy boom element D to 90 to boom element C see Fig 7 16 Position boom element horizontally approx 1 m above the ground Open the catch and release the discharge hose see Fig 7 17 Use the joystick s 1 to 3 on the radio remote control to move the distributor boom to the desired working position THP 94 42 R 4 XXT THP 125 42 R 4 XXT THP 140 H 42 R 4 XXT GB 07 2005 7 15 f STARTING UP AND OPERATING CHAPTER 7 7 5 Pump operation 7 5 1 Motor Start Stop Speed control The vehicle engine can be started from the remote control pendant using the push button Item 4 Fig 7 20 This can only be done if the key switch Item 14 Fig 7 6 on the control panel desk is set to Remote Control Pressing the push button Item 5 Fig 7 20 stops the vehicle engine and inhibits its restart for approx 10 sec Pressing the rocker switch Item 7 Fig 7 20 or Item 9 Fig 7 21 brings the vehicle engine from idling to full speed within 10 sec 7 5 2 Pump Suck control at the control panel desk The operating mode selection switch Item 14 Fig 7 21 must be set to Desk The rocker switch Item 11 Fig 7 21 selects Pump or Suck For confirmation one of the two indicator lamps Item 10 or 12 Fig 7 21 will light The stroke rate depends on the setting of the stroke rate potentiometer Item 13 Fig 7 21 and the engine speed
15. to EC directive 75 439 EWG and statutory instruments under 5a 5b AbfG and Alt lV r Electrical control equipment resistors and contactors should be kept clean and cleaned as required r Check electrical cables for damage to the insulation rx Check mechanical components for wear deformation crushing cracks breakage corrosion and secure mounting r Regularly check all pipes hoses and screwed connections for leaktightness and for externally evident damage r Fluids which emerge at high pressure can be hazardous 9 2 1 Lubricants and solvents N WARNING gt As far as possible avoid allowing lubricants and solvents to contact the skin gt Store fluids especially hydraulic oils and also engine oils lubricants and liquefied or compressed gaseous products only in the containers legally prescribed for them These should carry appropriate warning notices identifying their contents Comply with all warning notices When handling these materials wear protective clothing at all times skin eyes hand and foot protection Used protective clothing must be placed in sealed plastic sacks after wearing THP 94 42 R 4 XXT THP 125 42 R 4 XXT 9 2 GB 07 2005 THP 140 H 42 R 4 XXT A CHAPTER 9 9 2 2 Sealing rings containing fluorine N WARNING WARNING r Always wear protective clothing when removing the remains of sealing rings gt Fluorine is c
16. 2 Fig 5 7 to position B e Set the key switch Item 14 Fig 7 21 to position Desk or Remote control e Switch on the Pump Suck function using rocker switch Item 11 Fig 7 21 or rocker switch Item 13 Fig 7 22 NOTE r The stroke rate the power control and switching speed do not function in setting A r The concrete delivery can only be changed via engine speed gt A lower gear should generally be engaged on the vehicle gearbox THP 94 42 R 4 XXT THP 125 42 R 4 XXT 7 18 GB 07 2005 THP 140 H 42 R 4 XXT STARTING UP AND OPERATING f CHAPTER 7 7 5 4 2 Pump control at the hydraulic control block When controlling the valves manually never run the engine at full speed WARNING N i LI Valves and solenoids can be up to 100 C temperature risk of burns e Moving the drive cylinder Actuate Y4 a or b using a screwdriver 4 mm or similar tool Then press Y3 manually and move the drive cylinder to the desired position Simultaneously releasing Y3 and Y4 will bring the cylinder to a halt Moving the oscillation cylinder Actuate Y5 a or b using a screwdriver 4 mm or similar tool Then press manually and move the drive cylinder to the desired position Simultaneously releasing Y3 and Y4 will bring the cylinder to a halt me Ep y gt Wimmer 1 Valve Y5b 3 Valve Y3 5 Valve Y5a 7 Valve Y4b 2 Push button 4 Pressu
17. 2 26 Item 10 WAI105940 Slewing range of boom Beim Ausfahren der St tzf 3e Abstand halten Quetschgefahr Stand clear of outriggers when activating UB Danger of bruise FE z WAI 105941 Waitzinger Baumaschinen GmbH D 89231 Neu Ulm Fig 2 27 Item 11 WAI105941 Extending the support feet THP 94 42 R 4 XXT THP 125 42 R 4 XXT 140 42 4 GB 07 2005 2 29 SAFE TY INSTRUCTIONS AND INFORMATION CHAPTER 2 Waitzinger Baumaschinen GmbH D 89231 Neu Ulm Fig 2 28 Item 12 WAI105939 Do not reach into the hopper Bei laufender Maschine niemals in eine der ffnungen des Trichters greifen Keep hands out ofthe hopper while the engine is running WAI 105939 Schmierstelle Grease Point I Bevor Mast bet tigt wird pr fen ob Abst tzung komplett ausgefahren ist Check all stabilizers fully extended before arms operation WAI 106370 Fig 2 29 Item 13 WAI106369 Grease point Fig 2 30 Item 14 WAI106370 Fully extend the outrigger 2 30 THP 94 42 R 4 XXT THP 125 42 R 4 XXT GB 07 2005 THP 140 H 42 R 4 XXT SAFETY INSTRUCTIONS AND INFORMATION A A CHAPTER 2 WAI 106366 Waitzinger Baumaschinen GmbH D 89231 Neu Ulm Fig 2 31 Item 15 WAI106366 Max inclination 3 u WAI 106367 Waitzinger Baumaschinen GmbH D 89231 Neu Ulm Fig 2 32 Item 16 WAI106367 Crush hazard T
18. 7 3 litres To change the oil in the transfer shift gearbox proceed as follows 1 Remove the oil level screw 1 and drain plug 2 and let the oil drain into a tray 2 If the oil was very dirty it is essential to fill the gearbox completely with flushing oil and run the hydraulic system for a short period This ensures that any deposits of dirt in the gearbox are fully mixed into the oil after this repeat point 1 3 Reinsert the drain plug 4 Use a funnel to fill the gearbox slowly with oil through the breather screw opening 3 until the oil comes out of the oil level screw hole 5 Screw in the oil level screw Fig 9 11 Transfer shift gearbox 9 7 3 Changing the oil in the hydraulic system Use oil grades alternative grades as shown in the hydraulic oil reference table Fig 9 4 Oil capacity 600 litres CAUTION CAUTION Always refill with the same gra de as was used previously Before changing over to a biologically degradable oil the entire hydraulic system must be rendered totally oil free This procedure can only be performed by an authorised specialist company 1 Remove the drain plug from the drain cock Item 1 Fig 9 12 Fig 9 12 Oil drain pipe 2 Connect a J hose from the drain cock to the container THP 94 42
19. Achslast to Masch No Axle weight perm to Baujahr max Abst tzdruck kp Year of construction _________ Outriggers press max Hydraulikdruck Betondruck bar max Hydr pressure LU Concrete press bar V max km h 55 Drehzahl rpm WAI106179 Fig 2 17 Item 1 WAI106179 Serial plate Pafrohrl ngen F rderleitung Delivery line fitting pipe max Rohrgewicht kg m Rohr Arm 1 max weight pipe Pipe boom max Gewicht F rderbogen max weight elbow Rohr Arm 2 kg pipe boom 2 Rohr Podest Rohr Arm 3 pipe decking pipe boom 3 Rohr Turm Rohr Arm 4 pipe tower pipe boom 4 Rohr Rohr Arm pipe pipe boom WAI106032 Fig 2 18 Item 2 WAI106032 Matching pipe lenghts Conveying pipes THP 94 42 R 4 XXT THP 125 42 4 XXT 2 24 GB 07 2005 THP 140 H 42 R 4 XXT CHAPTER 2 SAFETY INSTRUCTIONS AND INFORMATION GENERAL HINTS FOR OPERATION OF CONCRETE PUMPS The pump operator has to know the Operation and Maintenance Manual He also has to know all safety regulations which are important for the operating of aconcrete pump and he has to keep them He must be able to control the machine Before setting the machine into operation Make the working and danger area safe block it off if necessary Fill all operating fluids hydraulic oil fuel water Check all safety devices emergency stops and co
20. Conventional greases Centoplex 2 EP MOBIL Mobilgrease Li MOLYKOTE TTF 52 inorg thinner Longtime PD 2 Li OLIT CLS Li Ca OPTIMOL SHELL Retinax C Ca WESTFALEN Gresalit ZSA 2 Li Li ZELLER amp GMELIN Li BAB EP 2 Top 2000 Bio Biogrease 1 Dolon E 2 Plantogel S2 Kl berbio M32 82 Fig 9 5 Greases reference table Biologically degradable greases THP 94 42 R 4 XXT THP 125 42 R 4 XXT THP 140 H 42 R 4 XXT GB 07 2005 9 17 S CS Ee a c5 c3 S S cc lt I O Lubrication system Transfer gearbox Slewing gearbox Roller bearing ity grease ISCOSI Low v N e e 0I CLP DIN 51517 Jueougn 001 ocg 9 0p 1e u Aysoas n ogewaury 09 Og asea asodind yinjy 9 ul aunyesaduua man 11916 cs aseauhlaug 9569 6 asod nd nnyy 459 asea d3 00 94 asealbieuz d3 00 IH 022 4 95 Dau 09 4 95 Van CL A ueJyeg 001 dX 49 Gau 022 dX u9 Gan OZE dX u9 097 9 00 02 1090 46 2909 asod nd nnyy Lk H josd pe 208 0 0806 09 0 00 022 9d 10 uu sqno3 yn 0979410 uu sqno3 yn 0 08 IQ 0sqn33 w 0508 10 AER 0908 10 0sqn93 YN 0 1810 josqnd3 yn
21. Filling with water using the C coupling e Connect the water hose to the C coupling Item 1 Fig 7 38 e Open the ball valve Item 2 Fig 7 38 e Start filling with water watch the water sight hose Item 2 Fig 7 37 Keep filling with water until water emerges from the filler opening Fig 7 38 Fill with water using the C coupling THP 94 42 R 4 XXT THP 125 42 R 4 XXT THP 140 H 42 R 4 XXT GB 07 2005 7 31 f STARTING UP AND OPERATING CHAPTER 7 7 8 3 Filling with water from the mixer truck Connect the water hose to the Geka coupling Item 1 Fig 7 39 e Open the ball valve Item 2 Fig 7 39 e Start filling with water watch the water sight hose Item 2 Fig 7 37 Keep filling with water until water emerges from the filler opening Fig 7 39 Fill with water from the mixer truck 7 8 4 Operation in winter e The machine must be standing level level the machine using the circular levels Item 1 Fig 5 5 and Item 3 Fig 5 6 Completely drain all water by opening all ball valves Item 2 Fig 7 38 and Item 2 Fig 7 39 e Drain the wash out tank THP 94 42 R 4 XXT THP 125 42 R 4 XXT 7 32 GB 07 2005 THP 140 H 42 R 4 XXT A 8 Trouble shooting TROUBLE SHOOTING 9 8 1 General information CHAPTER 8 amk The actions described in this chapter for trouble shooting should be employed if during operation deviations from normal performance are found Trouble
22. MAINTENANCE amp INSPECTION See CHAPTER 9 8 Use the drive cylinder to move the conveying piston far enough for there to be room to fit the spacer 8 9 Remove the snap coupling 4 and back off the drive cylinder to the end of its travel 10 Fit the spacer 3 to the drive cylinder with the snap coupling 4 11 Push the conveying piston 1 on to the spacer 8 by levering with a pry bar and fit the snap coupling 4 12 Fit the hose clip 2 Fig 9 31 Changing the conveying piston 6 9 9 3 Changing turning the conveying cylinder 1 Remove the conveying cylinder as described in section 9 9 2 2 Move both drive cylinders to the limit of their travel Disconnect the oscillation pipe from a retracted drive cylinder and hang it over a container Slowly move the drive cylinder to limit of its travel by actuating valves Y5 Y6 manually 3 Disconnect the shaft support the wash out tank 4 Remove the 26 screws 1 and support the conveying cylinder e g with a fork lift truck 5 Lift the slide housing with a crane Fig 9 32 Changing turning the conveying cylinder NOTE When lifting take care that no hoses or cables are trapped 6 Remove or turn the conveying cylinder 94 42 4 XXT 125 42 4 9 32 GB 07 2005 THP 140 H 42 R 4 XXT MAINTENANCE
23. Neu Ulm Fig 2 22 Item 6 WAI105974 Keep away Diese Maschine ist fernge steuert und kann zu jedem Zeitpunkt starten Vor Repa raturarbeiten Motor stoppen This machine is remote controlled and may start at any time Stop engine before servicing unit Waitzinger Baumaschinen GmbH D 89231 Neu Ulm WAI 105938 Abb 2 23 Item 7 WAI105938 Remotely controlled machine THP 94 42 R 4 XXT THP 125 42 R 4 XXT THP 140 H 42 R 4 XXT GB 07 2005 2 27 SAFE TY INSTRUCTIONS AND INFORMATION CHAPTER 2 Mast nicht als Kran oder Aufzug benutzen Do not use the boom as a crane or hoist ERES WAI 105937 Waitzinger Baumaschinen GmbH D 89231 Neu Ulm Fig 2 24 Item 8 WAI105937 Boom is not a crane Gesamtgewicht von End schlauch Reduzierungen und Schalenkupplungen darf mit Beton 160 kg NICHT ber schreiten Total weight of end hose reducers and clamps including concrete must CHD exceed 350 pounds Waitzinger Baumaschinen GmbH D 89231 Neu Ulm ced A Fig 2 25 Item 9 WAI105975 Total weight of discharge hose THP 94 42 4 XXT THP 125 42 R 4 XXT 2 28 GB 07 2005 THP 140 H 42 R 4 XXT SAFE TY INSTRUCTIONS AND INFORMATION N CHAPTER 2 Halten Sie sich niemals unter dem Schwenkbereich des Mastes auf Do not stay under the booms operating area WAI 1 4 Waitzinger Baumaschinen GmbH D 89231 Neu Ulm 05940 Fig
24. XXT THP 140 H 42 R 4 XXT GB 07 2005 2 17 SAFETY INSTRUCTIONS AND INFORMATION CHAPTER 2 DANGER TANGER c Direct contact with high tension cables can cause fatalities gt Even coming close to high tension overhead electric cables can cause the machine and the surrounding ground to become live due to a flashover gt Always maintain the stated safety distance 2 12 1 Safety distance tx The machine operator must ensure that when moving the distributor boom the clearances to overhead electric cables are maintained as set out in the table The following minimum safety distances are those specified for the German Federal Republic in VDE 0105 Nominal voltage Minimum safety distance up to 1 000 Volt 1 0 metre over 1 kV bis 110 kV 3 0 metre over 110 kV bis 220 kV 4 0 metre over 220 kV bis 380 kV 5 0 metre if the voltage is not known 5 0 metre Fig 2 14 Minimum safety distance from overhead electric cables tx If the minimum safety distance from overhead electric cables shown in the table cannot be maintained the machine operator must ensure that they are e switched off for the duration of the work or e they are shrouded or insulated in the vicinity of the concrete pump and distribution boom tx The same minimum safe distances apply to driving underneath overhead electric cables Make allowance for the swing of the cables and the distributor boom in the wind High ambient humid
25. amp INSPECTION Chapter 9 NOTE To increase the working life of the conveying cylinders these can be turned by 180 Be sure to turn the conveying cylinders at the right tim If the wear has already passed the point of no return the conveying cylinders must be replaced 7 Refit the conveying cylinders in the reverse sequence to removal 8 Fit the conveying pistons and oscillation pipe as described in section 9 9 2 9 Manually activate valves Y3 and Y4 or the rocker switch Item 11 Fig 5 2 to slowly extend the right hand drive cylinder 10 Bleed air from the drive cylinder 11 Perform a trial run 9 9 4 Changing the agitator blades 1 Remove the screws 2 2 Change the agitator blades 1 Check that the seating faces are clean The right hand agitator blades must be 90 out of phase with the left hand blades 3 Fit the screws 2 and tighten them to the torque set out in the table in section 9 3 Always replace these screws Fig 9 33 Changing the agitator blades THP 94 42 R 4 XXT THP 125 42 R 4 XXT THP 140 H 42 R 4 XXT GB 07 2005 9 33 MAINTENANCE amp INSPECTION See CHAPTER 9 9 9 5 Changing the agitator seals 1 Remove the agitator blades 2 Pull the right hand motor 4 out approx 10 mm and 6 put the agitator shaft 3 to one side 3 3 Remove the retaining ring 5 p
26. are secured against free movement e check that the boom is in the transport position height 6 1 2 During the journey Always drive the truck mounted concrete pump having regard to the dimensions of the vehicle and its weight Further information on driving can be found in the separate vehicle manufacturer s user manual 6 2 Towing The truck mounted concrete pump should be towed only in accordance with the instructions of the vehicle manufacturer and only using the attachment points provided for the purpose For towing the truck mounted concrete pump the front towing ring should be used for towing other vehicles by the truck mounted concrete pump the rear towing plate Further information on towing can be found in the separate vehicle manufacturer s user manual THP 94 42 R 4 XXT THP 125 42 R 4 XXT THP 140 H 42 R 4 XXT GB 07 2005 6 1 DRIVING TOWING LOADING CHAPTER 6 6 3 Loading N CAUTION Not all the identified lifting points are suitable for lifting the complete machine Always check before lifting The attachment points for lifting the truck mounted concrete pump are specifically identified A transport company should be entrusted with loading and transporting by crane if necessary THP 94 42 R 4 XXT THP 125 42 R 4 XXT 6 2 GB 07 2005 THP 140 H 42 R 4 XXT STARTING UP AND OPERATING f A CHAPTER 7 T Starting up and operating This chapter contains all the important informatio
27. around to keep their distance step voltage and have the high tension cable switched off t Only then can the machine be moved and the injured be assisted 2 12 4 1 Actions after contacting a high tension overhead cable tx Stay in the machine c Drive the machine out of the hazard area gt Warn those standing around to keep away and not to touch the machine gt Have the high tension cable switched off gt Do not leave the machine until the high tension cable that was contacted damaged has been switched off 2 13 Operation in winter When operating in winter take care gt Increased danger of slipping especial when cleaning t Keep steps and platforms free of snow and ice c Risk of blockages due to ice in the conveying pipe THP 94 42 R 4 XXT THP 125 42 R 4 XXT 2 20 GB 07 2005 THP 140 H 42 R 4 XXT SAFETY INSTRUCTIONS AND INFORMATION CHAPTER 2 2 14 Storms and thunderstorms From wind force 7 wind speed 50 km h stop work and move the distributor boom to the transport position c During thunderstorms there is a risk of lightning strikes 2 15 Noise emission measurement The noise emission measurement to EN ISO 3744 and EN ISO 4871 have yielded a value of Las 81 4 dB A 2 16 Environmental protection tx Use should be found around the building site for surplus concrete or it should be disposed of as building waste according to the statutory requirements tx Consumables such as l
28. be deployed beyond the lengths stated in the user manual r Add extensions to the conveying pipe to the distributor boom only if they do not place any additional load the boom rx When the wind reaches the critical speed retract the distributor boom and secure it Retract the boom and secure it also at the end of the day s work rx If hazard areas are out of the operator s field of view employ an assistant Such hazard areas can be those within the slewing area of the distributor boom or the discharge hose gt When the wind reaches the critical speed retract the distributor boom and secure it Retract the boom and secure it also at the end of the day s work The machine operator must ensure that when moving the distributor boom the clearances to overhead electric cables are maintained as set out in the table 2 9 2 Conveying pipes tx The machine operator must securely fasten the conveying pipes particularly riser pipes that are not incorporated in the distributor boom and ensure that the forces arising in the components and other parts of the design are appropriately taken up The conveying pipes must be aligned so as to avoid kinks sharp bends and damage in operation THP 94 42 R 4 XXT THP 125 42 R 4 XXT 2 12 GB 07 2005 THP 140 H 42 R 4 XXT SAFETY INSTRUCTIONS AND INFORMATION CHAPTER 2 c If worn or defective components high pressure hoses etc are not immediately replaced WAITZINGER will not accep
29. bearing slewing rim must be adjusted by a skilled fitter 9 8 6 Checking the boom backlash ball bearing slewing rim in the slewing gearbox Boom backlash means the increased play between outer ring and inner ring of the ball bearing slewing rim in the slewing gearbox Boom backlash vi e The calculation of boom backlash may only be performed by a specialist authorised workshop Fig 9 20 Checking the boom backlash e The measurement must be performed at 2 points ded side and unloaded side as shown in the diagram alongside Fig 9 21 Measurement points for checking the boom backlash THP 94 42 R 4 XXT THP 125 42 R 4 XXT THP 140 H 42 R 4 XXT GB 07 2005 9 27 MAINTENANCE amp INSPECTION vk CHAPTER 9 e The difference between the two values is the exact value for the measured backlash x This value must be entered in the boom Rolling dia test book every time the boom is tested meter mm 20 22 25 30 40 The maximum permissible value shown in 1 000 1 8 1 9 1 9 2 0 25 the adjoining table must not be exceeded 1 250 1 9 2 0 2 0 2 1 2 6 1 500 2 0 2 1 2 1 2 2 2 7 1 750 2 2 2 2 2 3 2 8 2 000 2 3 2 4 2 9 2 250 2 5 3 0 2 500 3 1 Fig 9 22 Maximum values for the boom backlash 9 8 7 Checking the operation of the sensors The operation of the sensors is checked as follows There are tw
30. control block left 8 Control panel agitator water pump 2 Changeover to transfer shift gearbox 9 Surplus concrete discharge opening 3 Water tank drain cock 10 Manometer agitator water pump 4 Outrigger control block right 11 Manometer concrete pump 5 Boom control block 12 Radio remote control 6 Control elements on the control cabinet 13 Cable remote control 7 Control panel desk Fig 5 1 Controls and displays for the truck mounted concrete pump THP 94 42 R 4 XXT THP 125 42 R 4 XXT THP 140 H 42 R 4 XXT GB 07 2005 5 1 CONTROLS AND DISPLAYS CHAPTER 5 5 2 Control panel desk N HI gt ol 14 10 13 12 11 1 Emergency Stop button 8 Rocker switch Vibrator Auto Manual 2 Indicator lamp Emergency Stop 9 Rocker switch Engine speed 3 Indicator lamp Controls on 10 Indicator lamp Pumps 4 Indicator lamp Hydraulic oil temperature 11 Rocker switch Pump Suck 5 Control panel lighting 12 Indicator lamp Suck 6 Rocker switch Horn Reset Lubrication 13 Stroke rate potentiometer 7 Rocker switch Light 14 Key switch Desk Remote control Fig 5 2 Control panel desk THP 94 42 R 4 THP 125 42 R 4 XXT 5 2 GB 07 2005 THP 140 H 42 R 4 XXT CONTROLS AND DISPLAYS CHAPTER 5 5 3 Control panel agitator water pump Manometer Agitator Water pump Display instrument Concrete pump Manome
31. is running Blockages increase the risk of accidents 2 9 3 3 Use the guide rod to hold the discharge hose e Do not hold the discharge hose by hand if necessary to guide it use the guide rod as shown here 2 9 3 4 Securing the discharge hose with the catch e Always secure the discharge hose with the catch SAFETY INSTRUCTIONS AND INFORMATION CHAPTER 2 A Fig 2 10 Kink in the discharge hose Fig 2 11 Use the guide rod to hold the discharge hose Boom element D Coupling T Safety chain SS A zz La Clamp Discharge hose Fig 2 12 Securing the discharge hose with the catch THP 94 42 R 4 XXT THP 125 42 R 4 XXT THP 140 H 42 R 4 XXT GB 07 2005 2 15 SAFETY INSTRUCTIONS AND INFORMATION CHAPTER 2 2 9 4 Agitator gt To avoid air being sucked into the system leading to spurting concrete the hopper must be kept filled with concrete up to the level of the agitator shaft c Keep the safety grill closed in order to avoid injuries due to reaching into the agitator hopper or falling into it Do not place anything on the safety grill Do not step on the safety grill gt Never operate the machine unless the safety grill is closed and bolted into place or otherwise secured 2 10 Safety instructions at concrete pressures in excess of 85 bar If concrete is to be pumped at pressures in excess of 85 bar the discharge must only be through the side outlet no
32. is switched off and the hydraulic system is depressurised accumulator pressure or hydraulic pressure generated by static pressure in the conveying pipework c The distributor boom must be stowed for transport or propped Changing a filer always involves some loss of hydraulic oil Therefore be sure always to have a container or oil barrel to hand e Filters should be changed in a short a time as possible so that there is the least opportunity for contamination to enter the hydraulic system Therefore before starting work have the replacement filter element O rings lint free wipe cloths and petrol for washing down ready to hand e After changing the filter always check the oil level and top up with oil as necessary NOTE Do not let hydraulic oil drain into the ground always use a sufficiently large bowl or container and dispose of it in accordance with the applicable regulations THP 94 42 R 4 XXT THP 125 42 R 4 XXT THP 140 H 42 R 4 XXT GB 07 2005 9 19 MAINTENANCE amp INSPECTION CHAPTER 9 9 6 2 High pressure filters for the boom and hydraulic pumps If the red ring in the clogging indicator Item 1 Fig 9 7 is visible the filter element must be changed 1 Unscrew the filter casing 2 anti clockwise 2 Pull the filter element 3 downwards from the casing 4 3 Clean the filter casing replace the O ring and grease the thread and O ring 4 Fill the filter casing
33. nimmt mit zunehmendem Verschleiss ab Do not open couplings when they are under pressure Use only original couplings and sealings Check pipeline thickness frequently Rising wear out means lower burst pressure SE WAI 105935 Waitzinger Baumaschinen GmbH D 89231 Neu Ulm Fig 2 36 Item 20 WAI105935 Coupling pipe wall thickness THP 94 42 R 4 XXT THP 125 42 R 4 XXT THP 140 H 42 R 4 XXT GB 07 2005 2 33 SAFE TY INSTRUCTIONS AND INFORMATION CHAPTER 2 A H nde nicht in den Wasser kasten Trichter halten Falls notwendig Motor stoppen Unbeabsichtigtes Motor starten verhindern Keep hands out of waterbox hopper Stop engine if access is required Keep guards in place Waitzinger Baumaschinen GmbH D 89231 Neu Ulm WAI 105936 Fig 2 37 Item 21 WAI105936 Keep hands out of water box Kupplung betatigen male Schalter auf stellen Gang einlegen und Kupplung l sen Press the clutch Set switch to I Shift gear and release clutch WAI 105943 Waitzinger Baumaschinen GmbH D 89231 Neu Ulm Fig 2 38 Item 22 WAI105943 Disengage the clutch THP 94 42 R 4 XXT THP 125 42 R 4 XXT 2 34 GB 07 2005 THP 140 H 42 R 4 XXT SAFETY INSTRUCTIONS AND INFORMATION CHAPTER 2 SAFETY OPERATING INSTRUCTIONS Pump and boom operators must read and be familiar with the operator s manual before operating this equipment Safely devic
34. of the lubrication distributor 9 12 4 Checking the lubrication pipes 0000 e 9 12 5 Checking the grease nipples for manual 9 13 6 Lubricating manually serus ata B a RO ds 9 13 T Blocked grease polhits be an ed du a de d 9 13 9 5 2 Manual I briCatioris Garg ag EEN re a a la 9 14 9 5 3 Sliding SUrfAC8S u rue ye ed Se eae d 9 14 9 5 4 Overview of grease issu ee nn nn Pe 9 14 9 5 5 Reference tables for hydraulic oils greases and gear oils 9 16 9 6 Changing hl 9 19 9 6 1 General san ee en Cu beard PRE ae eee ERU 9 19 9 6 2 High pressure filters for the boom and hydraulic pumps 9 20 9 6 3 Return flow filter kee nn Pe ee ede eee eae 9 20 9 6 4 In line filter cartridge 2244 ea en Ree eee bene 9 21 9 7 Changing the Oll e ran a rare uem end pus Pus 9 21 9 7 1 Changing the oil in the slewing 9 21 9 7 2 Changing the oil in the transfer shift gearbox 6 eee 9 22 9 7 3 Changing the oil in the hydraulic system 9 22 9 8 Performing tests
35. outriggers 7 3 Operating the outriggers N DANGER When the outriggers are being slewed in out or extended there is high crush risk hazard THP 94 42 R 4 XXT THP 125 42 R 4 XXT 7 6 GB 07 2005 THP 140 H 42 R 4 XXT STARTING UP AND OPERATING f A CHAPTER 7 tx The operator must continuously monitor the hazard area The outrigger slew in out and extension areas must be kept clear of all persons and objects tx All instructions set out in Chapter 2 Safety instructions must be strictly complied with 7 3 1 Stability checking If the option Stability checking is installed refer to the separate user manual 7 3 2 Extending retracting the outriggers DANGER c For safety reasons the operator must always face towards the outrigger that is being extended retracted and have an unimpeded view of the entire hazard area r When activating the functions with the respective operating lever for safety reasons the other hand should always be keeping the safety button Item 3 Fig 5 5 Item 1 Fig 5 6 pressed Moving the operating lever on the outrigger control block downwards means for all functions Extend e Moving the operating lever on the outrigger control block upwards means for all functions Retract e The functions Slew out and Telescopic extension can be performed concurrently for the front outriggers This causes the front outriggers to extend automat
36. pump bar 320 320 320 Max hydraulic pressure agitator bar 250 250 250 Max hydraulic pressure water pump bar 250 250 250 Max speed of cardan shaft rpm 1 650 1 650 1 650 WARNING Note transmission ratio from vehicle gearbox THP 94 42 R 4 XXT THP 125 42 4 XXT 3 4 GB 07 2005 THP 140 H 42 R 4 XXT DESCRIPTION CHAPTER 4 4 Description 4 1 Proper use The truck mounted concrete pump is a working machine and is exclusively intended for conveying concrete up a density in the pipe of 2 400 kg m The machine is not to be used for transport of goods other than transporting accessories such as pipes and hoses etc The maximum permissible total weight must not be exceeded Any use that is not covered by proper use is deemed to be improper use or misuse WAITZINGER accepts no liability for damage that arises under such circumstances The truck mounted concrete pump as delivered is in accordance with current technology and complies with recognised safety standards for construction and use The truck mounted concrete pump should be operated only when it is in good technical condition and for its proper purpose The mandatory regulations for accident prevention applicable in the country and location of operation and the recognised technical safety rules for safe and proper working practices together with the instructions for operation and maintenance must all be complied with THP 94 42 R 4 XXT THP 125 42 R 4 XXT TH
37. screw connections on the cardan shaft joints Change the oil in the boom slewing gearbox and transfer shift gearbox see sections 9 7 1 and 9 7 2 AIS Lubricate all grease points on the boom boom mounting pump and ball bearing slewing rim see section 9 5 Check the oil level in the slewing gearbox Make a thorough visual check for damage of all seals on the S valve and agitator Check the adjustment of the S valve and adjust it as necessary After at least 24 hours settling time check the condensation water in the hydraulic oil tank drain it through the ball valve until hydraulic oil comes out x X X THP 94 42 R 4 XXT THP 125 42 R 4 XXT THP 140 H 42 R 4 XXT GB 07 2005 9 9 MAINTENANCE amp INSPECTION Gem CHAPTER 9 A Maintenance work Maintenance intervals e a 8 2 Ch 2 SE 2S BS Se 5 58 ES ES 8 2 528 22 Check the operation of all safety equipment such as Emergency Stop grill and guards x Check the structural steelwork of the boom boom mounting and outriggers for cracks x Completely drain the hydraulic oil flush out the hydraulic oil tank and fill with the necessary x quantity of hydraulic oil see section 9 7 3 Replace the filter cartridges in the hydraulic oil tanks for the boom and concrete pump K Clean the magnetic rod Check the oil level in the tra
38. slip from timber baulks Fig 2 5 Ground 2 7 3 4 Quality of ground The ground must be of a quality sufficient to ensure the stability of the machine and the distributor boom The outriggers exert a surface pressure up to 260 N cm 26 kg cm If the ground quality is insufficient to accept this the bearing area should be enlarged with two crossed layers of support plates See DIN 1054 for recommended values Premissible ground pressure Types of ground N cm kg m A Backfilled ground not artificially consolidated 0 10 0 1 Mature obviously undisturbed ground 1 Silt marsh topsoil Non cohesive sufficiently firm ground fine to medium sand Coarse sand to gravel Cohesive ground Mushy Soft Stiff Semi hard Hard Rock unweathered with little fissuring and in a good position 150 300 15 30 Fig 2 6 Premissible ground pressures for various types of ground THP 94 42 R 4 XXT THP 125 42 R 4 XXT 2 10 GB 07 2005 THP 140 H 42 R 4 XXT SAFETY INSTRUCTIONS AND INFORMATION CHAPTER 2 2 8 Safety instructions for remote control tx The remote control is active when the connecting cable is plugged into the machine tx When remote control is in operation the pendant must be put down unless the Emergency Stop button has been pressed To restart the machine also after rectifying a fault the Emergency Stop button must be released twist it in the directi
39. with 2 7 1 Set up location When selecting the set up location the following aspects should be considered rx Check the route to the set up location if necessary have someone guide the driver to the location t Keep a safe distance from obstacles such as site cranes buildings and equipment gt Check there is sufficient room to extend the outriggers rx Check there is sufficient room to deploy the distributor boom gt Check there is sufficient ventilation to clear the vehicle exhaust gases 2 7 2 Hazard area The hazard area is the area around the truck mounted concrete pump within which a person could encounter movements of the distributor boom the truck and the outriggers and thus be at risk DANGER BIN gt The is a risk of crushing when slewing and extending the outriggers and when extending the support cylinders gt The operator must continually monitor the hazard area tx The outriggers must not be extended when personnel are in their area of movement Interlock the outriggers hydraulically or mechanically THP 94 42 R 4 XXT THP 125 42 R 4 XXT 2 8 GB 07 2005 THP 140 H 42 R 4 XXT SAFETY INSTRUCTIONS AND INFORMATION CHAPTER 2 gt Press the Emergency Stop button immediately if anyone approaches the hazard area c Extending the outriggers on only one side may be performed only of the manufacturer has approved this after consideration of the stability of the arra
40. 1 Loading 32x ei ters e EE re dE edu o Rake me e bw 6 2 Starting up and operating 2 2000 ee 7 1 Personal safety equipment t raas ee ee 7 1 General information for operating the truck mounted concrete 7 2 Before staring UP la iat rete ee aha eae GS Beara eee 7 2 During operation ueri une aloe a ee REY qd e oe a bow ee ete bee aan 7 2 At the end of operations 5 anssi eee 7 2 Setting up the truck mounted concrete 7 3 Adjustments and actions before starting up 7 4 Changeover to transfer shift gearbox eee 7 4 Bue lee NEE 7 5 Selecting the operating 7 6 Operating the Hear ean eee 7 6 Stability checking 22s suem ee ne ne 7 7 Extending retracting the outriggers 7 7 Back up operatioli eea Aea cleus EEN 7 8 Functions at outrigger control block left 7 8 Functions at outrigger control block right 7 8 Building up the Outrigger IH er 7 9 Distributor boom operation 00 eee 7 10 Distributor boom operation using the master control 7 10 Back up slewing function 7 13 Controlling the dis
41. 2 2 18 4 Machine operator s responsibilities 2 22 2 19 Safety and warning notices rras d ewe E Lua Dru ee ek 2 23 3 Technical GALA Seed ee ete cele ae ae S Rea ecu ute ee de 3 1 3d Leading dimensions of the truck mounted concrete 3 1 3 2 lege EE 3 1 3 3 Distributor boom 42 R 4 XXT assum Sa a en RR RE RE Rex en ea 3 2 3 4 Concrete DUImp sa xenon ere a xr ac RON e ROC ace Eur neben 3 4 4 lares ET 4 1 4 1 Proper USE x or ERR ARTI ar Rost a Sox RR Ros BE operan 4 1 4 2 Structure and function of the concrete 4 2 4 2 1 Structure of the concrete pump 4 2 4 2 2 Function of the concrete pump 2m Hassan nennen 4 4 4 2 2 1 Distrib tor beem xo aem EROR RR Red nue anal rare 4 4 4 2 2 2 OUNOGG S 4 4 4 2 2 3 COMMON Rou Re ee ee 4 4 4 2 2 4 En Meel Net 4 4 4 2 2 5 Function of the concrete PUMP nme eee 4 5 4 2 2 6 Method of operation of the concrete pump 4 6 5 Controls and displays e cnt 2 2 aa RR A ae 5 1 5 1 Controls and displays for the truck mounted concrete 5 1 5 2 Control panel desk 5 2 5 3 Co
42. 2 2 Check transmitter battery charge Restart the radio remote control horn Change the frequency Use cable remote control instead Check solenoid and wiring Operate pre selector valve manually Seek advice from WAITZINGER customer service on this point Stop engine immediately and top up with hydraulic oil WARNING The boom cylinder must be bled Seek advice from WAITZINGER customer services on this point THP 94 42 R 4 XXT THP 125 42 R 4 XXT THP 140 H 42 R 4 XXT GB 07 2005 TROUBLE SHOOTING c CHAPTER 8 Fault Cause Remedy Dirt in the hydraulic system Change the filter and have WAITZINGER customer service clean out the entire system Nozzle in Load sensing pipe Have nozzle cleaned by closed from 42 m boom WAITZINGER customer service Set the switch Item 10 Fig 5 12 The boom will moves only The 50 100 switch is in the slowly 50 position to the 100 position Incorrect valves settings Have the settings checked by WAITZINGER customer service Incorrect gear or stage Engage the correct gear see engaged in the vehicle gearbox section 7 2 1 Check pressure setting at the Check pressure setting shown on boom block is too low the data sheet adjust as necessary Clean the pressure relief valve Seek advice WAITZINGER customer service on this point Hydraulic pump defective Have pump replaced by WAITZINGER customer servi
43. 4 XXT 9 34 GB 07 2005 THP 140 H 42 R 4 XXT MAINTENANCE amp INSPECTION A Charter 9 9 10 Changing the conveying pipework N CAUTION The maximum weight of the conveying pipework and the conveying elbows on the boom and the maximum pressure of 85 bar in the conveying pipework must be observed When the distributor boom is in the stowed position for transport it is not under stress elements can thus easily be exchanged when it is in this configuration If conveying pipes are replaced when the distributor boom is deployed stresses may be introduced during assembly CAUTION H A distance of 3 mm must be maintained between the flanges e Arrange the Matching pipe lengths Conveying pipes as shown in the safety notice in Figure 2 16 9 11 Crack checking on the steelwork CAUTION gt Cracks on the distributor boom on the boom mounting and the outriggers must be rectified immediately they are noticed To do this request the WAITZINGER repair guide without delay tr Repairs must only be performed by an authorised specialist company e Forcrack checking the machine must be clean Excess grease on the joints must be removed e Patches of rust and cracks in the paintwork can indicate underlying structural cracks e fthere is doubt have the steelwork checked by an authorised skilled operator using the Dye penetrant crack d
44. EMT 9 24 9 8 1 Measuring the wall thickness of the conveying pipework 9 24 9 8 2 Minimum wall thicknesses and conveying pipework operating 9 25 9 8 3 Adjusting the S valve 2 0 0 20 eee eee 9 26 9 8 4 Checking the chain tension on the 9 26 9 8 5 Checking the backlash in the slewing gearbox 9 27 9 8 6 Checking the boom backlash ball bearing slewing rim in the slewing gearbox 9 27 9 8 7 Checking the operation of the 5 9 28 9 9 Replacing Worn 9 29 9 9 1 Exchanging the wear plate and wear 9 29 THP 94 42 R 4 XXT THP 125 42 R 4 XXT THP 140 42 4 GB 07 2005 0 5 C Sat 9 9 2 Changing the conveying piston 9 30 9 9 3 Changing turning the conveying 9 32 9 9 4 Changing the agitator blades 9 33 9 9 5 Changing the agitator Sals EES AR REGE ek eee ER RE RUE Y 9 34 9 9 6 Changing the agitator wear sleeves 9 34 9 10 Changing the conveying pipework 9 35 9 11 Crack checking on the steel
45. HP 94 42 R 4 XXT THP 125 42 R 4 XXT 140 42 4 GB 07 2005 2 31 A SAFETY INSTRUCTIONS AND INFORMATION CHAPTER 2 50 45 40 35 30 25 20 ur u 9 250 9 250 9 250 10 200 7 fam 20 29m 30 38 m 35 45 40 35 30 25 20 15 10 5 0 5 10 15 20 25 Fig 2 33 Item 17 WAI105976 Distributor boom range THP 94 42 R 4 XXT THP 125 42 4 XXT 2 32 GB 07 2005 THP 140 H 42 R 4 XXT SAFETY INSTRUCTIONS AND INFORMATION CHAPTER 2 Waitzinger Baumaschinen GmbH Neu Ulm Germany max Rohrdurchmesser DN max pipe diameter Schalenkupplungen Modell m ssen mit Federstek model ker gesichert werden meinen max Betonduck bar mi masch No max concrete pressure e max L nge Endschlauch max length of endhose Baujahr year of construction Use safety pin with Dee snap coupling ee pice WAI 105942 WAI106769 Fig 2 34 Item 18 WAI105942 Spring plug Fig 2 35 Item 19 WAI106769 Distributor boom serial plate Kupplungen niemals bei unter Druck stehenden Leitungen ffnen Nur passende Originalkupplungen und Dichtungen verwenden Regelm ssig Rohrwanddicke pr fen Berstdruck der Rohre
46. Neu Ulm TT tsvorkehrungen vornehmen Nach dem Betrieb Leersaugen der F rderleitung Reinigen der F rderleitung mit Reinigungsball und Wasser Reinigen des Trichters und der kompletten Maschine Durchf hren von Wartungsarbeiten und Reparaturen die w hrend des Betriebes angefallen sind GA WAI 105933 Waitzinger Baumaschinen GmbH D 89231 Neu Ulm Fig 2 19 Item 3 WAI105933 WAI105932 General instructions GB D THP 94 42 R 4 XXT THP 125 42 R 4 XXT THP 140 H 42 R 4 XXT GB 07 2005 2 25 SAFETY INSTRUCTIONS AND INFORMATION CHAPTER 2 Waitzinger Baumaschinen GmbH D 89231 Neu Ulm Fig 2 20 Item 4 WAI105944 Safety equipment WAI 105944 Tod durch Stromschlag Mindestabstand von Hoch spannungsleitungen 5 Meter Electrocution hazard Stay back from high voltage wires at least 20 feet Waitzinger Baumaschinen GmbH D 89231 Neu Ulm WAI 105934 Fig 2 21 Item 5 WAI105934 High tension overhead electric cables 2 26 GB 07 2005 THP 94 42 R 4 XXT THP 125 42 R 4 XXT THP 140 H 42 R 4 XXT SAFE TY INSTRUCTIONS AND INFORMATION N CHAPTER 2 Abstand halten Ber hrung kann den Tod oder schwere Verletzungen herbeif hren falls die Maschine unter Strom steht Stay clear Contact will result in death or serious injury if the unit becomes electrically charged WAI 105974 Waitzinger Baumaschinen GmbH D 89231
47. P 140 H 42 R 4 XXT GB 07 2005 4 1 DESCRIPTION CHAPTER 4 4 2 Structure and function of the truck mounted concrete pump 4 2 1 Structure of the truck mounted concrete pump The truck mounted concrete pump comprises a concrete pump conveying unit mounted on a truck chassis The concrete pump conveying unit comprises the following major subassemblies 1 12 Vehicle left hand side 7 6 5 4 9 3 2 Vehicle right hand side 1 Catch hook 8 Outrigger control block right 2 Rear outrigger catches in transport position 9 Gearbox changeover valve 3 Water tank filling and drain cock 10 Boom control block 4 Outrigger control block left 11 Concrete pump control block 5 Telescope limit of travel catch front 12 Horn 6 Control 13 Control panel 7 Lubrication system 14 Control panel water pump agitator Fig 4 1 Main components of the truck mounted concrete pump sheet 1 THP 94 42 R 4 THP 125 42 R 4 XXT 4 2 GB 07 2005 THP 140 H 42 R 4 XXT DESCRIPTION CHAPTER 4 Joint Joint B Joint D 1 as 13 12 11 10 9 1 Pump group 8 Discharge hose 2 Boom block 9 Front outrigger cylinder 3 Slewing head 10 Front telescopic s
48. R 4 XXT THP 125 42 R 4 XXT 9 22 GB 07 2005 THP 140 H 42 R 4 XXT MAINTENANCE amp INSPECTION CHAPTER 9 K 3 Open the filler neck cap Item 3 Fig 9 13 4 Open the ball valve Item 2 Fig 9 12 and allow oil to drain into the container 5 Ifthe old oil is very dirty or has significant water content flush the oil tank with suitable flushing oil 6 Close the ball valve Item 2 Fig 9 12 and watch the oil emerging from the drain hole 7 Pour hydraulic oil into the hydraulic tank through the return flow filter element or pump it in using a pump with a fine filter Fig 9 13 011 filter neck N CAUTION Never pour hydraulic oil into the tank directly from the barrel without filtration 8 Keep feeding hydraulic oil until the maximum oil level 2 cm below the upper edge of the sight glass 9 Close the filler neck cap Item 3 Fig 9 13 or the return flow filter 10 Perform a trial run to check for leak tightness NOTE Before operating the hydrau lics first run the system at idling for 15 minutes Fig 9 14 Hydraulic oil tank sight glass THP 94 42 4 125 42 4 THP 140 H 42 R 4 XXT GB 07 2005 9 23 MAINTENANCE amp INSPECTION See CHAPTER 9 9 8 Performing tests 9 8 1 Measuring the wall thickness of the conveying pipework N DANGER TANGER r Only knock the conveying pipes apart and open them when t
49. STRUCTIONS AND INFORMATION CHAPTER 2 gt Work on or with the machine may be performed only by suitably instructed reliable personnel and or technical staff tx Before starting work it should be determined which personnel shall perform the necessary operating and maintenance work tx When operating the machine the legislation and regulations applicable at the place of use should be observed In the interests of safe working procedures the user supervision and equipment operator are responsible for complying with regulations c Before starting work all necessary functional checks should be performed on the machine gt Items not required in the immediate working process tools lubricants cleaning materials etc must be stowed only in their proper places since otherwise they may obstruct safe operation tx During cleaning work especially with solvents or petrol washes safety gloves and safety glasses must be worn No naked lights or smoking when cleaning is being performed Disposal of consumable materials to TA waste code 524 02 should be to EC directive 91 689 EWG gt Consumables such as lubricants cleaning materials during maintenance repair and oil change should be collected in suitable containers and disposed of in accordance with regulations to EC directive 75 439 EWG and statutory instruments under 5a 5b AbfG and Alt lV 2 6 Information on risks of injury Improper use of the truck mounted concrete
50. Setting up the truck mounted concrete pump Select the location having regard to the safety instructions in section 2 7 and drive the machine to the location NOTE Be sure to allow sufficient space for setting up truck mounted concrete pump Allow additional space for the mixer truck also Fully deployed outriggers right 0 6 m for outrigger plates Space requirement at the front 8 5 m 0 6 m 9 1 m i p d Space requirement at the rear 8 0 m 0 6 m 8 6 m A Slewing range 0 360 2 H SS Su Narrow outriggers one side 0 6 m for outrigger plates gt Space requirement at the front 6 1 m 0 6 m 6 7 m WA Space requirement at the rear 5 7 m 0 6 m 6 3 m Slewing range 0 200 oder 360 160 5 700 6 100 N CAUTION Narrow outriggers may only be used when controls are installed and in use Narrow outriggers on both sides 0 6 m for outrigger plates Space requirement at the front 3 7 m 0 6 m 4 3 m Space requirement at the rear 3 4 m 0 6 m 4 0 m EI Slewing range 160 200 3 700 3 400 CAUTION Narrow outriggers may only be used when controls are installed and in use Fig 7 2 Space requirement for outriggers for the truck mounted concrete pump On sloping ground put chocks behind t
51. ate 16 WAI106367 Crush hazard 2 WAI106032 Matching pipe lenghts Conveying pipes 17 WAI105976 Distributor boom range 3 WAI105932 General instructions GB 18 WAI105942 Spring plug WAI105933 General instructions D 19 WAI106769 Distributor boom serial plate 4 WAI105944 Safety equipment 20 WAI105935 Coupling pipe wall thickness 5 WAI105934 High tension overhead electric cables 21 WAI105936 Keep hands out of water box 6 WAI105974 Keep away 22 WAI105943 Desengage the clutch 7 5938 Remotely controlled machine 23 WAI106478 Safety instructions GB 8 WAI105937 is not a crane WAI106477 Safety instructions D 9 WAI105975 Total weight of discharge hose 24 WAI106348 Operating panel right hand outrigger 10 WAI105940 Slewing range of boom 25 WAI106349 Operating panel left hand outrigger 11 WAI105941 Extending the support feet 26 WAI106519 Operating panel dustributor boom 12 WAI105939 Do not reach into the hopper 27 WAI106030 Operating panel agitator 13 WAI106369 Grease point 28 WAI106031 Operating panel water pump 14 WAI106370 Fully extend the outrigger 29 WAI104770 supports 15 WAI106366 max inclination 3 Fig 2 16 Overview of safety and warning notices THP 94 42 R 4 XXT THP 125 42 R 4 XXT THP 140 H 42 R 4 XXT GB 07 2005 2 23 SAFE TY INSTRUCTIONS AND INFORMATION CHAPTER 2 Waitzinger Baumaschinen GmbH Neu Ulm Germany Modell Zul Gesamtgewicht kg Model Total weight perm kg Maschinen Nr Zul
52. ce Individual boom movements Solenoids in the boom control Have solenoids and wiring checked do not operate block defective or replaced WAITZINGER customer service Element A does not rise Sensor on the boom mount is Have sensor replaced by activated WAITZINGER customer service Slewing not operational Boom is at the limit of travel Slew it in the opposite direction Boom Slew limit switch or Have the limit switch or solenoid solenoid at the boom control replaced by WAITZINGER block defective from 42 m boom 9 727471627 The boom moves although no Dirt in the load retention valve Clean the load retention valve at no element is activated the boom cylinder Set the pressures to the data sheet values If necessary replace the valves Seek advice from WAITZINGER customer service on this point THP 94 42 R 4 XXT THP 125 42 R 4 XXT 8 6 GB 07 2005 THP 140 H 42 R 4 XXT TROUBLE SHOOTING 2 CHAPTER 8 Less Fault Cause Seal in boom cylinder worn Book cylinder distorted by excessive pressure Slew operation too slow or or does not move Pressure setting too low Machine inclination too great Ball bearing slewing rim insufficiently lubricated Slewing motor worn The boom slews although Slew not activated Brake in slewing drive worn Agitator does not operate Water pump does not operate Grill open Water pump also running Concrete t
53. ction 9 7 1 AX A Change the oil in the transfer shift gearbox see section 9 7 2 THP 94 42 R 4 XXT THP 125 42 R 4 XXT THP 140 H 42 R 4 XXT GB 07 2005 9 11 MAINTENANCE amp INSPECTION See CHAPTER 9 9 5 Lubrication 9 5 1 Central lubrication system Use only greases of NLGL classes 0 to 2 See documentation for the central lubrication system 9 5 1 1 Checking the central lubrication system The operation of the central lubrication system must be checked daily To do this all grease points should be lubricated once manually 1 Starting the lubrication system manually The ignition must be switched on and all Emergency Stop switches released Set the concrete pump to the setting Pump Actuate the lubrication system for approx 2 sec CAUTION CAUTION Check whether the rotor vane on the lubrication pump rotates and sufficient grease is fed in gt grease emerges from the safety valve no grease points are being lubricated This fault must be rectified immediately 2 Checking the grease points on the hopper Fig 9 2 At the bearings of the S valve no 2 and no 3 and agitator no 4 and no 5 grease must emerge into the hopper at S valve no 1 grease must emerge into the conveying pipe the flap elbow must be open 3 Checking the operation of the lubrication distributor After waiting no more than 4 minutes the control pin in the lubrication
54. danger to life and health of personnel Disregard of this information can lead to serious effects on health through to life threatening injuries and even death N WARNING This symbol indicates a possible danger to life and health of personnel Disregard of this information can lead to serious effects on health through to life threatening injuries N CAUTION This symbol indicates a situation that may possibly be dangerous Disregard of this information can lead to minor injuries or damage to property These symbols are placed in front of the text to which they refer in order to alert the operator to possible hazards before undertaking any activity on the machine equipment NOTE This symbol is used to draw the operator s attention to notes and specially useful information for technical requirements and handling the machine equipment These notes assist in making the best use of the functions of the machine equipment This symbol follows the text to which it relates THP 94 42 R 4 XXT THP 125 42 R 4 XXT THP 140 H 42 R 4 XXT GB 07 2005 2 3 SAFETY INSTRUCTIONS AND INFORMATION CHAPTER 2 2 3 Safety equipment r The safety equipment fitted to the whole system must be given particular attention rx The safety equipment must be continually checked for correct operation gt Safety equipment that operates on the basis of set values must not b
55. distributor must be seen to move in and out 4 Checking the lubrication pipes CAUTION Immediately replace any defective lubrication pipes THP 94 42 R 4 XXT THP 125 42 R 4 XXT 9 12 GB 07 2005 THP 140 H 42 R 4 XXT MAINTENANCE amp INSPECTION Charter 9 Check the lubrication pipes for damage and leak tightness All lubrication pipes must be securely connected 5 Checking the grease nipples for manual lubrication No grease must be leaking from the grease nipples Either replace the defective grease nipple and non return valve immediately or close it off 6 Lubricating manually CAUTION Before starting work check that grease is issuing at all grease points see point 2 If the central lubrication system is defective all grease points can be lubricated manually using a grease gun This should be performed no less frequently than every 2 hours of operation 7 Blocked grease points If no grease can be injected into a lubrication point this problem must be rectified as soon as possible by a WAITZINGER customer service fitter A o o o Control pin 6 Oscillation cylinder 7 Swing lever 5 Fig 9 2 Lubrication system THP 94 42 R 4 XXT THP 125 42 R 4 XXT THP 140 H 42 R 4 XXT GB 07 2005 9 13 CHAPTER 9 MAINTENANCE amp INSPECTION Qa 9 5 2 Manual lubrication An acid free multi purpose grease should be used for manual lubrication se
56. djusting screws 5 10 Water tank shut off valve 1 Ball valve Water tank filling emptying 2 Filling and emptying connection EY Fig 5 10 Water tank drain 94 42 4 XXT 125 42 4 5 8 GB 07 2005 THP 140 H 42 R 4 CONTROLS AND DISPLAYS CHAPTER 5 5 11 Water connection rear 1 Geka connection for water hose 2 Ball valve for retaining or draining the water up to the water pump 3 Ball valve fro filling wash out tank optional Fig 5 11 Water connection rear 5 12 Radio remote control cable remote control 14 13 12 11 40 9 8 7 6 1 Joystick Deploy and retract boom elements and D 8 Rocker switch Outrigger Boom 2 Joystick Deploy and retract boom element 9 Emergency Stop button selector switch Outrigger Boom Joystick Deploy retract and slew boom element A 10 Rocker switch Boom speed 50 1009 4 Push button Start engine 11 Rotary switch Stroke rate potentiometer 5 Push button Stop engine 12 Rocker switch Pump Suck 6 Push button Frequency changeover 13 Rocker switch Pump On Off 7 Rocker switch Engine speed 14 Push button Horn Reset Fig 5 12 Radio remote control Cable remote control THP 94 42 R 4 XXT THP 125 42 R 4 XXT THP 140 H 42 R 4 XXT GB 07 2005 5 9 CONTROLS AND DISPLAYS CHAPTER 5 5 13 Emergency Stop button Emergency Stop buttons are
57. e Figure 9 5 9 5 3 Sliding surfaces Use graphite grease for sliding surfaces see Figure 9 5 9 5 4 Overview of grease points a aaa 8 m i t Fig 9 3 Grease points overview 94 42 4 THP 125 42 4 XXT 9 14 GB 07 2005 THP 140 H 42 R 4 XXT MAINTENANCE amp INSPECTION Chapter 9 1 Schmiernippel 2 Schmiernippel 2 Schmiernippel gegen berliegend 2 2 Schmiernippel gegen berliegend 2 Schmiernippel auf der Innenseite 2 Schmiernippel auf der Innenseite gegen berliegend Q 2 2 Schmiernippel auf der Innenseite gegen berliegend Fl chenschmierung Fig 9 3 Grease points overview Boom control block THP 94 42 R 4 XXT THP 125 42 R 4 XXT THP 140 H 42 R 4 GB 07 2005 9 15 MAINTENANCE amp INSPECTION Qe CHAPTER 9 A 9 5 5 Reference tables for hydraulic oils greases and gear oils Lubricants suitable for the truck mounted concrete pump are listed in table below WAITZINGER Takes no responsibility for the quality of the lubricants that are listed nor for variations in their quality CAUTION Hydraulic oils with different characteristics biolog
58. e engine off and depressurise the system rz When climbing on to and off the machine use the handrails and the steps Keep steps platforms controls and regulation devices etc free of dirt oil snow and ice gt Whilst the machine is running never remove any guards e g water tank cover nor disable or bypass safety devices e g limit switches or mechanical catches for the grill interlocks Whilst the pump is running keep off the machine All operation should be by remote control only THP 94 42 R 4 XXT THP 125 42 R 4 XXT THP 140 H 42 R 4 XXT GB 07 2005 2 11 SAFETY INSTRUCTIONS AND INFORMATION CHAPTER 2 DANGER DANGER c Under the slewing area of the distributor boom there is a risk of injury due to falling parts c At the discharge hose there is a there is a risk of injury due to falling concrete c Unauthorised persons must leave the hazard area immediately If necessary stop the machine immediately 2 9 1 Distributor boom tx The operator must ensure that no unauthorised person is in the hazard area c The distributor boom should not be moved before the outriggers have been fully extended and all support cylinders correctly set The truck mounted concrete pump must not be driven with the distributor boom deployed gt Do not use the distributor boom as a crane jib or as a lever to push aside obstacles such as trees r The distributor boom should be not
59. e reprogrammed without expressed permission from WAITZINGER gt f the safety equipment is not operational or is malfunctioning the truck mounted concrete pump must not be used 2 4 Personal safety equipment In the entire working area of the truck mounted concrete pump suitable safety equipment should be worn particularly when handling mortar additives The symbols for the necessary safety equipment are shown in the graphics panel alongside The symbols shown are as follows Hard hat Safety boots Ear defenders Safety gloves Safety glasses Face mask Protective clothing Safety harness ONDARON Fig 2 1 Symbols for personal safety equipment 2 5 Ensuring safe working and safety The following safety regulations were taken into account when designing the truck mounted concrete pump gt pr EN 12001 Conveying spraying and distribution machines for concrete and mortar gt EN 292 Safety of machines equipment and systems gt EN 60204 1 Safety of machines electrical equipment for industrial machines gt EMC Electromagnetic compatibility Directive 89 336 EWG THP 94 42 R 4 XXT THP 125 42 R 4 XXT 2 4 GB 07 2005 THP 140 H 42 R 4 XXT SAFETY INSTRUCTIONS AND INFORMATION CHAPTER 2 The following instructions for ensuring health and safety at work must be observed by the user the supervisor and the operator of the equipment at all times VBG ZH1 653 H
60. ealth and safety when operating truck mounted concrete pumps VBG ZH1 573 In the German Federal Republic Directives for truck mounted concrete pumps and distributor booms BGR 182 Rules for handling truck mounted concrete pumps and distributor booms r VDM 24119 Graphical signs BGG Basic requirements selection and qualification of truck mounted concrete pump operators VDMA Safety Handbook VBG 1 General instructions VBG 4 Electrical systems and equipment VBG 5 Power operated equipment VBG 8 Winches hoists and drawgear VBG 9 Cranes VBG 9a Load bearing equipment for use as lifting gear VBG 12 Accident prevention regulations UVV for vehicles VBG 37 Accident prevention regulations UVV for building work gt VBG 109 First aid gt VBG 121 Noise gt VBG 125 Safety signage at the workplace gt EC directive 89 655 EWG Minimum machine instructions guidelines EC directive 98 37 Essential machine guidelines EC directive EN 60204 1 Electrical equipment of machines part 1 gt EG directive 73 23 Insulation of cables gt EG directive Electromagnetic compatibility EMC EG directive 92 58 Personal safety equipment EG directive 89 689 Waste disposal THP 94 42 R 4 XXT THP 125 42 R 4 XXT THP 140 H 42 R 4 XXT GB 07 2005 2 5 SAFETY IN
61. ection 4 Boom element A 11 Transfer shift gearbox 5 Boom element B 12 Rear outrigge 6 Boom element C 13 Rear outrigger cylinder 7 Boom element D Fig 4 2 Main components of the truck mounted concrete pump sheet 2 THP 94 42 R 4 XXT THP 125 42 R 4 XXT THP 140 H 42 R 4 XXT GB 07 2005 4 3 DESCRIPTION CHAPTER 4 4 2 2 Function of the truck mounted concrete pump The concrete is delivered into the hopper and is pumped by the concrete pump through the S valve and the conveying pipework to the discharge hose 4 2 2 1 Distributor boom All distributor boom functions are hydraulically actuated The conveying and riser pipes comprise pipes and pipe elbows Snap couplings allow the pipes to be joined together and the joints to be rotated 4 2 2 2 Outriggers The rear outriggers are swung out hydraulically The telescopic front outriggers are hydraulically swung out and extended The hydraulic support cylinders ensure the necessary stability of the truck mounted concrete pump The rear outriggers contain the water tanks with a capacity of 400 litres each 4 2 2 3 Control The controls actuate the hydraulic systems for the concrete pump and distributor boom The operator can use the controls either at the control panel or at the remote control pendant 4 2 2 4 Central lubrication The central lubrication system is operated by compressed air from the pressure accumulator on the vehicle chassis It supplies all lubrication poi
62. ee Ree PUR Ie 9 1 9 2 Safety instructions for maintenance and 9 1 9 2 1 Lubricants and solvents sssusa eana cro een ade a ee 9 2 9 2 2 Sealing rings containing 9 3 9 2 3 le Bel EE ea RE 9 3 THP 94 42 R 4 XXT THP 125 42 R 4 XXT 0 4 GB 07 2005 THP 140 H 42 R 4 XXT C A amr E 9 2 4 Paints varnishes and thinners 0 0 0 cee ee ee eee eee teens 9 4 9 2 5 Glues adhesives and solvents 9 4 9 2 6 Battery acid es gases ue bora te Dee UE e RENS eb eee ar 9 5 9 2 7 Safety precautions when charging 9 6 9 2 8 Safety instructions for welding work 9 6 9 3 Tightening torques for screw connections 9 7 9 4 Maintenance schedule 9 8 9 5 lubrication ir sues artes eI eher RLIEEG See ba Rex eas Pee eid Pade Fhe oe eee 9 12 9 5 1 Central lubrication System aaa an 9 12 9 5 1 1 Checking the central lubrication 9 12 1 Starting the lubrication system manually 9 12 2 Checking the grease points on the hopper Fig 9 2 9 12 3 Checking the operation
63. en cleaning the conveying pipes the discharge hose can swing out c The hazard area around the discharge hose has a diameter twice the length of the discharge hose c If anyone is within this hazard area stop the machine immediately and press the Emergency Stop button c If the discharge hose becomes snagged never use the distributor boom to pull it free This might put the stability of the machine at risk or overload the steel structure c The freely suspended discharge hose must not be extended with additional couplings discharge pieces or other hazardous discharge arrangements tx The discharge hose must not be extended beyond the length supplied by the manufacturer gt If the machine operator connects another discharge piece in place of the discharge hose this must not be guided manually gt The machine operator must use only the end hose approved by the manufacturer for delivering concrete into high places 2 9 3 1 Hazard area for the discharge hose gt When the pump is started or a blockage occurs the end hose must hang freely c There is an injury risk of being struck by the discharge hose or by stones shooting out of it Hazard area 2 x discharge hose length Fig 2 9 Hazard area for the discharge hose THP 94 42 R 4 THP 125 42 R 4 XXT 2 14 GB 07 2005 THP 140 H 42 R 4 XXT A 2 9 3 2 Kinks in the discharge hose e Never kink the discharge hose whilst the pump
64. ent D at 90 to boom element B e Position boom element D horizontally approx 1 m above the ground e Open the discharge hose retainer arrowed and release the discharge hose e Use the control levers Items 5 to 9 Fig 7 11 on the boom control block to move the distributor boom into the desired working position STARTING UP AND OPERATING CHAPTER 7 Fig 7 17 Release the discharge hose Fig 7 16 Deploy boom element D WARNING WARNUNG When using manual control at the boom control block all safety circuits including Emergency Stop are disabled 7 4 1 1 Back up slewing function If the controls system fails slewing the boom must be enabled by engaging the additional back up controls Item X Fig 7 11 by inserting a suitable screwdriver 4 mm into the holes in the cover and pushing THP 94 42 R 4 XXT THP 125 42 R 4 XXT THP 140 H 42 R 4 XXT GB 07 2005 7 13 7 4 2 Controlling the distributor boom using f STARTING UP AND OPERATING CHAPTER 7 the radio remote control pendant Set the operating mode selection switch Item 14 Fig 7 6 to Remote control Activate the remote control pendant See information in the separate user manual supplied by the manufacturer Release the Emergency Stop by pressing the Horn Reset 14 The horn will sound Switch the selector switch Outrigger Boom 8 to Boo
65. er and all the parts that come in contact with the material with the spray hose also Push 2 or 3 cleaning sponges soaked with water into n s the cleaning port and the seal the cleaning port tightly Fig 7 34 Cleaning with water hose THP 94 42 R 4 XXT THP 125 42 R 4 XXT THP 140 H 42 R 4 XXT GB 07 2005 7 29 STARTING UP AND OPERATING CHAPTER 7 e Close the cleaning valve and fill the hopper with water e Switch the pump on again in Suck mode Push the material in the conveying pipework forwards to the discharge If a single filling of the hopper is insufficient for a long pipe run switch the pump off before air is drawn in and fill the hopper again with water Then continue with the discharge of the material until the cleaning sponges emerge from the discharge hose e Take care that the water flowing from the discharge hose does not flow into the formwork Fig 7 35 Cleaning with sponges e Suck the water back into the hopper by reversing the pump e fthe protective grill has a safety cut out agitator and S valve come to a halt as soon as the protective grill is opened When cleaning briefly shut the protective grill let the pump run through one cycle open the protective grill again A protective grill that is bolted in position remains in position throughout cleaning e Remove the remaining water by opening the cleaning valve Carefully spray the S valve hopper conve
66. ermo electric cutout is located in the hydraulic oil tank Fig 7 32 Control panel desk 7 7 Cleaning the conveying pipework 7 7 1 General e Do not use any aggressive cleaning additives for cleaning the conveying pipework e Put the remote control pendants in a dry place e Follow the directions of the vehicle manufacturer e Dispose of the cleaning materials according to regulations 7 7 2 Suction cleaning e Pump out the agitator hopper down to the upper edge of the agitator shaft then switch the pump off J e Push a wetted cleaning sponge cube into the outlet of the discharge hose ED sone age E ER ER W s e Pull the cleaning sponge back through the boom by operating the pump in reverse feed strike the conveying pipework with light hammer blows until the cleaning sponge has passed that point the hollow ring is recognisable RR Banna TM ee Fig 7 33 cleaning sponge in suction cleaning THP 94 42 R 4 XXT THP 125 42 R 4 XXT 7 28 GB 07 2005 THP 140 H 42 R 4 XXT STARTING UP AND OPERATING f CHAPTER 7 Switch off the pump Open the hinged base and retrieve the sponge On long conveying pipework runs repeat the cleaning process One back suction run is not enough If the protective grill has a safety cut out agitator and S valve come to a halt as soon as the protective grill is opened When cleaning briefly shut the p
67. es must not be altered or removed f failures or malfunctions occur stop operation and repair immediately eep hands off from turning or moving machine parts f something happens to hinder the safe operation of this machine halt use until corrected This machinery is remote controlled and may start at any time Stand clear f vision is obscured an assistant is required Ensure stability of unit when in doubt of ground condition use extra EISE blocking under outrigger legs Operate unit on level ground durch ausgebildete und aintain safe distance from Slopes could break away ner mu das Bedienungs Do not drive with an unfolded placing boom or unretracted outriggers ein Engage outrigger transport looking device before moving this machine deckt oder entfernt werden No structural extension or additional hose should added to the boom tip oder entfernt werden selection One tip hose 10 15 feet allowed unsupported Additional hose arden and or line system require proper support of boom structure Do not use boom structure as crane hoist or for lifting work Use of the placing boom as a hoist is strictly prohibited Minimum distance to any electrical wires Voltage Volt minimum safety distance m up to 1000 V nen over 1 kV to 380 kV or at itet sein Je nach Untergrund unknown voltage and during alken unterbaut werden high humidity Boom should be folded retracted upon competit
68. etection method THP 94 42 R 4 XXT THP 125 42 R 4 XXT THP 140 H 42 R 4 XXT GB 07 2005 9 35 MAINTENANCE amp INSPECTION See CHAPTER 9 9 12 Checking the hoses DANGER TANGER A hg splits suddenly under pressure personnel can be seriously WAITZINGER takes no responsibility for damages that result from the use of worn or defective components Regular checking of hoses is part of the technical safety checks to be performed on the machine Do not repair damaged hydraulic or conveying pipes instead replace them immediately Damaged or weeping hydraulic hoses must also be replaced immediately All hydraulic hoses must be renewed after a life of 6 years including a shelf life of 2 years even if they exhibit no evident damage The period of time can be calculated from the identification mark on the connection fitting date of manufacture of the hose 9 13 Cleaning the machine e f the truck mounted concrete pump is to be moved to another location for cleaning move all parts of the machine to their transport positions e The truck mounted concrete pump must not be driven with the distributor boom deployed or the outriggers extended even for short distances DANGER No highly flammable materials e g petrol may be used for cleaning c Never direct a water jet or steam jet towards electrical components this can occasion a flashover with fatal consequences e Protect elec
69. fitted to the truck mounted concrete pump at the following places c Control panel desk c Outrigger control block right c Boom control block c Radio remote control c Outrigger control block left c Cable remote control 5 14 Control elements on the hydraulic block Fig 5 13 Emergency Stop button 1 Valve Y5b 5 Valve Y5a 2 Push button 6 Valve Y4a 3 Valve Y3 7 Valve Y4b 4 Pressure sensor z gt BZ Wim Fig 5 14 Hydraulic block 5 10 GB 07 2005 THP 94 42 R 4 XXT THP 125 42 R 4 XXT THP 140 H 42 R 4 XXT Driving TOWING LOADING A CHAPTER 6 6 Driving towing loading 6 1 Driving DANGER TANGER 1 The centre of gravity of the truck mounted concrete pump is very high due to the nature of the design Take extreme care when negotiating curves The truck mounted concrete pump may be driven on public roads only in accordance with the applicable legislation and regulations of the country concerned The driver must have a valid driving licence for this truck mounted concrete pump 6 1 1 Before a journey The following actions must be taken before a journey e take all actions as described in the vehicle manufacturer s user manual e check all components and transport restraints on the truck mounted concrete pump to ensure they are in good condition e check the outrigger catches to ensure they are properly engaged e check that all components
70. g NOTE The controls must be reset after an Emergency Stop by pressing the Horn Reset rocker switch Item 6 Fig 5 2 on the control panel desk All functions that were in operation when the Emergency Stop button was pressed must be restarted THP 94 42 R 4 XXT THP 125 42 R 4 XXT THP 140 H 42 R 4 XXT GB 07 2005 7 5 STARTING UP AND OPERATING CHAPTER 7 When the Emergency Stop button is pressed the following conditions are set on the truck mounted concrete pump e Truck Engine is switched to idling or optionally switched off e Truck mounted concrete pump Pumping sucking is immediately switched off Distributor boom The distributor boom is halted at its current position 7 2 3 Selecting the operating mode The control panel is at the right rear of the vehicle The functions on the control panel desk Pump Suck 11 and Stroke rate 13 are disabled if the remote control is activated The key switch 14 allows switching between Control Desk and Remote control If the cable for remote control is plugged in remote control is activated automatically In the setting Remote control the respective remote control pendant must be switched on otherwise the controls are switched off in an Emergency Stop Fig 7 6 Selecting the operating mode NOTE The key should be withdrawn when the machine is in operation so that no unauthorised person can tamper with the
71. gen ansonsten erlischt der Garantieanspruch WAI 106477 Waitzinger Baumaschinen GmbH D 89231 Neu Ulm Fig 2 39 Item 23 WAI106477 WAI106478 Safety instructions GB D THP 94 42 R 4 XXT THP 125 42 R 4 XXT THP 140 H 42 R 4 XXT GB 07 2005 2 35 CHAPTER 2 A SAFETY INSTRUCTIONS AND INFORMATION Fig 2 40 Item 24 WAI106348 Operating panel right hand outrigger WAI106349 Fig 2 41 Item 25 WAI106349 Operating panel left hand outrigger ON IA Fig 2 42 Item 26 WAI106519 Operating panel distributor boom WAI106519 94 42 4 XXT 125 42 4 2 36 GB 07 2005 THP 140 H 42 R 4 XXT SAFETY INSTRUCTIONS AND INFORMATION A A CHAPTER 2 WAI106030 WAI106031 Fig 2 43 Item 27 WAI106030 Operating panel agitator Fig 2 44 Item 28 WAI106031 Operating panel water pump Fig 2 45 Item 29 WAI104770 Operating panel supports THP 94 42 R 4 XXT THP 125 42 R 4 XXT 140 42 4 GB 07 2005 2 37 TECHNICAL DATA CHAPTER 3 3 Technical data 3 1 Leading dimensions of the truck mounted concrete pump Vehicle dimensions approx 13 070 mm x 2 500 mm x 3 980 mm Length x Width x Height Weight approx 31 900 kg in full working order 6 100
72. gers are released Injuries due to opening the conveying pipes when they are under pressure due to a blockage gt Injuries due to reaching into the agitator hopper or falling into it gt Injuries due to slipping from or on the oily and slippery walkways on the machine Injuries during pumping operations due to reaching into the water tank at the same time as the piston is in motion Amputation of the hand if the arm is trapped in the S valve when cleaning with the flap elbow open gt Injuries due to tripping over cables hoses or reinforcing rods Injuries due to being caught in the mixing hopper or its parts chute gt Injuries due to unsecured conveying pipes slipping down or falling down gt Risk of crushing at the complete outriggers Injuries due to unintended movement of the distributor boom following inadvertent operation of the controls THP 94 42 R 4 XXT THP 125 42 R 4 XXT THP 140 H 42 R 4 XXT GB 07 2005 2 7 SAFETY INSTRUCTIONS AND INFORMATION CHAPTER 2 2 7 Safety information for setting up DANGER gt The distributor boom should not be moved before all the outriggers have been fully extended and all support cylinders correctly set c The truck mounted concrete pump must be driven with the distributor boom deployed gt The safety regulations for the country in which the truck mounted concrete pump is being operated must be complied
73. hapter 2 Safety Instructions 94 42 4 XXT 125 42 4 9 6 GB 07 2005 THP 140 H 42 R 4 XXT MAINTENANCE amp INSPECTION Chapter 9 A 9 3 Tightening torques for screw connections The following values apply to tightening torques for machine screws to DIN 912 931 and 934 based on a friction factor of u 1 25 lightly oiled Thread Tightening torque Mo Nm Tightening torque Mo Nm 8 8 10 9 M8 23 32 M10 46 64 M12 80 110 M14 125 180 M16 195 275 M18 270 390 M20 385 540 M22 510 720 M24 660 930 M27 980 1 400 Fig 9 1 Tightening torque for screw connections THP 94 42 R 4 XXT THP 125 42 R 4 XXT THP 140 H 42 R 4 XXT GB 07 2005 9 7 MAINTENANCE amp INSPECTION Gem CHAPTER 9 9 4 Maintenance schedule Certain maintenance work must be carried out on the machine at specified intervals These intervals are expressed either as numbers of operating hours or as periods of time such as semi annually or annually whichever interval is reached earlier Before performing the work for any maintenance interval the maintenance work for all previous maintenance intervals must have been completed Maintenance work Maintenance intervals s s 52 gt Ch S SS ri PSI 85 gt gt Po Pe Check all components for wear deformatio
74. he wheels release the brakes and allow the truck mounted concrete pump to roll back on to the chocks Then apply the handbrake and extend the outriggers The ground must be checked for its load bearing capability THP 94 42 R 4 XXT THP 125 42 R 4 XXT THP 140 H 42 R 4 XXT GB 07 2005 7 3 f STARTING UP AND OPERATING CHAPTER 7 7 2 Adjustments and actions before starting up 7 2 1 Changing over the transfer shift gearbox Use the key switch 2 in the cab to change over the transfer shift gearbox in the drive train from travel drive O to pump drive I For the changeover the ignition switch must be in the ON position vehicle engine can run but need not be running the pneumatic pressure must be more than 5 bar and the clutch fully disengaged The indicator lamp 1 lights up when the gearbox is switched to pump drive Fig 7 3 Changing over the transfer shift gearbox To drive the hydraulics a definite gear must be selected as shown in the information plate Example 8 high Kupplung betatigen Schalter auf I stellen Gang einlegen und Kupplung l sen Press the clutch Set switch to 1 Shift gear and release clutch Fan 5 WAI 105943 Waitzinger Baumaschinen Vertrieb und Service GmbH D 89231 Neu Ulm Fig 7 4 Selecting a gear WARNING gt Selecting the wrong gear can lead to overspeeding and damage to the hydraulic pumps
75. hey have been depressurised Always pump backwards 1 2 piston strokes e Check the wear condition of the conveying pipework by knocking it or better by using a wall thickness gauge Replace worn parts e e e e The wallthickness can also be measured using a special e3 Z wall thickness gauge Br Fig 9 15 Measuring the wall thickness of the conveying pipework THP 94 42 R 4 XXT THP 125 42 R 4 XXT 9 24 GB 07 2005 THP 140 H 42 R 4 XXT MAINTENANCE amp INSPECTION A Charter 9 9 8 2 Minimum wall thicknesses and conveying pipework operating pressures Always comply with the maximum pipe weight of the conveying pipework Unless stated otherwise on the serial plate Pipe 12 8 kg m Elbows Y Concrete pressure in bar X Minimum wall thickness in mm to DIN 2413 part 3 DN Nominal diameter Conveying pipework designation Standard size Maximum pressure Code YA 200 190 180 170 160 150 S 1 140 ay ES S S 3 130 S I 5 S 120 SS WAS 5 110 SKS o AS 9 100 gt E d 2 9 90 S o S s O 70 60 50 40 30 20 10 X 0 0 1 2 3 36 4 5 6 Y 8 Minimum wall thic
76. ically degradable mineral based hydraulic oils must on no account be mixed Engine oil data can be found in the separate user manual issued by the vehicle manufacturer Standard Tropic HLP 46 HLP 100 Arnica 46 L HV 46 Blasia S 220 Vitam CF 46 Vitam CF 100 Energol HLP 46 Energol HL P10 Olna 46 Olna 100 Nuto H 46 Nuto H 100 Salvo MWS 46 Salvo MWS 100 Renolin B 15 Renolin B 30 DTE 25 DTE 27 Tellus I 46 Tellus l 100 Fig 9 4 Hydraulic oils reference table THP 94 42 R 4 THP 125 42 R 4 XXT 9 16 GB 07 2005 THP 140 H 42 R 4 XXT MAINTENANCE amp INSPECTION Chapter 9 The automatic lubrication system can convey greases only up to NLGI class 2 or mineral oils which have at least 40 5 CST at 40 C IMPORTANT When handling greases be scrupulous about cleanliness Contaminants remain in suspension in the grease they do not settle out They can lead to blockages in the delivery pipes causing damage to bearings vesignaton Type of saponification Min conveying temperature F1 Grease 24 Mehrzweckfett ZS 1 2 Top 2000 Top 8000 W Abschmierfett C1 Abschmierfett CASTROL CLS Grease Cazar K2 BP ESSO High pressure grease FIAT LUBRIFICANTI Comar2 Ceran LT Ceran WR2 FN 745 Renocal FN3 Renolit HLT 2 FINA
77. ically to their full extent e The outriggers are secured in the stowed position for vehicle travel by hydraulically locked catches WARNING Before moving the vehicle and before starting work make absolutely sure that the hydraulically locked catches are engaged THP 94 42 R 4 XXT THP 125 42 R 4 XXT THP 140 H 42 R 4 XXT GB 07 2005 7 7 STARTING UP AND OPERATING CHAPTER 7 A NOTE If the operating mode selector switch Item 14 Fig 5 2 is in the remote control position the remote control must be switched from the Boom control mode to the Outrigger control mode using rocker switch Item 8 Fig 5 12 7 3 2 1 Back up operation If the control system fails the outriggers can be operated manually from the master control block To do this a send person must stand at the Outrigger Boom control panel and hold the control lever Item 4 Fig 7 11 in the UP position 7 3 3 Functions at outrigger control block left Move the operating lever as shown to perform the respective functions on the outrigger Circular level Emergency Stop button Outrigger safety button Extending retracting the rear outrigger cylinder Slewing the rear outrigger cylinder out in Slewing the front outrigger cylinder out in Extending retracting the front telescopic outrigger 8 7 6 5 4 Extending retracting the front outrigger cylinder D JO Om P o 7 3 4 Functions at outrigger contr
78. ictional resistance is greater so make sure you pump sufficient laitance through e Fill the hopper with concrete from the silo or the mixer truck and keep pumping with the concrete pump NOTE If the pipework is rusted on the inside high conveying resistance do not increase the conveying quantity until you have pumped several m continuously Fig 7 29 Conveying quantity diagram THP 94 42 R 4 XXT THP 125 42 4 XXT 7 24 GB 07 2005 THP 140 H 42 R 4 XXT STARTING UP AND OPERATING f CHAPTER 7 e f a blockage occurs immediately pump the concrete back into the hopper and mix it Only switch over to forward conveying when the conveying cylinder and transfer tube are correctly switching over automatically Carefully start pumping through again 7 6 1 1 Causes of blockages Laitance too thin or with insufficient cement e Insufficient laitance used e S valve leaking wear plate worn and ring too large replace the parts e Leaking pipework concrete bleeds out e Set concrete residues in the transfer tube or conveying pipes e Unsuitable concrete composition 7 6 2 General instructions for pumping e Whilst pumping be sure not to draw any air in since compressed air can emerge violently at the discharge hose causing concrete to spray out Therefore keep the hopper filled at least up to the level of the agitator shaft e When pumping keep the agitator running e Avoid long pauses du
79. ig 7 22 off and on again 7 5 4 Back up function for Pump Suck NOTE This function should only be switched on if the normal Pump Suck controls are not operational 7 5 4 1 Pumping with the control panel desk or via radio remote control cable remote control e Set the Back up Pump control selector switch Item 2 Fig 5 7 to position A or If the pump does not start see trouble shooting back up operation may be necessary in two possible fault situations THP 94 42 R 4 XXT THP 125 42 R 4 XXT THP 140 H 42 R 4 XXT GB 07 2005 7 17 STARTING UP AND OPERATING CHAPTER 7 Fault possibility 1 Defective sensors in the drive cylinder or oscillation cylinder e Set the Back up Pump control selector switch Item 2 Fig 5 7 to position e Set the pressure switch Item 2 Fig 7 23 to the anticipated pumping pressure min 60 bar max 280 bar e Set the key switch Item 14 Fig 7 21 to position Desk or Remote Control e Switch on the Pump Suck function using rocker switch Item 11 Fig 7 6 or rocker switch Item 13 Fig 7 22 NOTE r If the pressure at the pressure switch is set too low the stroke will be short and the S valve may not swing over fully r If the pressure at the pressure switch is set too high the pump can stop at the end of its travel Fault possibility 2 Controller failure e Set the Back up Pump control selector switch Item
80. ion of work and during high wind conditions In storm conditions put boom in folded travel position Before opening any area of concrete pipeline depressurize system by reverse pumping Then be cautious when opening couplings le werden k nnen mu r stet und kann jederzeit en einhalten und Hohlr ume silermast bzw iusschwenken gesichert sein Only trained personnel should clean conveying pipeline with compressed hla chesistverboteri air and water A ball catcher or trap basket must be used at the discharge end Always wear approved safely helmet working around concrete pump unit Full protective safely goggles to eliminate eye burns and damage are helpful Check machine once a year and document in checkbook otherwise guaranty will expire verwendet werden stand m WAI 106478 Waitzinger Baumaschinen GmbH D 89231 Neu Ulm EES TE 15 Bei Sturm und nach Beendigung der Arbeit Maschine in Aufser Betrieb Stellung bringen 16 Bei Arbeiten an der F rderleitung mu sichergestellt werden da das System drucklos ist 7 Nur Fachpersonal sollte die F rderleitung mit Wasser bzw Druckluft reinigen Auffangkorb f r Reinigungsball mu montiert sein Endschlauch entfernen 8 Schutzhelm Schutzbrille und Schutzkleidung m ssen getragen werden 9 Die Maschine ist mindestens einmal j hrlich durch einen Sachkundigen zu pr fen und im Pr fbuch einzutra
81. ities require safety distances greater than those listed Refer to the regulations for the country where the machine is in use THP 94 42 R 4 XXT THP 125 42 R 4 XXT 2 18 GB 07 2005 THP 140 H 42 R 4 XXT SAFETY INSTRUCTIONS AND INFORMATION CHAPTER 2 c If the minimum distance cannot be maintained for all possible working positions it is essential to contact the electricity supply company It may be necessary to forgo the use of the distributor boom altogether and use a separate conveyor pipe 2 12 2 High tension contacts High tension contacts bring the risk of fatal injury for all persons who are on the machine and in its vicinity or are in any way connected to it remote control discharge hose etc High tension contacts form a Voltage funnel underneath the equipment and in a circle around it The voltage decreases as the radius increases Every step within the voltage funnel is hazardous A step can span two different potentials step voltage so that the current flows through the body in proportion to the potential difference f a high tension contact occurs keep calm stand still step voltage and don t touch anything No one else should enter the hazard area Immediately have the high tension cable switched off AN After the high tension cable has been switched off move the machine away help the injured and perform first aid 15 000 V 10 000 V gt Using re
82. kness mm Fig 9 16 Minimum wall thickness diagram THP 94 42 R 4 XXT THP 125 42 R 4 XXT THP 140 H 42 R 4 XXT GB 07 2005 9 25 MAINTENANCE amp INSPECTION Se CHAPTER 9 9 8 3 Adjusting the S valve Perform the following steps to adjust the S valve 1 Remove the locking plate 1 from the swing lever 2 Tighten the screw 2 to approx 100 Nm then back off by 30 3 Refit the locking plate 4 Perform a trial run of the concrete pump Fig 9 17 Adjusting the S valve 9 8 4 Checking the chain tension on the outrigger feet When the chain tension is correctly set the chin should sag no more than 30 mm If the chain tension reduces it must be tightened To do this proceed as follows e Use the adjustment nut 1 to tighten the chain until the correct sag of 30 mm is achieved Fig 9 18 Checking the chain tension 94 42 R 4 XXT THP 125 42 4 XXT 9 26 GB 07 2005 THP 140 H 42 R 4 MAINTENANCE amp INSPECTION A Charter 9 9 8 5 Checking the backlash in the slewing gearbox The backlash is checked as follows 1 Remove the pinion gear cover min 0 1 mm S max 0 5 mm 2 With the boom in the horizontal position slew it slightly until a tooth is engaged without play 3 Insert a feeler gauge to measure the engagement clearance as shown in the adjoining diagram 4 If the backlash is excessive the gearbox and the ball
83. m and uncap the Emergency Stop button The 50 100 switch 10 controls the boom speed 5096 when pumping 10096 when deploying stowing Fig 7 18 Controll the distrib boom from the radio remote control pendant Press the master switch Deploy boom element A Slew boom 3 and deploy boom element A until the catch hook releases and the boom element B can be deployed see Fig 7 12 Press the master switch Deploy boom element A Slew boom 3 to move the distributor boom into the position where the discharge hose retainer can be opened Press the master switch Deploy boom element B 2 and deploy boom element B until it is approx 120 to boom element A see Fig 7 14 Use the joystick Deploy boom element C and D 1 to deploy boom element C to 90 to boom element B see Fig 7 15 Use the joystick Deploy boom element C and D 1 to deploy boom element D to 90 to boom element C see Fig 7 15 Position boom element D horizontally approx 1 m above the ground Open the catch and release the discharge hose see Fig 7 17 Use the joystick s 1 to 3 on the radio remote control to move the distributor boom to the desired working position THP 94 42 R 4 XXT THP 125 42 R 4 XXT 7 14 GB 07 2005 THP 140 H 42 R 4 XXT 7 4 3 Controlling the distributor STARTING UP AND OPERATING f CHAPTER 7 boom using the cable remote control pendant Remove the right hand protective cap Unpl
84. me element 4 up down 235 sec 51 Rotate left right 370 sec 160 THP 94 42 R 4 XXT THP 125 42 R 4 XXT 3 2 GB 07 2005 THP 140 H 42 R 4 XXT TECHNICAL DATA CHAPTER 3 50 45 40 35 30 25 20 15 10 0 5 d Ce 10 20 z WV 29m 30 438m 45 40 35 30 25 20 15 10 5 0 5 10 15 20 25 Fig 3 2 Diagram of ranges THP 94 42 R 4 XXT THP 125 42 R 4 XXT THP 140 H 42 R 4 XXT GB 07 2005 3 3 TECHNICAL DATA CHAPTER 3 A 3 4 Concrete pump 94 42 R4 XXT 125 42 R 4 140 42 R 4 XXT Max concrete output rod side m h 94 125 140 Max concrete output piston side m h 57 75 96 Max concrete pressure rod side bar 75 55 80 Max concrete pressure piston side bar 125 95 119 Pump cycles min rod side 25 25 28 Pump cycles min piston side 15 15 19 Conveying cylinder D inner X stroke mm 200 x 2 000 230 x 2 000 230 x 2 000 Stroke volume double stroke litre 125 166 166 Hydraulic drive cylinder D piston D roa X Stroke mm 125 80 x 2 000 125 80 x 2 000 140 80 x 2 000 Oil tank volume litre 600 600 600 Water tank volume litre 600 600 600 Hopper capacity litre 600 600 600 Water pump pressure bar 20 20 20 Max hydraulic pressure concrete
85. mote control protects the machine operator only if he is standing outside the voltage funnel 5 000 V In all other cases all personnel risk fatal injury Fig 2 15 Step voltage gt When working close to high tension overhead cables have these switched off by competent electricians 2 12 2 1 Automatic reconnection c Electrical supply systems are equipped with automatic reconnection c After the switchgear has tripped the short circuited cable is automatically reconnected after a brief interval gt It is therefore necessary to arrange permanent disconnection THP 94 42 R 4 XXT THP 125 42 R 4 XXT THP 140 H 42 R 4 XXT GB 07 2005 2 19 SAFETY INSTRUCTIONS AND INFORMATION CHAPTER 2 2 12 3 Static discharge tx At close range to transmitting stations there can arise interference to radio and TV transmissions and hazardous static electrical discharges from the machine gt Persons touching a statically charged machine will receive an electric shock gt Machines close to transmitting stations should be earthed Connect the earthing cable to a clean unpainted metal part of the machine and anchor it in the ground with a conductive metal rod 2 12 4 Immediate measures c If an accident involving electric power occurs immediately institute first aid measures c If despite all precautions a high tension cable contact occurs keep calm stand still step voltage and don t touch anything tx Tell those
86. n corrosion and secure mounting x Check oil fuel grease and water levels top up as necessary The machine must be x standing on level ground at this time Check all filter clogging indicators x Check components that come in contact with concrete replace worn parts x Check the wear condition of the conveying pipework by knocking it or by using a wall thickness gauge see section 9 8 and replace worn parts The minimum wall thicknesses p lt can be found in the diagram in section 9 8 2 Check lubrication system for operation Ke Lubricate the conveying piston with grease unless the automatic piston lubrication option is x fitted Visually check all hydraulic lines and screwed joints for leak tightness x THP 94 42 R 4 XXT THP 125 42 R 4 XXT 9 8 GB 07 2005 THP 140 H 42 R 4 XXT MAINTENANCE amp INSPECTION Charter 9 Maintenance work Maintenance intervals gt o P 5 E 5 8 2 Ss u gt ee os 5 Ee 2 2 CP a gt gt 0 m ER 5 o 85 Sess zn us x Check the attachment of the discharge hose and the security of all snap couplings Perform all necessary maintenance work on the truck in accordance with the separate user manual supplied by the manufacturer Clean all filters and replace as necessary see section 9 6 Check all screw connections against the tightening torque table in section 9 3 Check the
87. n for setting UP 6 nenn 2 8 2 7 1 Set Up location iie sa NR ea er EE Pa Ow ea eee 2 8 2 7 2 Hazard alea eg cee eee EE CHE a a na en 2 8 2 7 3 SIDE EE 2 9 2 7 3 1 EE TEE 2 9 2 7 3 2 Safety distances to the edges of excavation 2 9 2 7 3 3 Underground euet tr Peed Merwin Rha ade bebe re bes eee ainda 2 10 2 7 3 4 Quality Of Ground ai scs woe See eed ee ae eee 2 10 2 8 Safety instructions for remote 2 11 2 9 Safety instructions for the working 2 11 2 9 1 Distributor DOOM UDINE tiec 2 12 2 9 2 5 aes ze nn dee E ERA MUERE Fauna 2 12 2 9 2 1 Locking the conveying pipe lt 5 2 13 2 9 2 2 Opening the conveying pipe connections 2 13 2 9 3 Discharge hose cg ssa epe ne EN ae ehe 2 14 2 9 3 1 Hazard area for the discharge hose 2 14 2 9 3 2 Kinks in the discharge hose 2 15 2 9 3 3 Use the guide rod to hold the discharge hose 2 15 2 9 3 4 Securing the discharge hose with the
88. n for the operator to safety start up and operate the truck mounted concrete pump WARNING WARNING Before first starting up the truck mounted concrete pump the operator must carefully read through this Chapter 7 Starting up and operating and perform all checks in accordance with the information set out in this chapter Only when the operating safety has been assured in this way may the truck mounted concrete pump be started up NOTE During start up and operation comply with the safety instructions set out in Chapter 2 a Personal safety equipment In the entire working area of the truck mounted concrete pump suitable safety equipment should be worn particularly when handling mortar additives The symbols for the necessary safety equipment are shown in the graphics panel alongside The symbols shown are as follows Hard hat Safety boots Ear defenders Safety gloves Safety glasses Face mask Protective clothing Safety harness Fig 7 1 Symbols for personal safety equipment 94 42 4 THP 125 42 R 4 XXT THP 140 H 42 R 4 XXT GB 07 2005 7 1 STARTING UP AND OPERATING CHAPTER 7 A b General information for operating the truck mounted concrete pump The operator must be familiar with and comply with the user manual and all safety measures for operating the truck mounted concrete pump He must be able to control the machine b 1 Before
89. ncrete see section 7 6 3 THP 94 42 R 4 XXT THP 125 42 4 THP 140 42 R 4 GB 07 2005 TROUBLE SHOOTING CHAPTER 8 Fault Cause Incorrect settings in the controls S valve stiff Remedy Have the settings checked by WAITZINGER customer service Check S valve settings check wear plate and ring for heavy wear or fracture and check the S valve bearings Concrete pump short strokes Back up function B switched on Piston rings in drive cylinder worn Outrigger does not extend Incorrect switch setting Safety switch on the outrigger has not been pressed Engine not running Vehicle gearbox in neutral Pre selector valve not actuated Pressure setting too low at the outrigger valve Outrigger catch does not open Switch offrotary switch Item 2 Fig 5 7 Switch on the pressure switch see section 7 5 4 Have piston rings replaced by WAITZINGER customer service Set selector switch Item 14 Fig 5 2 to position Desk or set remote control Item 8 Fig 5 12 to position Outriggers Set safety switch Item 3 Fig 5 5 or Item 1 Fig 5 6 Start the engine Select a gear see section 7 2 1 Check solenoid and wiring Actuate the pre selector valve Outrigger manually Seek advice from WAITZINGER customer service on this point Check pressure setting shown on the data sheet adju
90. nd of its travel d 3 Remove hose clip 2 and snap coupling 4 Fig 9 26 Changing the conveying piston 1 4 Push the conveying piston 1 about 5 mm towards the conveying cylinder by levering with a pry bar and remove the spacer 3 3 Fig 9 27 Changing the conveying piston 2 THP 94 42 R 4 XXT THP 125 42 R 4 XXT 9 30 GB 07 2005 THP 140 H 42 R 4 XXT A 5 Carefully move the drive cylinder out until it touches the flange Fit a snap coupling 4 MAINTENANCE amp INSPECTION CHAPTER 9 9 n ant Fig 9 28 Changing the conveying piston 3 6 Move the drive cylinder back in and remove the snap coupling 4 and the conveying piston 1 imme gt gt in e ZS 7 Liberally lubricate the new conveying piston 1 attach a shell coupling 4 and fit it Fig 9 30 Changing the conveying piston 5 THP 94 42 R 4 XXT THP 125 42 R 4 XXT THP 140 H 42 R 4 XXT GB 07 2005 9 31
91. ngement and the distributor boom is restricted so that it can only move within the slewing arc specified for the situation Fig 2 2 Crush hazard in the slewing area of the support feet Fig 2 3 Crush hazard when extending the support feet 2 7 3 Setting up 2 7 3 1 General e Set up the truck mounted concrete pump so that stability is assured e t must be at a sufficient distance from embankments pits excavations and other holes so that the pressure of the outriggers on the ground does not cause it to break into the hole 2 7 3 2 Safety distances to the edges of excavation pits A z 1 00 up to 12 t total weight gt 2 00m for more than 12 t total weight a Load bearing angle a x 30 on made ground and M Embankment angle loose ground A 2 xT M a x 45 on mature and cohesive ground A 1 x T T depht of excavation Without calculated proof of stability the following embankment angles must not be exceeded a for non cohesive or loosely cohesive ground p 45 on stiff semi stiff ground ul e Fig 2 4 Safety distances to the edges of excavation pits THP 94 42 R 4 XXT THP 125 42 R 4 XXT THP 140 H 42 R 4 XXT GB 07 2005 2 9 SAFE TY INSTRUCTIONS AND INFORMATION CHAPTER 2 2 7 3 3 Underground The ground must be flat horizontal and without voids Q On sloping ground the outriggers can
92. nsfer shift gearbox x Perform a wear check on the S valve verify 8 mm wall thickness x Perform a wear check on the conveying cylinders x Clean the diesel pre filter on the vehicle x Check the pressure setting of the pump and distributor boom against the data sheet see x sections 3 3 and 3 4 Check engine speed and operation of the pump together with stroke rate against the data x sheet see sections 3 3 and 3 4 Check that the conveying piston fastenings are tight x THP 94 42 4 XXT THP 125 42 R 4 XXT 9 10 GB 07 2005 THP 140 H 42 R 4 XXT MAINTENANCE amp INSPECTION Charter 9 Maintenance work Maintenance intervals EI E ZE 5 oe Ee Ss ut moz E S ee os 5 Ee Z8 be e Ze e 56 zn us Check all screw connections on the ball bearing slewing rim against the tightening torque table in section 9 3 Check that the conveying pipework fastenings on the distributor boom are tight Clean the air filter casing Change the breather filter on the hydraulic oil tank Have all mechanical and hydraulic components examined by an expert Check all safety equipment that is fitted for good condition Check distributor boom play between the pinion and the ball bearing slewing rim see section 9 8 5 Check play within the ball bearing slewing rim see section 9 8 6 Change the oil in the slewing gearbox see se
93. ntrol panel agitator water PUMP 2 0 6 5 3 5 4 Boom controll block Sang Ka x ar gef Base ei ETUR RE RUP eee died 5 4 5 5 Outrigger control block left 5 5 5 6 Outrigger control block right 5 6 5 7 Control cabinets cs opu eto wien eae 3 8 oe Rees od be eee 5 7 5 8 Changeover to transfer shift gearbox in the 5 8 5 9 Surplus concrete discharge opening 5 8 THP 94 42 R 4 XXT THP 125 42 R 4 XXT 0 2 GB 07 2005 THP 140 H 42 R 4 XXT C amr E 5 10 5 11 5 12 5 13 5 14 6 1 6 1 1 6 1 2 6 2 6 3 b1 b2 b3 7 1 7 2 7 2 1 7 2 2 7 2 8 7 3 7 3 1 7 3 2 7 3 2 1 7 3 3 7 3 4 7 3 5 7 4 7 4 1 7 4 1 1 7 4 2 7 4 3 7 5 7 5 1 7 5 2 7 5 3 Water tank shut off valve 5 8 Watetr COnnectlori he v pork ee reiten 5 9 Radio remote control cable remote control 5 9 Emergency Stop button elg ee eee NR re rebate ee ee ee ee da eae ee na 5 10 Control elements on the hydraulic block 5 10 Driving towing loading NNN NN EEN NNN EN EN a ee eee 6 1 Bu pa ETT 6 1 Before ajourngy au cirea e Rex E bbs eee ceeded bea EXER EAT 6 1 During the JOUIm gy i2 2 4 2 2050 E e ORO RO Pees eed E RODA an 6 1 EP 6
94. ntrol units of the Concrete Pump ISE Lubricate all grease points and check the automatic lubrication R BETONPUMPE system Check the stability of the machine Check the concrete pipes if the piping is made carefully and regarding ungsanleitung und alle the wear out wall thickness test 3tonpumpe kennen und During Operation Do not let the machine run without observation Stop the machine at once if any troubles occur which endanger the safety Is notwendig absperren At concrete blocking inside the concrete pipeline you have to suck craftstoff Wasser the concrete back into hopper and mix it with the agitator erheits und Start pumping very carefully and slowly Do not open snap couplings at the concrete pipeline if they are fen der Schmieranlage under pressure Protect your eyes against splashing concrete especially during opening of concrete pipes egung und Do not grab in or on moving parts First stop engine and release the accumulator pressure Do not do any modifications regarding safety devices After Operation ingen auftreten die eine Empty the concrete pipes by suction Cleaning of concrete pipes with cleaning sponge and water Trichter zur ckgef rdert Cleaning of hopper and the complete machine Carry out the daily maintenance and all repair work which is necessary 5ffnen wenn die after working nspritzern sch tzen TEE KE abschalten und Waitzinger Baumaschinen GmbH D 89231
95. nts on the truck mounted concrete pump apart from the conveying piston An optional central lubrication system is available for the conveying piston and or distributor boom THP 94 42 4 THP 125 42 R 4 XXT 4 4 GB 07 2005 THP 140 42 R 4 XXT DESCRIPTION CHAPTER 4 4 2 2 5 Function of the concrete pump The concrete pump is hydraulically driven by the vehicle engine through a transfer shift gearbox and hydraulic pump The controls are electric and fully automatic In addition a back up function can be engaged by a selection switch this allows the concrete pump to continue to be run at a reduced speed should the control system or the sensors fail The stroke rate can be varied between minimum and maximum The drive cylinders 1 are fitted with an automatic leakage compensation The S valve automatically compensates for wear at the wear plate and wear ring N Q n um Q SN R N Q fa gt DA A D X Nue ffo x A a LSA a 4 10 9 8 7 6 1 Right drive cylinder 6 S valve 2 Control block 7 Wear plate 3 Wash out tank 8 Slewing drive 4 Conveying piston 9 Conveying cylinder Il 5 Slide housing with agitator 10 Left drive cylinder Fig 4 3 Operation of the concrete pump THP 94 42 R 4 XXT THP 125 42 R 4 XXT THP 140 H 42 R 4 XXT GB 07 2005 4 5 DESCRIPTION CHAPTER 4 4 2 2 6 Method of operation of the concrete pump The conc
96. o switch at the battery if this is fitted gt Disconnect machines with electrical equipment such as radio remote control receiver controls etc before performing electric arc welding t Modifications welding and repair work on the distributor boom and all assemblies associated with it load bearing elements securing points outriggers on the mounting frame and any part of the pump or pressure bearing components may only be performed by persons appointed by the manufacturer Special care must be taken in respect of boom mountings and outriggers used as hydraulic or diesel tanks gt When replacing electrical pneumatic or hydraulic components valves pumps etc the required data pressure voltage etc should be checked from the machine data sheet test sheet or circuit diagram and adjusted as necessary c Maintenance and repair work may be carried out only after fluids have been depressurised No changes of any sort to the hydraulics are permissible We emphatically warn against improper repairs to hydraulics Test certificates supplied with hydraulic components should be carefully filed away for reference c If any component is removed carefully note how it was fitted and replace it correctly referring to the spare parts data sheet service information 2 12 High tension overhead electric cables Fig 2 13 Safety distances to high tension overhead electric cables THP 94 42 R 4 XXT THP 125 42 R 4
97. o ways of checking the condition of the sensors 1 Directly in the sensor or in its plug there are one or two LEDs One LED Green Switch activated Two LEDs Green Poweron Yellow Switch activated 2 On the 4 fold distributor there are Two green LEDs Power for the sensors Each with a yellow LED Switch activated Drive cylinder sensors Move the drive cylinder 1 to the end of its travel to check the operation ofthe sensor 2 Oscillation cylinder sensors Move the oscillation cylinder 3 to the end of its travel to check the operation of the sensor 4 m Drive cylinder lt Ew m N E j Oscillation cylinder m I Fig 9 23 Checking the operation of the sensors 9 28 GB 07 2005 THP 94 42 R 4 THP 125 42 R 4 XXT THP 140 H 42 R 4 XXT 9 9 1 9 A 9 9 Replacing worn parts MAINTENANCE amp INSPECTION CHAPTER 9 9 Exchanging the wear plate and wear ring DANGER When working in the hopper and in the area of the oscillation cylinder always switch the engine off and remove the ignition key Remove the locking plate 1 from the swing lever Undo the screws 2 and 3 to relieve the load on the S valve by 15 mm Exchange the free wear plate 4 by removing the first 2 screws 6 and tighten the screws Swing the S valve over to the other side Remove the second wear plate by removing the other two sc
98. oint Disassemble the water pump and clean it See separate user manual from the manufacturer Undo the coupling and adjust to the mid value Lubrication system does not operate Fuse blown Pump switched off Grease too stiff Lubrication point blocked Lubrication distributor blocked Pump impeller defective Replace fuse Switch the pump on Replace grease with suitable grease see Figure 9 5 Clear the blockage at the lubrication point Replace the grease up to the lubrication distributor and replace the lubrication distributor replace pump impeller GB 07 2005 THP 94 42 R 4 XXT THP 125 42 R 4 XXT THP 140 H 42 R 4 XXT MAINTENANCE amp INSPECTION Charter 9 9 Maintenance amp Inspection 9 1 General information The truck mounted concrete pump must be thoroughly cleaned maintained and inspected at regular intervals All parts ofthe machine should be checked that they are in good condition and safe working order The maintenance actions are listed in the Maintenance Schedule section 9 4 WARNING A wanne AN rz Maintenance and inspection work must always be carried out when the truck Do not place system in operation mounted concrete pump is stopped and switched off Risk of serious injury rx The adjacent notice must be placed in a suitable place where it is easily visible DANGER TANGER Work on the h
99. ol block right Move the operating lever as shown to perform the respective functions on the outrigger Outrigger safety button Emergency Stop button Circular level Extending retracting the front outrigger cylinder Extending retracting the front telescopic outrigger Slewing the front outrigger cylinder out in Slewing the rear outrigger cylinder out in Extending retracting the rear outrigger cylinder DD JO Om P o Fig 7 8 Outrigger control block right THP 94 42 R 4 XXT THP 125 42 R 4 XXT 7 8 GB 07 2005 THP 140 H 42 R 4 XXT STARTING UP AND OPERATING f CHAPTER 7 7 3 5 Building up the outrigger e Fully extend the outrigger and fully extend the telescopic sections e Extend the front telescopic outriggers until it clicks into a second registration point at the working setting see detail left Check that the arrows match see detail right indicating the that the outrigger is fully extended e Extend the front outrigger cylinder so far that the front wheels are lifted clear of the ground e The rear wheels must remain gently touching the ground braking and stability Fig 7 9 Telescopic outrigger extended and locked e The truck mounted concrete pump may not stand more than 3 from level Check the circular levels Circular level Fig 7 10 Setting up the truck mounted conc
100. om 9 8 7 6 5 4 Pressing the control lever downwards rotates the boom clockwise pressing the control lever upwards rotates Fig 7 11 Controll the distrib boom from the boom control block the boom anticlockwise THP 94 42 R 4 XXT THP 125 42 R 4 XXT 7 10 GB 07 2005 THP 140 H 42 R 4 XXT STARTING UP AND OPERATING f CHAPTER 7 e Press control lever boom A Item 8 Fig 7 11 and deploy the boom package until the catch hook releases Fig 7 12 Deploy the boom package the catch hook releases e Press the boom rotation control lever Item 9 Fig 7 11 to rotate the boom package into the working position u O mm Waar Fig 7 13 Slew the boom package into the working position THP 94 42 R 4 XXT THP 125 42 R 4 XXT THP 140 H 42 R 4 XXT GB 07 2005 7 11 L STARTING UP AND OPERATING CHAPTER 7 e Press control lever B Item 7 Fig 7 11 and deploy boom element B at 120 to boom element A au SES SE SS Leet eee e Press control lever C Item 6 Fig 7 11 and deploy boom element C at 90 to boom element B Fig 7 15 Deploy boom element C THP 94 42 4 125 42 4 7 12 GB 07 2005 THP 140 H 42 4 A e Press control lever D Item 5 Fig 7 11 and deploy boom elem
101. on of the arrow or pull it outwards t Before starting up the remote control press the Emergency Stop button so that all control and regulation devices for remote control are set to O c During interruptions pauses whilst pumping takes place also during maintenance and repair work secure the remote control against unauthorised use e g by locking it in the cab or in a tool box etc 2 9 Safety instructions for the working area c During operation of the truck mounted concrete pump the machine operator is responsible for the entire working area The working area must be fully within his field of view otherwise an assistant is necessary When leaving the machine secure it against unauthorised use and self acting movement Barrier off the working area to other traffic in accordance with instructions Personal protective clothing hard hat safety glasses face mask safety gloves etc must be worn within the entire working area in particular when working with cement or with chemical mortar additives gt Unauthorised access to the hazard area of the machine is prohibited If anyone is in the hazard area first warn them then if they still do not leave the hazard area shut down the machine Never irrespective of whether the machine is running or not reach with the hand into the transfer mechanism pre compression system water tank transfer tube or other moving part of the machine Always first switch th
102. ontained in Viton sealing rings O rings and flat gaskets gt Under normal conditions of use Viton seals and O rings are safe to use However at temperatures in excess of 400 C they decompose e g if equipment catches fire r The remains of such seals are then extremely aggressive and generally cannot be removed from the skin 9 2 3 Oils and greases MAINTENANCE amp INSPECTION Qa N WARNING KT Allergic reactions can arise when handling oils and greases Use barrier creams and avoid all contact with the skin Never wash your hands in oil Hydraulic oil emerging at high pressure can penetrate the skin and cause severe injuries To avoid severe infections call a doctor immediately Dispose of oils and filters in accordance with statutory regulations Never pour lubricating oil down the public drains THP 94 42 R 4 XXT THP 125 42 R 4 XXT THP 140 H 42 R 4 XXT GB 07 2005 9 3 MAINTENANCE amp INSPECTION See CHAPTER 9 9 2 4 Paints varnishes and thinners gt These materials are highly inflammable when applied as sprays and mists c Thinners vapours are heavier than air and create an extremely high explosion hazard WARNING gt Materials soaked in paint varnish or thinners can ignite spontaneously if they are carelessly thrown into a rubbish bin t Do not breathe in paint or thinners mists c When painting ensure good ventilation and ne
103. ontinues to rise change the water continuously Discover the cause of the overheating and rectify it If the oil temperature rises above 40 C the thermostatically controlled fan under the master control block will cut in e Under no circumstances spray the oil tank with water This usually leads to a build up of condensate water and damage to the hydraulic pump If the cooling measures are insufficient direct a water jet on to the drive cylinder hydraulic cylinder as shown here All pumps have a thermo electric cut out If the oil temperature exceeds 80 C the pump will be switched off automatically and the red indicator lamp on the control cabinet or control desk Item 4 Fig 5 2 will light up Fig 7 31 Water on the drive cylinder THP 94 42 R 4 XXT THP 125 42 R 4 XXT THP 140 H 42 R 4 XXT GB 07 2005 7 27 STARTING UP AND OPERATING CHAPTER 7 7 6 4 1 Measures to reduce the oil temperature e Switch the pump to the OFF 11 position The indicator lamp Control System ON 8 on the control panel will go out Do not switch the engine off the oil cooler must remain in operation e Renew the water in the water tank e When the red indicator lamp Temperature 4 has gone out switch the pump on again Continue to pump but at a lower power e When pumping is complete establish the cause for the oil overheating and rectify it e The temperature sensor for the th
104. oo stiff or setting in the hopper Pressure setting at the agitator control block is too low Water tank empty Agitator switched on Remedy Have seal replaced by WAITZINGER customer service Rectify the cause and replace the cylinder Seek advice from WAITZINGER customer service on this point Check pressure setting to data sheet and adjust Clean the pressure relief valve Seek advice from WAITZINGER customer service on this point Reduce the inclination see section 7 3 4 Lubricate the ball bearing slewing rim Have motor replaced by WAITZINGER customer service Have the brake linings replaced by WAITZINGER customer service Close grill Switch off the water pump Empty the hopper and clean it Check pressure setting to data sheet adjust as necessary Clean the pressure relief valve Seek advice from WAITZINGER customer service on this point Fill up with water Switch the agitator off using the control lever Item 5 Fig 5 3 THP 94 42 R 4 XXT THP 125 42 R 4 XXT THP 140 H 42 R 4 XXT GB 07 2005 TROUBLE SHOOTING CHAPTER 8 Fault Cause Pressure setting at the agitator control block is too low Dirt in the water pump Axial play in the pump shaft incorrect Remedy Check pressure setting to data sheet adjust as necessary Clean the pressure relief valve Seek advice from WAITZINGER customer service on this p
105. outrigger control panel THP 94 42 R 4 XXT THP 125 42 R 4 XXT THP 140 H 42 R 4 XXT GB 07 2005 5 5 CONTROLS AND DISPLAYS CHAPTER 5 5 6 Outrigger control block right Outrigger safety button Emergency Stop button Circular level Control lever Extending retracting the front outrigger cylinder Control lever Extending retracting the front outrigger telescope Control lever Slewing the front outrigger out in Control lever Slewing the rear outrigger out in Control lever Extending retracting the rear outrigger cylinder OO P WD Fig 5 6 Right outrigger control panel THP 94 42 R 4 XXT THP 125 42 R 4 XXT 5 6 GB 07 2005 THP 140 H 42 R 4 XXT 5 7 Control cabinet CONTROLS AND DISPLAYS CHAPTER 5 1 Display instrument Operating hours 2 Rotary switch Back up function A 0 B 3 Indicator lamp Fault 4 Indicator lamp Lubrication system Fig 5 7 Control cabinet control panel THP 94 42 R 4 XXT THP 125 42 R 4 XXT THP 140 H 42 R 4 XXT GB 07 2005 CONTROLS AND DISPLAYS CHAPTER 5 5 8 Changeover to transfer shift gearbox in the cab 1 Indicator lamp Transfer shift gearbox on 2 Key switch Transfer shift gearbox on off 5 9 Surplus concrete discharge opening 1 Lever Surplus concrete discharge opening 2 A
106. per is filled only to the lower edge of the agitator shaft This procedure means that air will be drawn by the concrete pump into the conveying cylinder and the concrete will be conveyed in air plug mode Caution blockages may occur The pressure should be relieved in the conveying pipework by brief reversal of the pump 2 3 strokes during pauses in conveying Frequently pump back and forwards Never allow the conveying pipework to stand under pressure If the concrete is very fluid with a high proportion of large gravel and tends to bleed from the conveying pipework always pump out into the hopper during pauses in pumping During longer pauses pump the concrete back into the hopper mix it and pump it through again During longer pauses in pumping switch off the drive engine so that its vibrations do not cause the concrete to separate out At intervals of 10 15 minutes pump the concrete back and forth Never force concrete that has separated out or concrete that is lumpy because it is beginning to set through the conveying pipework Especially with concrete that has a low capacity for retaining water tendency to bleed avoid pauses when working at high throughputs and when restarting conveying be sure to let the pump run long enough for the transfer tubes on both sides to be filled Only then switch over to forwards conveying again Air inclusions in the conveying pipework can be hazardous since compressed air can emerge violently a
107. pump may lead to the following injuries gt Injuries to the eyes due to splashes of concrete concrete mixing water or other chemical substances gt Injuries to the eyes and other injuries due to hydraulic oil spurting out if the system is not depressurised gt Injuries due to centrifugal forces of bursting couplings bursting pipework or plugs blown out of the concrete conveying pipework gt Hazards of touching electrical cables gt Electric shock which can be fatal from machines with electrical drives if electrical connections are not properly made or the connecting cables are defective gt Danger of tipping over due to collapse of the outriggers tx Injuries due to burns if hot parts are touched tx Injuries due to falling pipes tx Injuries to personnel due to inadvertent operation of the machine controls and hence inadvertent operation of the machine THP 94 42 R 4 XXT THP 125 42 R 4 XXT 2 6 GB 07 2005 THP 140 H 42 R 4 XXT SAFETY INSTRUCTIONS AND INFORMATION CHAPTER 2 gt Head and shoulder injuries due to concrete discharging from the discharge hose or concrete conveying pipes Injuries due to parts falling from the concrete conveying pipes if these are not properly aligned gt Injury to the hose operator from the discharge hose if this was secured in the catch and then suddenly swings out on release The truck mounted concrete pump can roll away if the brakes or outrig
108. pump operation 0 000 ee 7 24 7 6 1 Instructions TOF PUMPING t rn en 7 24 7 6 1 1 Eege uu scie e en a ee 7 25 7 6 2 General instructions for Dumping 7 25 7 6 3 Instructions for pumping depending on the material to be pumped 7 26 7 6 4 Instructions for pumping depending on the 7 27 7 6 4 1 Measures to reduce the 7 28 7 7 Cleaning the conveying pipework 1 2 RR 7 28 7 7 1 GOST EE 7 28 7 7 2 Suctionieleaning 22 4 EE ee wee ER ea ee 7 28 7 7 3 Cleaning with pressurised water 7 29 7 7 4 Draining the remaining 7 31 7 8 Water tanks Ree are 7 31 7 8 1 Filling up topping up with water by removing the 7 31 7 8 2 Filling with water using the C coupling nnm 7 31 7 8 3 Filling with water from the mixer truck 7 32 7 8 4 Operation Ini WINKED ioc ies UE hele Ree Dh a wa a ba 7 32 8 Troubleshooting gege se 8 1 8 1 General information 123m vex x EG PRA en ee he ne 8 1 8 2 lee ite hr 8 1 9 Maintenance amp Inspection HHHuuaun ann ee 9 1 9 1 General information cna code tas ete be bee
109. re sensor 6 Valve Y4a Fig 7 23 Pump hydraulic control block THP 94 42 4 THP 125 42 R 4 XXT THP 140 H 42 R 4 XXT GB 07 2005 7 19 STARTING UP AND OPERATING CHAPTER 7 7 5 5 Agitator DANGER TANGER c During cleaning work the control lever Item 5 Fig 7 24 must always be in the 0 position and must on no account be moved during the cleaning work r When working in the hopper keep the vehicle engine switched off at all times The control lever Agitator Item 5 Fig 7 24 switches the agitator on even when the Emergency Stop button has been pressed The agitator should always be set to move the concrete inwards to the centre push the control lever to the right Setting the agitator to move the concrete outwards control lever to the left should be done only for brief periods to relieve a blockage or the remix the concrete Opening the safety grill automatically stops the agitator The manometer Item 1 Fig 7 24 shows the actual pressure at the agitator water pump optionally high pressure water pump and compressor The maximum pressure that can be set is 210 bar Fig 7 24 Control panel Agitator Water pump THP 94 42 R 4 XXT THP 125 42 R 4 XXT 7 20 GB 07 2005 THP 140 H 42 R 4 XXT STARTING UP AND OPERATING f CHAPTER 7 7 5 6 Water pump The control lever Water pump Item 4 Fig 7 24 switches the water pump on The manome
110. rete pump operates as follows The oscillation cylinders are in position 513 On pumping the pressure relief valve is electrically actuated and closes and Y4b is started The drive cylinders move in direction A The concrete in the left hand conveying cylinder is pushed into the S valve into the conveying pipe Concrete is sucked into the right hand conveying cylinder through the free opening in the hopper As soon as sensor 512 trips valves Y4b and Y5b are started The drive cylinders remain stationary and the oscillation cylinders start to move in direction The S valve is now in line with the right hand conveying cylinder Sensor S14 starts Y4a and Y5b stops and the drive cylinders move in direction The right hand conveying piston now pushes concrete through the S valve and the left cylinder sucks concrete in from the slide housing Sensor S11 stops Y4a and Y5a swings the S valve back in direction D A full cycle is now complete THP 94 42 R 4 THP 125 42 R 4 XXT 4 6 GB 07 2005 THP 140 H 42 R 4 XXT CONTROLS AND DISPLAYS CHAPTER 5 5 Controls and displays 5 1 Controls and displays for the truck mounted concrete pump Vehicle left hand side 1 Outrigger
111. rete pump using the circular level THP 94 42 R 4 XXT THP 125 42 R 4 XXT THP 140 H 42 R 4 XXT GB 07 2005 7 9 STARTING UP AND OPERATING CHAPTER 7 7 4 Distributor boom operation N WARNING c Do not deploy the distributor boom until the truck mounted concrete pump outriggers are fully extended c Never drive the truck when the distributor boom is deployed gt When deploying and stowing the distributor boom there are many points against which the boom can foul and cause damage Therefore be sure to follow the correct sequence of operations for deploying the boom NOTE Normally the distributor boom is controlled using the radio cable remote control pendant All boom functions are performed proportionally 7 4 1 Distributor boom operation using the master control block NOTE Distributor boom operation using the master control block should only be used as back up Whenever possible control the boom using the ra dio cable remote control pendant e Set the operating mode selection switch Item 14 Fig 7 6 to Control panel desk e Control each boom element individually by moving the respective control levers Element A 8 Element B 7 Element C 6 and Element D 5 in desired direction Moving a control lever downwards moves the element inwards moving a control lever downwards moves the element outwards e The boom rotation lever 9 controls the rotation of the bo
112. rews 6 Swing the S valve back to the other side and exchange the wear ring 5 Swing the S valve on to the wear plate already fitted and fit the second wear plate Restore the S valve pre load by tightening the 4 screws S Tighten the screw 2 by hand until the gap is closed Back off the screw by at least 1 6 of a turn and refit the locking plate NOTE Tighten the screws 3 and 4 to the torque set out in the table in section 9 3 Perform a trial run Fig 9 24 Changing the wear plate and wear ring 1 Fig 9 25 Changing the wear plate and wear ring 2 THP 94 42 R 4 XXT THP 125 42 R 4 XXT THP 140 H 42 R 4 XXT GB 07 2005 9 29 MAINTENANCE amp INSPECTION Ve CHAPTER 9 A 9 9 2 Changing the conveying piston e Turn a hardened conveying piston by 180 after 2 mm wear 4 mm on the diameter turn a chromium plated conveying piston by 180 when the chromium plate layer is 30 um EE gt When working in the wash out tank always switch off the engine and take out the ignition key gt Never reach your hands into the wash out tank when the engine is running gt Always actuate the hydraulic cylinder by actually actuating the valves see section 7 5 4 3 at a low engine speed and reduced stroke rate 1 Drain the water tank and remove the protective grill 2 Actuate valves Y3 and Y4 to move one drive cylinder to the e
113. ring which no concrete is pumped During pauses in pumping the concrete observe the following points e Do not leave the conveying pipework under pressure e Depressurise the conveying pipework by briefly reversing the pump e Keep the concrete moving by briefly pumping through and back e lf there is along pause in pumping pump the concrete back into the hopper and mix it again before pumping it through the conveying pipework If the distributor boom whips around determine the cause of this The following causes may lead to this e The outriggers may have moved repeat the outrigger set up procedure see section 7 3 4 WARNING Before restarting determine the reason why the outriggers had moved THP 94 42 R 4 XXT THP 125 42 R 4 XXT THP 140 H 42 R 4 XXT GB 07 2005 7 25 STARTING UP AND OPERATING CHAPTER 7 The pump speed is too high reduce the pump speed The distribution boom is badly positioned move the distribution boom to a better position Example of a badly positioned distribution boom Boom fully extended element 4 vertical 7 6 3 Instructions for pumping depending on the material to be pumped NOTE r Only ever use pumpable concrete gt If you are unsure contact the concrete manufacturer If pumping concrete that is hard to pump the agitator shaft should be visible at all times Difficult concrete extremely stiff low sand mixtures light weight concrete etc will pump better when the hop
114. rotective grill let the pump run through one cycle open the protective grill again A protective grill that is bolted in position remains in position throughout cleaning Remove any remaining material by opening the cleaning valve Carefully spray the S valve hopper conveying cylinder and water tank until they are clean Clean the rest of the machine and spray it with formwork release oil If there is a risk of frost drain the wash out tank water tank and water pump The wash out tank should also be drained at normal temperatures during long pauses in pumping overnight and at weekends 7 7 3 Cleaning with pressurised water Cleaning the machine with pressurised water is a method well proven in practice Empty the hopper as far as possible Switch the pump to Suck mode using rocker switch Item 11 Fig 7 32 and pump 1 or 2 strokes to depressurise the conveying pipework Switch off the pump Drain out the remaining material by opening the cleaning valve see section 7 7 4 When conveying upwards close the blocking slide and open the cleaning port in the rising pipe Switch the pump on again in Suck mode and carefully wash down the conveying pipe with the spray jet working through the cleaning port Take care that the hose is not cut through when the S valve operates Keep spraying the conveyor pipework until clear water emerges from the conveying cylinders Switch off the pump Clean the hopp
115. sed skilled staff If maintenance work is neglected or improperly performed we may no longer be liable to perform our warranty obligations under our conditions of supply Only original WAITZINGER spare parts ensure quality and interchangeability NOTE gt Safety instructions should be complied with at all times r We reserve the right to make technical changes and improvements to the equipment and its components from the illustrations and data set out in this user manual This user manual is applicable only insofar as the truck mounted concrete pump corresponds to the version and equipment described gt In the following sections the truck mounted concrete pump is also referred to as the machine or equipment Only qualified and trained personnel over 18 years of age may work on and with the truck mounted concrete pump Our customer service department will be pleased to offer you further information and advice if despite consulting this user manual you encounter any problem with your truck mounted concrete pump We wish you all the best in trouble free driving and use of your truck mounted concrete pump The management THP 94 42 R 4 XXT THP 125 42 R 4 XXT THP 140 H 42 R 4 XXT GB 07 2005 1 1 SAFETY INSTRUCTIONS AND INFORMATION CHAPTER 2 2 Safety instructions and information r In addition please comply with the safety instructions and information for the truck itself tr
116. shooting should be performed based on the following table Only skilled technical staff should investigate the causes of faults and implement measures to rectify the fault If the fault cannot be rectified contact WAITZINGER customer service 8 2 Tracing faults Fault Cause Remedy Gearbox does not shift to Pump position No indicator lamps lit on the controls green LED on desk and Emergency Stop not illuminated Vehicle ignition not switched on Clutch was not disengaged Pressure in vehicle compressed air system too low Pneumatic valve iced up Solenoid on pneumatic valve defective Fuse in vehicle blown Vehicle ignition not switched on Gearbox in driving position Gearbox limit switch defective Main fuse battery or fuse F1 F2 blown Switch on the ignition Disengage the clutch and engage the required gear Allow the engine to run until It has built up sufficient pressure De ice the muffler on the pneumatic valve Check solenoids and wiring The valve can also be actuated with a screwdriver Establish cause and rectify it Replace fuse Switch on the ignition Change the gearbox over Replace gearbox limit switch Short term remedy Bridge the two contacts on the plug Establish cause and rectify it Replace fuses THP 94 42 R 4 XXT THP 125 42 R 4 XXT THP 140 H 42 R 4 XXT GB 07 2005 TROUBLE SHOOTING CHAPTER 8
117. sonnel may perform repair work on electrical systems r Before carrying out electrical repair work the system must be electrically de energised and this state must be secured for the duration of the work The VDE regulations and the VBG 4 regulations must be complied with r When fitting fuses fit only fuses of the same type and rating as were originally fitted It is absolutely prohibited to repair fuses THP 94 42 R 4 XXT THP 125 42 R 4 XXT THP 140 H 42 R 4 XXT GB 07 2005 10 1 LIST OF OPERATORS OF THE EQUIPMENT CHAPTER 11 11 List of operators of the equipment e Each operator of the equipment confirms here by his signature that he has received read and understood this user manual e He agrees to comply with all instructions conscientiously e If he does not do so the manufacturer s warranty will become void Operator name Accepted on Operator signature THP 94 42 R 4 XXT THP 125 42 R 4 XXT THP 140 H 42 R 4 XXT GB 07 2005 11 1 i4 LIST OF OPERATORS OF THE EQUIPMENT CHAPTER 11 A Make further copies if required Operator name Accepted on Operator signature THP 94 42 R 4 XXT THP 125 42 R 4 XXT 11 2 GB 07 2005 THP 140 H 42 R 4 XXT MAINTENANCE AND MODIFICATIONS LIST 12 12 Maintenance and modifications list
118. st it if necessary Clean the pressure relief valve Seek advice from WAITZINGER customer service on this point Lubricate the outrigger catch if necessary disassemble it and clean it replace the seals and d burr the edges Seek advice from WAITZINGER customer service on this point GB 07 2005 THP 94 42 R 4 XXT THP 125 42 R 4 XXT THP 140 H 42 R 4 XXT A TROUBLE SHOOTING 9 CHAPTER 8 amk Fault Cause The outrigger moves of its own accord Releasable non return valve dirty Cylinder seal worn Cylinder distorted by over Pressure The boom will not move Incorrect switch setting Engine not running Vehicle gearbox in neutral Emergency Stop button has been pressed Radio remote control not operational Pre selector valve not actuated Insufficient hydraulic oil Remedy Have valve cleaned or replaced by WAITZINGER customer service Have seal replaced by WAITZINGER customer service Check valves for operation Replace the cylinder Seek advice from WAITZINGER customer service on this point Set selector switch Item 14 Fig 5 2 to position Remote control or set remote control Item 8 Fig 5 12 to position Boom Start the engine Select a gear see section 7 2 1 Establish why the Emergency Stop button was pressed and remedy the cause Release the Emergency Stop and restart the controls with the horn see section 7
119. starting up gt Secure the working and hazard area and barrier it off if necessary gt Top up the fluids hydraulic oil fuel water gt Check the functioning of all safety devices and controls c Lubricate all grease points and check that the lubrication system is functioning gt Check the stability of the machine gt Check the conveying pipes for alignment and degree of wear wall thickness measurement b 2 During operation tx Never allow the machine to operate unattended gt Stop the machine immediately if any fault occurs that might create a safety hazard r In the event of blockages the material must be return to the hopper immediately Start up again slowly gt Open the snap couplings on the conveying pipes only when the conveying system has been depressurised rx When opening pipe joints wear safety glasses to protect the eyes from spurting concrete gt Never reach into or on to moving parts first switch the engine off or depressurise the accumulator r Do not modify any safety device b 3 At the end of operations c Empty the conveying pipes gt Clean the conveying pipes using a cleaning ball and water tx Clean the hopper and the complete machine gt Perform routine maintenance and repair any faults that have developed whilst the machine was running THP 94 42 R 4 THP 125 42 R 4 XXT 7 2 GB 07 2005 THP 140 H 42 R 4 XXT STARTING UP AND OPERATING f CHAPTER 7 7 1
120. t product liability Conveying pipes are not under stress when the distributor boom is stowed and can thus be replaced without problems at that time If conveying pipes are replaced when the distributor boom is deployed stresses may be introduced during assembly gt To ensure a long working life for the conveying pipes after delivering approx 6 000 m rotate all conveying pipes 120 clockwise and rotate the elbows 180 Check the minimum wall thicknesses and operating pressure WARNING WARNING If you use compressed air for cleaning the conveying pipes this is at your own risk WAITZINGER accepts no liability for the risks involved If never theless you do use compressed air for cleaning information can be found in an additional sheet which can be requested from WAITZINGER as required 2 9 2 1 Locking the conveying pipe connections e All conveyor pipe couplings must be secured with spring clips arrowed against bursting open 2 9 2 2 Opening the conveying pipe connections e Conveying pipe connections must be knocked apart and opened only in the depressurised state e Always pump backwards 1 2 piston strokes Fig 2 8 Conveyor pipe coupling opening THP 94 42 R 4 XXT THP 125 42 R 4 XXT THP 140 H 42 R 4 XXT GB 07 2005 2 13 SAFE TY INSTRUCTIONS AND INFORMATION CHAPTER 2 2 9 3 Discharge hose DANGER TANGER 1 When pumping after interruptions after undoing a plug or wh
121. t the discharge hose causing concrete to spray out explosively Air inclusions occur particular when pumping through by sucking in air when the hopper is insufficiently filled with concrete and when the conveying pipework has been extended The characteristics of the concrete must not be changed in any way THP 94 42 R 4 THP 125 42 R 4 XXT 7 26 GB 07 2005 THP 140 H 42 4 STARTING UP AND OPERATING f CHAPTER 7 7 6 4 Instructions for pumping depending on the machine e The max running speed of the diesel engine must under no circumstances be exceeded since otherwise the hydraulic pump will overspeed The permissible speeds can be found on the machine data sheet e Pay attention if the piston strokes are shortened and if necessary take action to counteract this see Chapter 8 Trouble shooting e f during continuous operation under heavy loading the oil temperature exceeds 80 C the indicator lamp will light Item 4 Fig 5 2 Immediately top up the water tank with cold water Fig 7 30 Water in the wash out tank e After periods of heavy loading of the engine never just switch it off allow it to idle and cool down at a diesel engine speed of approx 1 000 rpm This is particularly important for turbo diesel engines e Set the engine speed to more than the minimum speed 500 700 rpm e Damage due to operator error is not covered by the WAITZINGER warranty e Ifthe temperature c
122. t through the distributor boom The machine operator must take the following safety precautions and perform the following tests a Use only pipework supplied by the concrete pump manufacturer At concrete pressures between 85 bar and 130 bar high pressure pipework is necessary b Perform a water pressure test on pipes and couplings no later than after pumping 2000 at a pressure 30 96 greater than the anticipated operating pressure c All couplings seals and pipe elbows that are less than 3 m from operating personnel should be regularly replaced e g after pumping each 1 000 m of concrete 2 11 Safety instructions for maintenance and repair WARNING Rectifying faults repairs and maintenance work may be performed only when the main drive engine is switched off hydraulic units are depressurised and conveying pipework is also depressurised Take out the ignition key gt Factory set chokes and pressure limiting devices may not be adjusted except by trained technical staff gt Removing the seals from safety valves is prohibited THP 94 42 R 4 XXT THP 125 42 R 4 XXT 2 16 GB 07 2005 THP 140 H 42 R 4 XXT SAFETY INSTRUCTIONS AND INFORMATION CHAPTER 2 WARNING Before performing any electric welding always unplug the cables from the control cabinet and disconnect the battery To disconnect the battery undo the positive and negative terminal connections or switch off the Nat
123. t too low the gearbox will be dam aged Maximum pressure 5 bar see manometer Item 1 Fig 7 28 Pull and twist the rotary controller Item 2 Fig 7 28 to adjust the pressure Fig 7 28 Manometer transfer shift gearbox THP 94 42 R 4 XXT THP 125 42 R 4 XXT THP 140 H 42 R 4 XXT GB 07 2005 7 23 STARTING UP AND OPERATING CHAPTER 7 7 6 Instructions for pump operation NOTE The maximum conveying pressure must not exceed the pressure listed on the serial plate or in the test book e Mix the concrete in the mixer truck at full power and the highest speed and check that the concrete is evenly mixed After addition of concrete additives accelerant retardant continue to mix for a further 4 minutes on site 7 6 1 Instructions for pumping e Immediately before starting pumping with the agitator running fill the hopper with several buckets of thin watery concrete and send through two sponge balls in advance Pump slowly until a full stream of concrete emerges from the discharge hose e If the conveying pipework is short and clean immediately before starting pumping with the agitator running fill the hopper with several buckets of laitance cement water mixture and send through two sponge balls in advance so that the laitance wets the whole periphery of the pipework Pump slowly until a full stream of concrete emerges from the discharge hose e Fornewer and longer conveying pipework the fr
124. ter Item 1 Fig 7 24 shows the actual pressure at the agitator water pump optionally high pressure water pump and compressor The maximum pressure that can be set is 210 bar NOTE When the agitator is switched on the power of the water pump is reduced Option High pressure water pump or compressor available as an option are controlled by the same control lever Item 4 Fig 7 24 7 5 7 Vibrator The control lever Vibrator Item 8 Fig 7 24 switches the vibrator on Two operating modes are available MANUAL Continuous operation AUTO The vibrator runs only when the pump is switched on 7 5 8 Horn Reset Irrespective of the operating mode setting Desk or Remote control the horn can be sounded from any control anel using the rocker switch Horn Reset Lubrication ic 6 Fig 7 25 Fig 7 25 Control panel desk If the Emergency Stop button has been pressed provided all Emergency Stop buttons has been released the controls will be switched on again reset THP 94 42 R 4 XXT THP 125 42 R 4 XXT THP 140 H 42 R 4 XXT GB 07 2005 7 21 STARTING UP AND OPERATING CHAPTER 7 NOTE If the operating mode selector switch Item 14 Fig 7 25 is set to Remote control the Emergency Stop button on the Remotecontrol pendant radio or cable must be released 7 5 9 Light The light switch Item 7 Fig 7 25 switches all operating lights on incl
125. ter protection valve Control lever Water pump Additional Equipm optional Control lever Agitatot Agitator reverse P sch Fig 5 3 Control panel Agitator Water pump THP 94 42 4 THP 125 42 4 XXT THP 140 H 42 4 GB 07 2005 5 3 CONTROLS AND DISPLAYS CHAPTER 5 5 4 Boom control block 9 8 7 6 5 4 1 Manometer Boom and outrigger 6 Control lever Deploy and retract boom element C 2 Lighting for control panel 7 Control lever Deploy and retract boom element B 3 Emergency Stop button 8 Control lever Deploy and retract boom element A 4 Control lever Outrigger Boom 9 Control lever Boom slew left right 5 Control lever Deploy and retract boom element D Fig 5 4 Boom control panel THP 94 42 R 4 XXT THP 125 42 R 4 XXT 5 4 GB 07 2005 THP 140 H 42 R 4 XXT A CONTROLS AND DISPLAYS 5 5 Outrigger control block left OO P Circular level Emergency Stop button Outrigger safety button Control lever Extending retracting the rear outrigger cylinder Control lever Slewing the rear outrigger out in Control lever Slewing the front outrigger out in Control lever Extending retracting the front outrigger telescope Control lever Extending retracting the front outrigger cylinder CHAPTER 5 Fig 5 5 Left
126. th oil and screw it in clockwise by hand 3 Check the in line filter for leak tightness 9 7 Changing the oil 9 7 1 Changing the oil in the slewing EE gearbox NOTE gt The slewing gearbox has only one oil circuit oil circuit A gt Use only gear oil as shown in the gear oil reference table Fig 9 6 Use oil grades alternative grades as shown in the gear oil reference table Fig 9 6 Oil capacity 10 litres To change the oil in the slewing gearbox proceed as follows 1 Remove the breather screw 1 and fully remove the drain plug 2 2 If the oil was very dirty it is essential to fill the gearbox completely with flushing oil and slew the distributor boom for several rotations This ensures that any deposits of dirt in the gearbox are fully mixed into the oil after this repeat point 1 3 Reinsert the drain plug 4 Open the air bleed screw 3 Use a funnel to fill the gearbox with oil through the breather screw opening until the oil reaches level A 5 Screw in the air bleed screw and the breather screw Fig 9 10_Slewing gearbox THP 94 42 R 4 XXT THP 125 42 R 4 XXT THP 140 H 42 R 4 XXT GB 07 2005 9 21 MAINTENANCE amp INSPECTION Gem CHAPTER 9 A 9 7 2 Changing the oil in the transfer shift gearbox Use oil grades alternative grades as shown in the gear oil reference table Fig 9 6 Oil capacity
127. thing or jewellery including rings Free long hair must be secured using a hair net This is an injury hazard since it may get caught or pulled in 2 18 3 Skills Personnel who are being trained taught instructed or educated on the machine may use it only under continuous supervision of an experienced operator If no skilled personnel or workshop equipment etc are available apply to WAITZINGER Customer Service for maintenance of your machine 2 18 4 Machine operator s responsibilities The user must make clear the machine operator s responsibilities including national regulations for driving on public roads and enable him to refuse instructions from third parties to commit unsafe actions The machine operator must be permitted to refuse to work at a location when there are technical safety problems THP 94 42 R 4 XXT THP 125 42 R 4 XXT 2 22 GB 07 2005 THP 140 H 42 R 4 XXT SAFETY INSTRUCTIONS AND INFORMATION CHAPTER 2 2 19 Safety and warning notices Safety and warning notices are attached to the truck mounted concrete pump as listed below All safety and warning notices are depicted below in more detail 12 27 28 11 345678910 26 21 16 15 14 13 29 2417 23 2 1 11 19 1 WAI106179 Serial pl
128. tributor boom using the radio remote control pendant 7 14 Controlling the distributor boom using the cable remote control pendant 7 15 PUMP Operation iier ed hes vas bee Se bee he an RC Ree 7 16 Motor Start Stop Speed contra 7 16 Pump Suck control at the control panel 5 7 16 Pump Suck control at the radio remote control cable remote control 7 17 THP 94 42 R 4 XXT THP 125 42 R 4 XXT THP 140 H 42 R 4 XXT GB 07 2005 0 3 B CONTENTS CHAPTER 0 7 5 4 Back up function for Pump Suck 0 0 0 0 eee eens 7 17 7 5 4 1 Pumping with the control panel desk or via radio remote control cable remote control 7 17 7 5 4 2 Pump control at the hydraulic control 7 19 7 5 5 Dude P X ETT 7 20 7 5 6 Water pumps aci coke EN Rx us RR Re KR ne 7 21 7 5 7 Vibrator ae aa ee 7 21 7 5 8 Horm HeSet rA Tr RE UE PE RR RAD ee ee T a 7 21 7 5 9 e ln ei 7 22 7 5 10 Concrete pump manometer 7 22 7 5 10 1 Distributor boom manometer s sensse sisicata a iaaa a aa eee 7 22 18 102 Filter clogging Gebees eg ripresi teswex ewe ERE Rr a a R eund 7 23 7 5 10 3 Manometer for transfer shift 7 23 7 6 Instructions for
129. trical components by covering them or sealing them shut to prevent ingress of water After completion of cleaning remove the covers and seals leaving no residues e Never use seawater or other saline water for cleaning Never use compressed air for cleaning THP 94 42 R 4 XXT THP 125 42 R 4 XXT 9 36 GB 07 2005 THP 140 H 42 R 4 XXT MAINTENANCE amp INSPECTION A Charter 9 e After completion of cleaning check all pipework for leaktightness and loose connections and check the machine for chafing points e Check all components for any sort of damage If faults are found rectify them immediately e lf there is a risk of frost completely drain the conveyor pipework water tank and water pump Leave all water drain points open 9 14 Disposal of the machine NOTE Observe national and regional legislative regulations and guidelines when disposing of the machine THP 94 42 R 4 XXT THP 125 42 R 4 XXT THP 140 H 42 R 4 XXT GB 07 2005 9 37 AA REPAIR WORK A CHAPTER 10 10 Repair work N WARNING ETIN rz Repair work must only be performed by trained personnel or service personnel who have been authorised by WAITZINGER r The user is not permitted to carry out repair work on his own account Any work on the machine in breach of this provision will render the warranty void and relieve the manufacturer of all liability A N WARNING gt Only skilled specialists or trained per
130. ubricants cleaning materials during maintenance repair and oil change should be collected in suitable containers and disposed of in accordance with regulations to EC directive 75 439 EWG and statutory instruments under 5a 5b AbfG and Alt l 2 17 First aid gt Information should be sought for treatment of injuries that may arise when working with the truck mounted concrete pump tx Injuries must be reported to the supervisor THP 94 42 R 4 XXT THP 125 42 R 4 XXT THP 140 H 42 R 4 XXT GB 07 2005 2 21 SAFETY INSTRUCTIONS AND INFORMATION CHAPTER 2 2 18 Responsible persons 2 18 1 Personnel The user must ensure that only personnel who have been properly trained and instructed work on or with the machine The persons responsible for operation and maintenance must be clearly established Furthermore he must ensure that only authorised persons use the machine 2 18 2 Requirements The following requirements apply to all personnel concerned with operation and maintenance of the machine c They must be at least 18 years of age c They must have appropriate physical and mental capabilities gt They must be in good health calm and not under the influence of alcohol drugs or medicines tx They must have been trained in the operation and maintenance of the machine tx They must have proved their capability to the user t They must be expected to fulfil their duties reliably Personnel must not wear any loose clo
131. uding the outrigger feet lighting optional and working area floodlights The lighting around the outrigger feet is permanently switched on It needs only be plugged into the appropriate socket on the outrigger foot 7 5 10 Concrete pump manometer By passing or blocking the manometer protection valve Item 3 Fig 7 24 the actual pump pressure is shown at the manometer Item 2 Fig 7 24 At 320 bar the hydraulic pump has switched to 0 The probable cause is a blockage in the conveying pipe 7 5 10 1 Distributor boom manometer The manometer Item 1 Fig 7 26 shows the actual pressure at the distributor boom Fig 7 26 Boom control block THP 94 42 R 4 THP 125 42 R 4 XXT 7 22 GB 07 2005 THP 140 H 42 R 4 XXT STARTING UP AND OPERATING f CHAPTER 7 7 5 10 2 Filter clogging display The display instrument Item 1 Fig 7 27 shows the degree of clogging of the return flow filter If when the hydraulic oil is at operating temperature the needle is in the red zone the filter element must be changed immediately The display instrument Item 2 Fig 7 27 shows the degree of clogging of the in line filter If the needle indicates 3 bar the filter cartridge must be changed Fig 7 27 Filter clogging indicator 7 5 10 3 Manometer for transfer shift gearbox CAUTION c If the pressure is set too low the transfer shift gearbox cannot change gear c If the pressure is se
132. ug the Radio plug from the left hand socket and plug it into the free right hand socket Lock the plug in place Plug the extension cable for the cable remote control into the left hand socket Lock the plug in place Radio remote control is now deactivated Set the operating mode selection switch Item 14 Fig 7 6 to Remote control Release the Emergency Stop by pressing the Horn Reset Item 14 Fig 7 18 The horn will sound Fig 7 19 Plug the extension cable for the cable remote control Switch the selector switch Outrigger Boom Item 8 Fig 7 18 to Boom and uncap the Emergency Stop button The 50 100 switch Item 10 Fig 7 18 controls the boom speed 50 when pumping 100 when deploying stowing Press the master switch Deploy boom element Slew boom Item 3 Fig 7 18 and deploy boom element A until the catch hook releases and the boom element B can be deployed see Fig 7 12 Press the master switch Deploy boom element A Slew boom Item 3 Fig 7 18 to move the distributor boom into the position where the discharge hose retainer can be opened Press the master switch Deploy boom element B Item 2 Fig 7 18 and deploy boom element B until it is approx 120 to boom element A see Fig 7 14 Use the joystick Deploy boom element C and D Item 1 Fig 7 18 to deploy boom element C to 90 to boom element B see Fig 7 15 Use the joystick
133. ull the left and right hand uf motors 4 out and put them to one side Take care not to kink the hydraulic hoses 4 Remove the screws 6 and take out the spacer plates with the seals 7 eh Ale In i a a 5 Exchange the seals 7 and refit them The gap between the seals must be completely filled with grease 4 5 6 Reassemble the motors 4 and shafts 3 together with the agitator blades in the reverse sequence to removal see Fig 9 24 Fig 9 34 Changing the agitator seals 9 9 6 Changing the agitator wear sleeves 1 Remove the motors Item 4 Fig 9 34 and put them in a safe place 2 Knock the securing pin 8 fully inwards remove the washer 9 and unscrew the nut 10 MEN g 3 3 Lever out the shaft 11 using pry bars XY 4 Splitthe wear sleeves 12 off the shaft 11 and remove them i al m Er 5 Clean the shaft and evenly spread it with Loctite Warm the new wear sleeves up to 200 C and quickly slide 12 11 10 them into place 6 Refit the agitators in the reverse sequence to removal A new hole must be drilled for the securing pin 8 FL ee eE THP 94 42 R 4 XXT THP 125 42 R
134. ver smoke c When spraying paint always wear close fitting face mask r Never allow petrol or paraffin to come into contact with rubber components Contamination of rubber components with these materials causes them to swell and soften CN leading to failure rx When working with paraffin or petrol naked flames and smoking are prohibited 9 2 5 Glues adhesives and solvents tx Some vapours from these materials are flammable and or poisonous if breathed in t Even gases which are not themselves flammable can decompose at high temperatures and release poisonous gases e g when drawn through the glowing tip of a cigarette c Thus the same safety instructions apply as for paraffin and petrol THP 94 42 R 4 XXT THP 125 42 R 4 XXT 9 4 GB 07 2005 THP 140 H 42 R 4 XXT 9 2 6 AN MA Battery acid WARNING r Battery fluid contains aggressive sulphuric acid Always wear protective clothing and protective gloves Handle batteries with care If any battery acid splashes on to the skin wash it off immediately with clean water If any battery acid splashes on to the eye wash it out immediately with clean water Then immediately summon a doctor r Because of the risk of an explosion keep sparks and naked flames away from batteries Battery acid can catch fire MAINTENANCE amp INSPECTION Chapter 9 Cob y 94 42 4 125 42 4
135. with clean oil 5 Plug in the filter element 6 Fit the filter casing and tighten it to approx 150 Nm 9 6 3 Return flow filter If the clogging indicator Item 1 Fig 9 8 is in the red zone when the oil is at operating temperature the filter element must be changed 1 Havea suitable container ready for the oil filter element and clean the outside of the filter casing 2 Undo the 4 screws 3 and place the cover 2 on aclean surface 3 Take out the filter element 4 with spring and dirt sleeve 5 4 Twist the dirt sleeve anti clockwise and pull it off then thoroughly clean it and fit it to the new filter element 5 Fit the new filter element into the return flow filter 6 Fit the spring and cover secure with 4 screws 7 Check filter for leak tightness NOTE When changing the return flow filter always change the air filter 6 also VV d ex FH o Fig 9 7 Changing the high pressure filter C 9 20 GB 07 2005 THP 94 42 R 4 XXT THP 125 42 R 4 XXT THP 140 H 42 R 4 XXT MAINTENANCE amp INSPECTION 9 9 9 6 4 In line filter cartridge If the manometer Item 1 Fig 9 9 shows a value in excess of 3 bar when the oil is at operating temperature the filter element must be changed 1 Turn the filter cartridge 2 anti clockwise by hand to undo it and dispose of it correctly 2 Wet the sealing ring of the new filter cartridge wi
136. work 9 35 9 12 Checking the hoses 9 36 9 13 Cleaning the machine nh 9 36 9 14 Disposal of the machine ss seses aes a ates en 9 37 10 Repair work RR ERR REG see ewe na 10 1 11 List of operators of the equipment 11 1 12 Maintenance and modifications Weit 12 1 94 42 4 125 42 4 0 6 GB 07 2005 THP 140 H 42 R 4 XXT FOREWORD IEAI CHAPTER 1 1 Foreword Dear customer Please read this user manual carefully before first using your truck mounted concrete pump so as to ensure that you use it safely and effectively We have written this user manual to familiarise you with the design use operation and operating conditions and to list the servicing and maintenance work required together with information on safe working Before starting to use the truck mounted concrete pump be sure that all the safety conditions have been satisfied This user manual forms part of the total documentation package for the truck mounted concrete pump It relates exclusively to the superstructure that is fitted to the truck For the truck itself see the separate user manual issued by the truck manufacturer There may be separate user manuals for certain components and options These user manuals should also be read and complied with All repair work should be performed only by authori
137. ydraulics pneumatics electrics and electronics must only be performed by suitably trained skilled staff Further information on the truck part of the vehicle can be found in the separate vehicle manufacturer s user manual 9 2 Safety instructions for maintenance and inspection Maintenance and inspection of the truck mounted concrete pump must only be carried out by authorised staff gt Repair work must only be carried out by authorised skilled staff of the manufacturer Maintenance and inspection work must be carried out precisely in accordance with the specifications and instructions in this maintenance section Make sure that the user manual for the truck mounted concrete pump the maintenance and special tools and fixtures for it the oilcans and grease guns for lubrication and the cleaning and lubrication media are always kept in the places provided for them tx Used cleaning materials must be removed from the truck mounted concrete pump and placed in a specially designated container fire hazard The use of highly flammable materials e g petrol is prohibited VBG 1 43 and 44 THP 94 42 R 4 XXT THP 125 42 R 4 XXT THP 140 H 42 R 4 XXT GB 07 2005 9 1 MAINTENANCE amp INSPECTION See CHAPTER 9 NOTE Consumables such as gearbox oil used during maintenance repair and oil change should be collected in suitable containers and disposed of in accordance with regulations
138. ying cylinder and wash out tank until they are clean e Clean the rest of the machine also and spray it with formwork release oil See further information in the separate documentation supplied by the manufacturer NOTE If there is a risk of frost drain the wash out tank water tank and water pump The wash out tank should also be drained at normal temperatures during long pauses in pumping overnight and at weekends THP 94 42 R 4 XXT THP 125 42 R 4 XXT 7 30 GB 07 2005 THP 140 H 42 R 4 XXT STARTING UP AND OPERATING f CHAPTER 7 7 7 4 Draining the remaining concrete The remaining concrete can be drained through the drain valve under the hopper e Strike the cover Item 1 Fig 7 36 of the drain valve lightly with a hammer to open it If the cover is too slack or too stiff adjust the clamping screws Item 2 Fig 7 36 e Collect the remaining concrete in a suitable container or on plastic sheeting for reprocessing or disposal e Observe the safety instructions set out the Chapter 2 Safety instructions 7 8 Water tank 7 8 1 Filling up topping up with water by removing the cover e Close all ball valves e Unscrew the cover 1 on the rear outrigger e Fill with water of a suitable quality clean water without foreign bodies such as sand e Watch the water level indicator 2 Fig 7 37 Fill up with water by removing the cover Screw the cover back in place 7 8 2

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