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Putzmeister Akademie GmbH � Postfach 2152 � D-72629 Aichtal � Tel. +49 (0) 7127 599-0 � Fax +49 (0)7127 599-900

AP 6005 - 1As at III / 01

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Table of contents

What are Akademie modules? Page 3

What benefits do Akademie modules offer the trainer Page 4

Topics available Page 5

AKM 505 Concrete technology Page 6

AKM 506 The principles of hydraulics Page 6

AKM 507 The principles of electricity Page 7

AKM 508 Pumping systems Page 8

AKM 510 Technical documentation Page 8

AKM 513 Troubleshooting – Electronics Page 9

AKM 514 Troubleshooting – Hydraulics Page 9

AKM 515 First steps in troubleshooting Page 10

AKM 518 Concrete pump operation Page 11

AKM 530 MBC boom control Page 12

AKM 533 Stationary pumping of concrete Page 13

AKM 535 Production of a truck-mounted concrete pump Page 13

AKM 536 Concrete Pump Technology Page 14

AKM 539 Hydraulic Oil and Filters Page 14

AKM 541 Stationary Booms MX

Productivity begins in the mind

Qualified and motivated staff thanks toregular training

Commercial success through quality inprofessional development


What are Akademie modules?

Putzmeister Akademie's seminars around the world offer testedknowledge gained in practice for practical application.

The Akademie modules which are founded in day-to-dayworking support trainers and seminar leaders in passing on theirknowledge.

One module is one learning unit. Professionally preparedknowledge is presented in excellent quality. The trainer is ableto concentrate on content when preparing his seminar and doesnot have to waste time creating presentations.

An Akademie module consists of:

� PowerPoint file of all colour slides for use on on-screenpresentation)

� Copy template for participant handouts� Participant handouts as a Word file� Seminar plan� Organizational notes for a seminar or presentation� All modules are linked for rapid searching

Akadamie modules are available in German and English; otherlanguages on request


What benefits do Akademie modules offer thetrainer

� The greatest benefit is the time saved by the trainer in thepreparation of presentations. Slides and the associatedparticipant handouts, in high quality, copy-ready format,can be used in the seminar right away.

� The presentation can be given from an OHP or anotebook computer. When presenting from a notebookcomputer, the trainer can jump from one module toanother with a click of the mouse, and so round off thelearning material with reference to similar topics.

� An enclosed seminar schedule gives the keywords for thepoints to be discussed with each slide and allows thetrainer to check that he is keeping to his timetable at alltimes.

� Every module contains organizational hints aboutpreparations for a presentation or seminar. Thesechecklists, copy-ready printouts and teaching notes arevaluable for both experienced and less experiencedtrainers.

� Akademie modules are subject to constant improvementand expansion in respect of both form and content. Amodule may be updated in the first two years for an extra


Topics available in German and English include:

AKM 505 introduction into concrete technologyAKM 506 Principles of hydraulicsAKM 507 Principles of electricsAKM 508 Pump systemsAKM 510 Technical documentationAKM 513 Fault finding and rectification on electrical

controller failureAKM 514

AKM 515 First steps in trouble-shootingAKM 518 Concrete pump operation

Fault finding and rectification onhydraulic controller failure

AKM 530 PM MBC boom control

AKM 533 Stationary Concrete Pumping

AKM 535 Building a truck-mounted concrete pump

AKM 536 Concrete pump technology

AKM 539 Hydraulic oil and filters

AKM 541 Stationary booms MX

Module price € 390.- per single module (German or English)��CD Rom including��Participant documentation file

��Trainer guide for the presenter (file) ��Powerpoint and Word files �

Package prices for order of several modules are possible.�

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Information H. W. Schulz, tel. +49 (0)7127 599 586 � [email protected]. Bullinger tel. +49 (0)7127 599 481 � [email protected]


Akademie modules (Contents / Topics)

AKM 505 Concrete technology

� Grading curve� Fines content of the concrete� Pumpability� Properties of freshly-mixed concrete Flow-table test� Properties of freshly-mixed concrete Slump test� Chemical concrete additives� Wear� Steel fibre-reinforced concrete� Use of steel fibres� Heavy concrete� Sprayed concrete

AKM 506 Principles of hydraulics

� Principles: Pressure distribution� Variable speeds� Laminar and turbulent flows� Main pump unit: inline construction.� Piston pump: axial piston variable-displacement

pump� Components� Variable displacement pump� Fixed construction� Internally toothed gear pump� Externally toothed gear pump� Valves: Spring pre-loaded return flow valve� Pressure limiting valve� Directional valves� Directional valve function� Nomenclature� Generation 7 monobloc� Circuit diagram� Accumulator� Charge conditions� Cylinders� Hydraulic motor� Hydraulic fluid


� Filter� Boom high-pressure filter� Main pump suction filter� Pressure gauge� Open and closed circuit� Closed circuit� Symbols: all components in the hydraulic control system� Exercises

AKM 507 Principles of electrics

� Basic knowledge� Assembly� Converter� Capacitor� Protective device� Alternator� Indicating device� Relay/contactors� Flasher relay� Interval time-delay relay� Two-wire timer relay� Timer relay with pickup delay� Timer relay with dropout delay� Make contact relay� Double make contact relay� Changeover contact relay� Multiple changeover contact relay� Latching changeover contact relay� Engine� Measuring device� Power switchgear� Potentiometer resistance� Make contact switch� Latched toggle switch� Toggle switch� Key-operated switch� Mechanically actuated switch� Emergency shut-down switch� Master switch� Inductive make contact switch� Transformer� Semiconductor diode� Semiconductor� Terminals/plug-in connection� Electrically-actuated valve

SZ BZ

90°

Masse


� Electrically-actuated proportional valve� Orientation: Machine� Orientation: Circuit diagram� List of devices (excerpt)

AKM 508 Pump systems

� Piston pump: single piston pump� Piston pump: with transfer tube� Trunk design transfer tube� C transfer tube� Self-adjusting ring� Gate valve systems wear parts� Transfer tube with S transfer tube� S transfer tube� Comparison of transfer tube systems� Piston pump with CS transfer tube� Rotor pump� Model identification� Machine test reading� Comparison of sizes� Output determination� Concrete pump pressure/output graph� Compressed air conveying

AKM 510 Technical Documentation

� Docubox� Technical data� Machine card� Operating Instructions� Spare parts list� Page layout� Group overview� Spare parts sheet, front� Spare parts sheet, reverse� Extract from spare parts sheet,

reverse� Spare parts purchasing� Technical appendix� Safety booklet� Inspection Log Book


AKM 513 Troubleshooting - electrical system

� Remote control output regulation is not operating� The controller for the entire system is not working, the red

EMERGENCY SHUT-DOWN LED is illuminated (cableremote control)

� The controller for the entire system is not working, the redEMERGENCY SHUT-DOWN LED is illuminated (radiotransmitter)

� The Putzmeister controller cannot be switched on, the 0-Ilamp on the control cabinet is out

� The engine speed cannot be increased in pumping operations� The pump cannot be switched on� The pump does not always switch over� The red “Oil overheating” warning lamp on the control cabinet

is illuminated� The hydraulic pump is frequently switched off because of

overheating� Switchover is taking too long

AKM 514 Troubleshooting Hydraulics

� The main pump(s) drive shaft is notturning

� Piston rods are not moving, the placing boomcan be moved

� Rattling can be heard in the drive train(Cardan shaft) at idling speed

� The piston rods for the drive cylindersare not moving when the pump is switched on

� The drive cylinders are blocked in the endposition

� The concrete pump is not running evenly, butmisfiring, piston rods are rattling

� One cylinder stroke takes twice as long as theother

� The piston rods do not come to a halt at PUMPOFF, but continue to run slowly

� No longer able to achieve the fastest stroketime

� The hydraulic system is frequently switched offbecause of overheating


� The stroke time is getting longer, smoke iscoming from around the power take-off

� The low pressure setting is not stable� The transfer tube switches over suddenly and

then slows down� There is low pressure, but no accumulator

pressure the piston rods do not move at PUMPON

� The power unit is throttled back at maximumpressure

� It is no longer possible to control the outputusing the remote control

� The piston rods run at normal stroke time forsoft concrete but the get slower, or even stops,with stiff concrete

� When the piston rod for cylinder II is retracted, ithalts briefly,while the piston rod for cylinder I extends slowlyand only then switches over

� Drive cylinder stroke change-over takes toolong

AKM 515 First steps in troubleshooting

� The concrete pump does not start when the pump isswitched on

� The change-over valve is not switching over because novoltage is applied.

� The change-over valve pistons are jamming� The output is set too low� EMERGENCY SHUT-DOWN chain activated� Pump is does not switch over� Fuse (2F80) has blown� Pump not changing over every second stroke� The proximity switch is defective� One coil on the change-over valve is defective� The connector has corroded� Delivery pistons do not start� Vacuum filter is dirty� The delivery pistons are locked in the end

position� The engine speed is too low� The drive cylinders are locking in the end

position� There is no pulse from the proximity switches ...� There is no pulse from the proximity switches ...


� Output cannot be regulated electrically� The downstream Manadrol valve is closed� The bypass is not closed� Faulty connector contact� Hydraulic fluid overheating� There is too little flushing water in the water box for high

output� The flushing water is too warm� Accumulator empties too quickly or no pressure� The accumulator dump cock is open

AKM 518 Operating the concrete pump

� Transmitter� Boom control� On-Off toggle switch� Pump On - Off - Change-over� Reverse pumping� Output controller� Boom speed preselect� Engine On - Off� Engine speed regulation� Horn/Emergency shut-down/Operating mode� Boom speed� Emergency shut-down switch� Green indicator lamp� Red indicator lamp� Control cabinet� Green indicator lamp: Ready for service� Engine speed regulation� Pump on-off reversal� Indicator lamp for emergency shut-

down� Hydraulic fluid overheating� Operating hours meter� Local/Remote control switchover� Horn/Deactivate emergency shut-down� Fan On� Temperature display� Emergency shut-down switch� Pump/boom wiring loom connection� Remote control cable connection� Truck mixer driver box� Support control block� Agitator control block


� Setting up the concrete pump� Engaging the power take-off� Connecting the remote control� Connecting the remote control� Supports� Boom operation� Programming the boom speed� EMERGENCY SHUT-DOWN function� Starting pumping� Pumping operations� Breaks in pumping� Blockages� Oil overheating (water box)� Oil overheating (fan)� Cleaning� Safety instructions for cleaning� Dismantling after cleaning� Manual emergency operation� Manual output regulation� Manual boom control� Manual boom operation� Manual support leg operation

AKM 530 MBC boom control

� Special features� Signal flow� Module control cabinet� Boom pump� Boom pump drive� 10µ high-pressure filter� MBC control block� Support leg operation monobloc� Support leg block� Manual support leg operation� Boom operation� Manual boom operation� Joysticks for boom movement� Hare/Snail� Cable remote control� Boom operation faults


AKM 535 Stationary Concrete Pumping

� Site preparation� Pumping� Delivery lines� Gate valves� Technical features of stationary pumps� Design (Concrete-Pressure-Performance)� Requirements for concrete

AKM 535 Production of a truck-mounted concrete pump

� Information about the Putzmeister group of companies� Putzmeister concrete pump product range� Available assembly areas� Quality control in production and for products� Walkthrough: Order - Production - Delivery� Production operation: Preparation of the

manufacturing job� Production operation: Drawing the parts from the

stores� Production operation: Delivery to assembly position� Production operation: Component assembly� Production operation: Hopper assembly� Production operation: Pre-assembly of core pump� Production operation: Assembly of core pump� Production operation: Priming the core pump� Production operation: Truck inspection� Production operation: Truck preparation� Production operation: Welding in the core pump� Production operation: Main assembly of hydraulic

system� Production operation: Main assembly of truck

superstructure� Production operation: Electrical assembly� Production operation: Preparation for painting the

arm assembly� Production operation: Painting the arm assembly


� Production operation: Assembly of the pump - riserpipe delivery line

� Production operation: Testing the pump� Production operation: Mounting the boom� Production operation: Testing the boom� Production operation: Quality optimization� Production operation: Preparation for painting� Production operation: Painting� Production operation: Finishing paintwork� Production operation: Finish coat� Production operation: Final assembly� Production operation: Pre-delivery inspection� Production operation: Transfer to stores� Handover to customer� After Sales: Putzmeister Akademie

AKM 536 Concrete Pump Technology

� Pumpsystems� Hydraulic drive� Delivery lines� Placing booms� Supports� Operating elements

AKM 539 Hydraulic Oil and Filters

� Properties of hydraulic fluid� Identification of mineral hydraulic fluids� Bio degradable oils� Saturated and unsaturated esters� Mixture with mineral oils� Why flushing the system� Types of contaminations� Origin of contaminants� Types of filters� Filter elements construction� Oil care� Commission filtering� Fluid analysis


AKM 541 Stationary Booms MX

� Overview of set-up variants� Cruciform base bolted to the foundation� Tubular columns� Special tools� Shaft climbing system� Shaft frame� Floor frame� Laying the concrete delivery line� Technical details of stationary booms� Boom control block� Satellite use� Preparations for relocation� Quick mounting adapter� Multi-boom� Climbing procedure� Daily checks and maintenance work� Inspection by subject expert

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