S5 EV - CM - TM Betriebsanleitung 01-0407 GB

Operating Instructions
for machine operator and maintenance staff

always keep by the machine
Auger pump S 5 EV/CM/TM

Art. no. 111452.010/020/030/040/080/
100/110/123/130/180
Machine no.
Rev. 01--0407 PMM_365188013
The paper on which this document is printed is 100% chlorine free

Putzmeister Postfach 2152 07127 / 599–0 07127 / 599 743 Internet:
Mörtelmaschinen D–72629 Aichtal www.putzmeister.de
GmbH Hotline:
Max–Eyth–Str. 10 (07127) 599--699 e--mail:
D–72631 Aichtal pmm@pmw.de
Contents
1 About these Operating Instructions

1.1 Foreword . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 — 2
1.2 Icons and symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 — 4
2 Safety Regulations
2.1 Principle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 — 2
Onwards sale . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 — 2
2.2 Designated use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 — 3
2.3 Use contrary to the designated use . . . . . . . . . . . . . . . . . . . . . 2 — 4
Extending the delivery line . . . . . . . . . . . . . . . . . . . . . . . . . . 2 — 4
Modifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 — 4
2.4 Liability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 — 5
Exclusion of liability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 — 5
2.5 Personnel selection and qualifications . . . . . . . . . . . . . . . . . . 2 — 6
Training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 — 6
Qualified electrician . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 — 6
2.6 Sources of danger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 — 7
Delivery line and coupling system . . . . . . . . . . . . . . . . . . . . 2 — 7
2.7 Safety equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 — 8
2.8 Risk of injury - residual risk . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 — 9
2.9 Risk of crushing and bumping . . . . . . . . . . . . . . . . . . . . . . . . . 2 — 10
Transporting the machine . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 — 10
Assembly of the auger pump . . . . . . . . . . . . . . . . . . . . . . . . 2 — 11
2.10 Electrical contact . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 — 12
2.11 Place of work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 — 13
Machine operator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 — 13
Accessories operator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 — 13
2.12 Working area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 — 13
2.13 Conduct in an emergency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 — 13
2.14 Sound emissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 — 14
Operator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 — 14
2.15 Spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 — 15
2.16 Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 — 15
2.17 Storing the machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 — 15
2.18 Injuries through unauthorised starting or use of the
machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 — 16
I
Contents
3 General Technical Description

3.1 Designation of machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 — 1
3.2 Machine versions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 — 2
3.3 Scope of supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 — 2
3.4 Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 — 3
3.5 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 — 6
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 — 6
Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 — 6
Performance data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 — 6
Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 — 6
3.6 Rating plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 — 8
3.7 Sound power level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 — 9
3.8 Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 — 10
3.9 Safety equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 — 11
EMERGENCY STOP button (optional) . . . . . . . . . . . . . . . . 3 — 11
Protective grille . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 — 12
3.10 Functional description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 — 13
General description of the machine . . . . . . . . . . . . . . . . . . 3 — 13
General layout of the flow-type mixer . . . . . . . . . . . . . . . . . 3 — 14
General layout of the plate mixer . . . . . . . . . . . . . . . . . . . . . 3 — 15
3.11 Control cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 — 16
3.12 Control unit control cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 — 17
3.13 Plate mixer control cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 — 18
3.14 Drive S 5 EV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 — 19
3.15 Flow-type mixer drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 — 20
3.16 Plate mixer drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 — 21
3.17 Auger pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 — 22
3.18 Cable remote control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 — 23
3.19 Vibrator (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 — 24
3.20 Remote control by compressed air (optional) . . . . . . . . . . . . 3 — 25
3.21 Fill-level sensor (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 — 26
II
Contents
4 Transport, Set-up and Connection

4.1 Unpacking the machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 — 1
4.2 Transporting the machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 — 2
4.3 Selecting the set-up site . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 — 3
4.4 Set-up site requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 — 3
Supporting ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 — 3
Lighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 — 3
Angle of inclination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 — 4
4.5 Fitting the flow-type mixer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 — 5
4.6 Fitting the plate mixer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 — 7
4.7 Water connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 — 9
4.8 Electrical connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 — 11
Prerequisites . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 — 12
Laying electrical supply cables . . . . . . . . . . . . . . . . . . . . . . 4 — 12
Connection to the mains power supply . . . . . . . . . . . . . . . 4 — 13
S 5 EV, S 5 EV/TM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 — 13
S 5 EV/CM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 — 14
5 Starting up
5.1 Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 — 2
Visual checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 — 2
Electrical connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 — 2
5.2 Test run . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 — 3
Switch-on conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 — 3
Switching on pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 — 3
Checking direction of rotation . . . . . . . . . . . . . . . . . . . . . . . 5 — 4
Checking function of EMERGENCY STOP button
(optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 — 6
5.3 The delivery line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 — 7
5.4 Shutting down the machine after operation . . . . . . . . . . . . . . 5 — 8
III
Contents
6 Operation
6.1 Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 — 1
6.2 Emergency shut-down procedures . . . . . . . . . . . . . . . . . . . . . 6 — 2
EMERGENCY STOP button (optional) . . . . . . . . . . . . . . . . 6 — 2
6.3 Initial pumping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 — 4
6.4 Adjusting the auger pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 — 5
6.5 Pumping operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 — 6
6.6 Mixing with the plate mixer . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 — 7
6.7 Mixing with the flow-type mixer . . . . . . . . . . . . . . . . . . . . . . . . . 6 — 9
6.8 Pumping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 — 11
6.9 Delivery rate adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 — 12
6.10 Reverse pumping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 — 13
6.11 Breaks in pumping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 — 14
6.12 Blockages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 — 15
Rectifying blockages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 — 15
6.13 Using the cable remote control . . . . . . . . . . . . . . . . . . . . . . . . . 6 — 16
6.14 Using the spray gun . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 — 17
Adjusting the air nozzle tube . . . . . . . . . . . . . . . . . . . . . . . . 6 — 19
Practical tip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 — 20
6.15 Cleaning the machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 — 21
Information on cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 — 21
Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 — 23
Delivery line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 — 24
Plate mixer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 — 26
Flow-type mixer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 — 27
Spray gun . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 — 28
IV
Contents
7 Faults, Cause and Remedy

7.1 Machine, general . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 — 2
7.2 Spray gun . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 — 4
7.3 Electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 — 5
On power failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 — 5
8 Maintenance
8.1 Maintenance intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 — 2
8.2 Operating materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 — 4
Geared motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 — 4
Manual lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 — 4
Auger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 — 4
Maintenance Chart
40--030 Maintenance tasks, general . . . . . . . . . . . . . . . . . . 8 — 5
40--001 Visual checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 — 6
40--036 Lubrication diagram S 5 . . . . . . . . . . . . . . . . . . . . . . 8 — 7
40--037 Flow-type mixer lubrication diagram . . . . . . . . . . . 8 — 8
40--038 Plate mixer lubrication diagram . . . . . . . . . . . . . . . 8 — 9
44--088 Setting the pressure switch . . . . . . . . . . . . . . . . . . . 8 — 10
46--021 Replacing the screw conveyor . . . . . . . . . . . . . . . . 8 — 12
46--027 Disassembly and assembly of the auger pump . 8 — 14
46--028 Adjusting the auger pump . . . . . . . . . . . . . . . . . . . . 8 — 18
V
Contents
9 Decommissioning
9.1 Temporary decommissioning . . . . . . . . . . . . . . . . . . . . . . . . . . 9 — 1
Shutting the machine down . . . . . . . . . . . . . . . . . . . . . . . . . 9 — 2
Frost protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 — 2
9.2 Final decommissioning, disposal . . . . . . . . . . . . . . . . . . . . . . . 9 — 3
Electric machines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 — 3
Material used . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 — 4
Parts requiring separate disposal . . . . . . . . . . . . . . . . . . . . 9 — 4
10 Appendix
10.1 General tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10— 1
Index of Key Words
VI
About these Operating Instructions
1 About these Operating Instructions
In this chapter you will find notes and information that will help you
use these Operating Instructions. Do not hesitate to contact us if you
have any queries:
Putzmeister Mörtelmaschinen GmbH

Postfach 2152
D-72629 Aichtal, Germany
Tel: +49 (0)7127 599-0
Fax: +49 (0)7127 599-743
Internet: http://www.moertelmaschinen.de
E-mail: pmm@pmw.de
or the branch or services agent responsible for you.
Address:
Telephone:
Fax:
E-mail:
01_0001_0505GB 1—1
1.1 Foreword These Operating Instructions are intended to familiarise the user with
the machine and to assist him in using the machine properly in va-
rious possible applications.
The Operating Instructions contain important information on how to

operate the machine safely, properly and economically. Taking these
instructions into consideration will help
-- to avoid dangers,
-- to reduce repair costs and downtimes,
-- to increase the reliability and service life of the machine.
The Operating Instructions must be supplemented by the relevant

national rules and regulations for accident prevention and environ-
mental protection.
The Operating Instructions must always be available wherever the

machine is in use.
The machine owner must make the location of these Operating In-
structions known to all personnel charged with performing jobs on
the machine and ensure they are accessible. These operating in-
structions must be read and applied by any person who carries out
work with or on the machine, e.g.
-- operation, including setting up, fault rectification in the course of
work, removal of production waste, care and disposal of fuels and
consumables,
-- service (maintenance, inspection, repair), and/or
-- transport.
The generally recognised rules of technology for safe and proper

working must be observed in addition to the Operating Instructions
and mandatory rules and regulations for accident prevention and
environmental protection in the country and place of use of the ma-
chine.
Continuation next side
1—2 01_0001_0505GB
The Branch or Agent serving you, or the Aichtal Works, will be happy
to give you more information, should you have any questions follo-
wing your study of the Operating Instructions.
You will make it much easier for us to answer any questions if you
can give us the details of the machine model and the machine num-
ber.
These operating instructions do not include a description of the drive

motor; please refer to the operating instructions provided by the mo-
tor manufacturer.
Modifications are made from time to time in the interests of constant

improvement and it could be possible that we were unable to take
these into consideration when these Operating Instructions were
printed.
These operating instructions are not covered by the Amendment Ser-

vice of Putzmeister Mörtelmaschinen GmbH. Alterations may be
made to these operating instructions without prior notification.
The contents of this document may not be reproduced, even in part,

without our written permission. All technical data, drawings, etc. are
protected by copyright law.
The pages are divided into chapters where they are numbered con-
secutively.
Example: Page 3--2

Chapter 3
Page 2
 Copyright by
01_0001_0505GB 1—3
1.2 Icons and symbols The following icons and symbols are used in the Operating Instruc-
tions:
" Action symbol

Text following this symbol describes tasks which you are required to
work through, generally in the sequence shown from top to bottom.
⇒ Text after this icon describes the result or the effect of an
activity.
Refer also to the maintenance charts:

This symbol is used to refer to the maintenance cards required, pos-
sibly as a supplement to the maintenance cards you are currently
reading.
The following special tool is required:

This icon identifies the special tools necessary to carry out the work.
Normal tools, i. e. standard tools or tools carried in the vehicle are
not listed additionally.
Environmental protection
This symbol is used to identify tasks during which particular attention
is to be paid to environmental protection. The associated text is writ-
ten in italics and is closed off with a line.
Notes
Particular specifications with regard to the economic use of the ma-
chine are introduced with the word ”Note” and the pictogram illustra-
ted. The associated text is written in italics and is closed off with
a line.
Caution
Particular specifications or instructions and prohibitions with regard
to the prevention of damage are introduced with the word ”Caution”
in bold and the pictogram illustrated. The associated text is written in
italics and is closed off with a line.
1—4 01_0001_0505GB
Danger
Particular specifications or instructions and prohibitions with regard
to the prevention of personal injury or significant damage are introdu-
ced with the pictogram illustrated, the word ”Danger” written in bold
and a line. The associated text is written in italics and is closed off
with a line.
The appropriate symbol will be used if it is possible to identify the

source of the danger precisely.
Suspended Load
This symbol is used to identify tasks in which suspended loads may
fall down.
Danger of crushing
This symbol is used to identify tasks during which there is the danger
of being crushed.
Heavy current
This symbol is used to identify tasks in which there is the danger of
electrocution, possibly with lethal consequences.
01_0001_0505GB 1—5
Safety Regulations
2 Safety Regulations
This chapter summarises the most important safety regulations. This

Chapter must be read and understood by all persons who handle
the machine. The various regulations are also repeated once more at
the appropriate points in the Operating Instructions.
Notes
Special safety regulations may be necessary for some tasks. These
special safety regulations will only be found in the description of the
particular task.
The following safety instructions should be regarded as a supple-

ment to already existing valid national accident prevention regula-
tions and laws.
Existing accident prevention regulations and laws must be observed

in all cases.
03_0001_0505GB 2—1
Safety Regulations
2.1 Principle Use only machines in a technically perfect condition, as designated

and being conscious of safety and the dangers, taking account of
the Operating Instructions. Any faults, especially those affecting the
safety of the machine, must, therefore, be rectified immediately.
Make sure that

-- no safety equipment is removed, rendered inoperable or modified,
-- safety equipment removed for the purposes of maintenance work
is refitted immediately after the work is completed.
Check operational safety every time you start work. Any defects
found or suspected must be eliminated immediately. If necessary,
inform the project supervisor.
If defects or faults are found or suspected during operation, opera-

tion must cease immediately. Eliminate the defect or fault before re-
starting.
Onwards sale The following should be noted if you sell the machine on:
Pass on to the new operator all the accompanying documentation

(Operating Instructions, Maintenance Instructions, diagrams, ma-
chine cards, inspection certificates etc.) you received with your ma-
chine. If necessary, you may have to order the papers from us, quo-
ting the machine number. The machine may not be sold on without
the accompanying documentation under any circumstances.
Reporting an onwards sale or acquisition to Putzmeister ensures

that you will be sent any information relating to modifications or in-
novations relevant to safety, and you will also be eligible for technical
consultancy from our works.
2—2 03_0018_0508GB
Safety Regulations
2.2 Designated use The machine has been built in accordance with the state of the art
and recognised safety rules. Nevertheless, its use may constitute a
risk to life and limb of the operator or of third parties, or cause da-
mage to the machine and to other property.
The machine must only be used as specified in the Operating In-

structions and the enclosed documentation. All information and sa-
fety regulations in the Operating Instructions must be observed.
The machine is exclusively designed to deliver pumpable plastering

material and mortar. The material granulation should be no more than
6 mm maximum.
On no account must any other materials or objects be used.
The maximum delivery pressure must be no higher than that speci-

fied on the rating plate and/or in the technical data.
The machine is filled via the hopper.
All items of the machine’s protective panelling must be fitted or con-

nected up during operation.
The machine must be operated only with the safety equipment fitted.
Specified inspection work should be carried out at regular intervals.
Any work on the electrical system of the machine must be carried out
by trained and qualified electricians only.
Never make any modifications, additions or conversions to the ma-

chine without first obtaining the manufacturer’s approval.
The machine must be inspected for operational safety by a technical

expert at least once a year. The operator is responsible for commis-
sioning the inspection.
03_0032_0510GB 2—3
Safety Regulations
2.3 Use contrary to the Use of the machine other than described in the section ”Designated
designated use use”, or which goes beyond such use, is considered contrary to the
designated use. Putzmeister Mörtelmaschinen GmbH accepts no
liability for damage resulting from such use. The risk of such misuse
lies entirely with the machine operator.
Extending the delivery Extending the delivery line beyond the length specified in the
line technical data is prohibited.
A new delivery line is only suitable for pressures entered on the

rating plate.
Modifications Never make any modifications, additions or conversions to the

machine which might affect safety without first obtaining the
manufacturer’s approval. This also applies to the installation and
adjustment of safety devices and valves as well as to welding work
on load-bearing elements.
The values quoted on the rating plate, in the Technical Data and on
the machine card are the maximum permissible values.
The control and safety settings made at Putzmeister Mörtel-

maschinen GmbH must not be changed.
The machine must not be operated with deactivated, modified or

defective safety devices.
Safety devices must only be repaired, adjusted or replaced by

technically qualified experts.
All devices of relevance for safety must be in place and fully
functional.
2—4 03_0123_0702GB
Safety Regulations
2.4 Liability The operator is obliged to act in accordance with the Operating In-
structions.
The safety and accident prevention regulations from the following

institutions must be observed:
-- Industrial Employers’ Liability Insurance Association,
-- the responsible corporate liability insurance company.
-- the legal authorities in your country.
The following persons are liable under the law for accidents which
can be ascribed to the failure to comply with safety regulations and
accident prevention regulations:
-- the operating personnel or (unless not liable due to lack of training
or basic knowledge)
-- their supervisors.
under the law.
Please therefore ensure that the necessary caution prevails.
Exclusion of liability We state here expressly that Putzmeister Mörtelmaschinen accepts

no liability for damage arising from incorrect or negligent operation,
servicing or maintenance or as a result of use contrary to the desi-
gnated use. This statement is equally valid for modifications to, addi-
tions to and customization of the machine which may compromise
safety. The guarantee will no longer be valid in such cases.
03_0021_0508GB 2—5
Safety Regulations
2.5 Personnel selection The machine may only be operated or serviced independently by
and qualifications persons who
-- have reached the minimum legal age;
-- are physically capable (rested and not under the influence of alco-
hol, drugs or medication);
-- have been instructed in the operation and maintenance of the ma-
chine;
-- can be expected reliably to execute the tasks they are charged
with.
Training The machine must only be operated, serviced or maintained by per-

sons who are trained to carry out such tasks and have been commis-
sioned to do so.
The areas of responsibility for personnel must be clearly defined.
The following personnel must only work on the machine under the
permanent supervision of an experienced person:
-- personnel who have not yet completed training or instruction,
-- untrained personnel,
-- uninstructed personnel,
-- personnel taking a general training course.
Qualified electrician Work on the electrical system and equipment of the machine must
be carried out by a qualified electrician or by instructed persons un-
der the supervision and guidance of a qualified electrician and in
accordance with electrical engineering rules and regulations.
2—6 03_0022_0610GB
Safety Regulations
2.6 Sources of danger Never reach into moving machine components, whether the machine
is running or switched off. Always switch off the main switch first.
Take note of the warning plate.
In the event of malfunctions, stop the machine immediately and se-

cure it. Have any faults rectified immediately.
Secure the machine at the set-up site against rolling away by means
of wedges.
Make sure that nobody is placed at risk by the running machine be-
fore starting up the machine.
Never release or tighten threaded unions that are under pressure.
Delivery line and The delivery line and coupling system is designed for a max. con-
coupling system crete pressure of 40 bar.
The max. concrete pressure must not exceed 40 bar.
03_0067_0603GB 2—7
Safety Regulations
2.7 Safety equipment Never remove or modify safety devices on the machine.
Any safety devices removed for set-up, maintenance or repair purpo-

ses must be refitted and checked immediately upon completion of
the maintenance and repair work.
Safety devices must only be repaired, adjusted or replaced by tech-

nically qualified experts.
All equipment required for safety and accident prevention (warning

signs and information plates, cover grilles, guards, etc.) must be in
place. Such equipment must not be removed, modified or damaged.
2—8 03_0014_0603GB
Safety Regulations
2.8 Risk of injury - resi- The machine has been built in accordance with the state of the art
dual risk and recognised safety rules. Nevertheless, its use may constitute a
risk to life and limb of the operator or of third parties, or cause da-
mage to the machine and to other property.
Some of the injuries that may be caused by improper use of the ma-
chine are listed below:
-- Risk of crushing and bumping when moving and setting up the
machine.
-- Electric contact (in some circumstances with fatal consequences)
with the electrical equipment. If the connection has not been made
correctly or electric subassemblies are damaged.
-- Noise pollution is a danger for persons working continuously near
the machine without hearing protection.
-- Injuries through unauthorised starting or use of the machine.
-- Injuries caused by opening pressurised delivery lines (e. g. after
blockages).
-- Injuries caused by tripping over cables, hoses or reinforcing steel.
03_0033_0510GB 2—9
Safety Regulations
2.9 Risk of crushing and During the following operating modes at the machine:
bumping -- Set-up
-- Starting up
-- Operation
-- Cleaning, Troubleshooting, Maintenance
-- Decommissioning
there is a risk of injury through crushing or bumping.
Transporting the The machine does not have any attachment points and should there-
machine fore loaded onto a suitable transport aid (Euro pallet). Use a suitable
crane with lifting gear or a fork-lift truck to lift the machine.
Danger of crushing
Lift the machine carefully with a fork-lift truck and move with great
care.
When lifting with the crane, determine the centre of gravity of the ma-
chine by lifting carefully. All cables or chains on the lifting gear must
be tensioned evenly and the machine must be raised evenly at all
support points.
The machine must only be loaded onto a suitable transport vehicle

and must be secured against rolling, sliding and overturning during
transport.
Suspended Load
Hoisted loads may fall if they are not loaded properly or if the auxi-
liary loading equipment is damaged.
Ensure no persons are under a suspended load.
Only use an auxiliary loading device with a load-bearing capacity
designed to support the gross weight of the machine!
2 — 10 03_0068_0603GB
Safety Regulations
Assembly of the auger There is a risk of crushing when installing the auger pump.
pump Depending on its installed position, the stator, or auger barrel, may
start turning until it comes to rest against the tie bolt when the ma-
chine is switched on.
Never place hands into the auger pump when switching the machine
on.
Risk of crushing in the end stop area of the auger pump
03_0068_0603GB 2 — 11
Safety Regulations
2.10 Electrical contact The control cabinet, electrical wiring and drive motor pose a risk of
fatal injury from electrical contact during the following:
-- Setting up
-- Operation
-- Decommissioning.
All electrical assemblies are protected as standard, as per

IEC 60204 Part1 or DIN 40050 IEC 144 in accordance with protec-
tion category IP 54.
Use only original fuses with the specified amperage! The electrical
system can be destroyed by overrated fuses or overriding.
Heavy current
Work on the electrical system and equipment of the machine must
accordance with the electrical engineering rules and regulations.
2 — 12 03_0016_0505GB
Safety Regulations
2.11 Place of work The place of work is the area in which people must remain in order to
carry out the work.
Machine operator The place of work of the machine operator during operation is at the
operating panel on the machine.
Accessories operator The workplace of the accessories operator is the area where
connected accessories are used, depending on the work required.
The accessories operator and the machine operator must have
visual contact.
2.12 Working area The working area is the area in which work is carried out with and at
the machine. Parts of the working area can become danger areas,
depending on the job being performed.
The working area is also the area where work is carried out with and
on delivery lines and attached accessories.
Secure the working area and affix signs clearly indicating the
dangers. Suitable protective equipment is compulsory within the
working area. The operator is responsible for safety in the working
area when the machine is in use.
2.13 Conduct in an Switch off the machine immediately in an emergency situation.

emergency
Refer also to chapter: ”Operation” -- section: ”Emergency shutdown
procedures” for further details.
Caution
In the event of malfunctions, stop the machine immediately and
secure it. Have any faults rectified immediately.
03_0121_0702GB 2 — 13
Safety Regulations
2.14 Sound emissions Sound emissions are generated during the following operating
modes at the machine:
-- Starting up
-- Operation
-- Cleaning, troubleshooting, maintenance
-- Decommissioning.
Refer to the technical data for the sound pressure level value in the
vicinity of the machine.
We recommend wearing ear defenders for noises louder than

85 dB (A); the employer should provide personnel with ear
defenders although this is not compulsory.
Wearing ear defenders for noises louder than 90 dB (A) is
compulsory.
Wear your personal ear defenders.
Operator Instruct your personnel always to wear their personal ear defenders.
As the operator, you are responsible for ensuring that your personnel
comply with this regulation.
All soundproofing equipment must be present and in perfect

condition. This equipment must be set to protective position during
operation. High sound levels can cause permanent hearing damage.
2 — 14 03_0112_0702GB
Safety Regulations
2.15 Spare parts Spare parts must comply with the technical requirements specified
by the manufacturer. Spare parts from original equipment manufac-
turers guarantee this.
Use only original spare parts. Putzmeister Mörtelmaschinen GmbH

accepts no liability for damage caused as a result of using non-
original spare parts.
2.16 Accessories Accessories must meet the requirements specified by Putzmeister

Mörtelmaschinen GmbH and be compatible with one another. Using
accessories from original equipment manufacturers guarantee this.
Note
Accessories that are not included in the scope of supply delivered
with the machine are supplied by Putzmeister and can be purchased
through Parts Sales.
Please refer to the delivery note for a list of accessories supplied.
The operating company is responsible for ensuring that the correct

accessories are used.
Putzmeister Mörtelmaschinen GmbH declines all responsibility and
liability for damage caused as a result of using non-original acces-
sories or using correct accessories inappropriately.
2.17 Storing the machine The machine should be stored only in a dry, frost-free location.
If there is a danger of freezing at the storage location, take

appropriate antifreeze protection measures.
For further details, refer also to the chapter: ”Decommissioning”.
03_0122_0702GB 2 — 15
Safety Regulations
2.18 Injuries through un- During the following operating modes at the machine:
authorised starting -- Starting up
or use of the machine -- Operation
-- Decommissioning
there is a risk due to unauthorised starting or use of the machine.
Always secure the machine against unauthorised starting before lea-

ving the work area. This means:
-- Switch the main switch to OFF.
2 — 16 03_0034_0510GB
General Technical Description
3 General Technical Description
This section describes the components and assemblies on this

machine and describes how they function. Please note that possible
options are also described. Please see the machine card to find out
whether a particular option is fitted.
3.1 Designation of machine Your machine is a S 5 from Putzmeister Mörtelmaschinen GmbH.

You will make it much easier for us to answer any questions or
respond to orders if you can give us the details of the machine
model and the machine number.
02_0031_0704GB 3—1
3.2 Machine versions These operating instructions are valid for subsequent versions of the
machine.
Model Type Material no.

S 5 EV 400/230V 50Hz 5.5KW 111452010
S 5 EV/CM 400/230V 50Hz 5.5KW 111452020
S 5 EV/TM 400/230V 50Hz 5.5KW 111452030
S 5 EV 400/230V 50Hz 5.5KW 111452040
S 5 EV/TM 400/230V 50Hz 5.5KW 111452080
S 5 EV 400/230V 50Hz 7.5KW 111452100
S 5 EV/TM 400/230V 50Hz 5.5KW 111452110
S 5 EV/TM 380/220V 60Hz 5.5KW 111452123
S 5 EV 400/230V 50Hz 5.5KW 111452130
S 5 EV/TM 220/440V 60Hz 5.5KW 111452180
The following data can be found on the accompanying machine card

and on the rating plate:
-- Machine version (voltage and frequency)
-- Machine number
Note
The machine number is allocated by Putzmeister Mörtelmaschinen
GmbH. Each machine number is only allocated once. This means
that the machine number identifies each individual machine.
3.3 Scope of supply The scope of supply includes:

-- the auger pump S 5,
-- Operating Instructions,
-- a spare parts list,
-- a document folder,
-- standard accessories.
Note
The specifications relate to the series machine and may deviate if
special equipment is fitted. Please refer to the supplied machine
card for details.
3—2 02_0031_0704GB
3.4 Summary Below you will find an overview of the most important components;
these will then be described on the following pages.
S 5 EV
1 2
9 8 7 6 5 4 3
Item Designation
1 Protective grille
2 Hopper
3 Discharge connection
4 Auger pump
5 Cardan shaft
6 Engine
7 Control cabinet
8 Axle and wheels
9 Handwheel adjuster
Continued on following page
02_0031_0704GB 3—3
S 5 EV/CM
11 10 9 8 7 6 5 4
Item Designation
1 Flow-type mixer
2 Protective grille
3 Hopper
5 Auger pump
6 Cardan shaft
7 Engine
8 Control cabinet
9 Axle and wheels
11 Control unit
3—4 02_0031_0704GB
S 5 EV/TM
1
10 9 8 7 6 5 4
Item Designation
1 Plate mixer
2 Protective grille
3 Hopper
5 Auger pump
6 Cardan shaft
7 Engine
8 Control cabinet
9 Axle and wheels
02_0031_0704GB 3—5
3.5 Technical data The technical data and characteristics stated below relate to the
SP 5.
Machine, general S 5 EV S 5 EV/CM S 5 EV/TM

Dimensions
Length: 2290 mm 2840 mm 2290 mm
Width: 680 mm
Height: 650 mm 1200 mm 1150 mm
Weights
Weight: 190 kg 360 kg 400 kg
Performance data
Pumping rate: 7 to 40 l/min.
Max. delivery pressure: 25 bar
Max. delivery distance: 80 m distance, 60 m high
Conveyed medium max.
6 mm
grain size:
Sound pressure level: 72 dB (A)
Inclination angle in
max. 7˚
longitudinal direction:
Inclination angle in
max. 7˚
transverse direction:
Connectors
Power connection: CEE connector plug, 5 x 6 mm2, 32 ampere, 5-pole, 400 V
Max. fuse: 25 ampere 32 ampere 25 ampere
Note
The stated outputs are guide values only.
The maximum pumping rate and the maximum delivery pressure
cannot be reached simultaneously.
The actual rates depend on the properties and consistency of the
material being delivered.
3—6 02_0032_0704GB
S 5 EV 111452010 111452040 111452100 111452130

Performance data
Electric motor Electric motor
Electric motor
50 Hz, 400 V, 50 Hz, 400 V,
S 5 drive motor 50 Hz, 400 V, 5.5 kW,
7.5 kW, n= 5.5 kW, n=
n= 43 -- 234 rpm
43 -- 234 rpm 43 -- 234 rpm
Cardan shaft: L 6 Paddel L 6 Hardy-S. L 6 Paddel
Auger pump: 2L6 3L7 2L6
S 5 EV/CM 111452020
Performance data
Electric motor
S 5 drive motor
50 Hz, 400 V, 5.5 kW, n= 43 -- 234 rpm
Electric motor
Drive motor for mixer:
50 Hz, 400 V, 5.5 kW
Cardan shaft: L 6 Paddel
Auger pump: 2L6
S 5 EV/TM 111452030 111452080 111452110 111452123 111452180

Performance data
Electric Electric
motor motor
60 Hz, 60 Hz,
Electric motor
S 5 drive motor: 220 / 380V, 220 / 440V,
50 Hz, 400 V, 5.5 kW, n= 43 -- 234 rpm
5.5 kW, 5.5 kW,
n= 43 -- n= 50 --
234 rpm 234 rpm
Electric Electric
motor motor
Electric motor 60 Hz, 60 Hz,
Drive motor for mixer:
50 Hz, 400 V, 2.2 kW 220 / 220 /
380 V, 440 V,
2.2 kW 2.2 kW
L 6 Hardy-
Cardan shaft: L 6 Paddel L 6 Paddel
S.
Auger pump: 2L6
02_0032_0704GB 3—7
3.6 Rating plate The most important machine data is shown on the rating plate.
1
2
3
4
5
6
7
Item Designation
1 Model (machine model)
2 Mach. no. (machine number)
3 Year of manufacture
4 Max. delivery pressure [bar]
5 Voltage [V]
6 Frequency [Hz]
7 Power [kW]
3—8 02_0274_0608GB
3.7 Sound power level In accordance with Directive 2000/14/EC the sound power level emit-
ted by the machine is given below.
Next to the rating plate on the machine there is the plate shown in
the picture below which gives the machine’s sound power level mea-
surement.
XXX
Item Designation
LWA Sound power level
dB Decibel value
02_0174_0603GB 3—9
3.8 Options Consult your dealer or local Putzmeister Mörtelmaschinen GmbH re-
presentative as to how and whether you should upgrade your ma-
chine.
The following options can be installed on your machine:

-- Compressed-air remote control
-- Vibrator
-- Fill-level sensor (for flow-type mixer)
Notes
You can obtain further information on options and accessories from
the catalogue (Item No. MM 2599/JJ) from Putzmeister
Mörtelmaschinen GmbH.
3 — 10 02_0033_0510GB
3.9 Safety equipment The following is a list of installed safety devices on the machine.
EMERGENCY STOP Depending on the version and country of use, your machine may be
button (optional) fitted with an EMERGENCY STOP button.
Caution
Familiarise yourself with the position of the EMERGENCY STOP but-
tons on your machine.
Should your machine not have an EMERGENCY STOP button, it

should be switched off at the main switch when an impending dan-
ger arises.
Item Designation
1 EMERGENCY STOP button on control cabinet
When the EMERGENCY STOP button is pressed, the following oc-

curs:
-- The pump comes to a halt.
-- The agitator stops.
-- All control and switch boxes are electrically disabled.
Notes
To cancel the EMERGENCY STOP status, you have to unlock the de-
pressed EMERGENCY STOP button by turning it.
02_0243_0607GB 3 — 11
Protective grille The protective grille is screw-fitted in the hopper of the machine.
The mesh size is such that material can fall unobstructed into the
drum, yet guarantees protection for the operator.
Item Designation
1 Protective grille
Danger
The protective grille must be installed in every operating mode and
after every repair.
3 — 12 02_0243_0607GB
3.10 Functional This chapter is intended to help you understand the operational se-
description quences of the machine so that you can limit the field of the machi-
ne’s applications to suitable areas and avoid errors in operation.
General description of Putzmeister machines are easy to assemble and operate. In spite of
the machine this, certain precautionary measures must be taken when operating
the machine to ensure that the wear parts have as high a life limit as
possible.
The auger pump is exclusively designed to deliver premixed, pum-

pable dry and wet mortar of a granulation up to a maximum of 6 mm.
It pumps and sprays continuously.
The machine is filled via the hopper.
The mixed material is conveyed from the hopper by the auger pump.
A spray gun can be attached to the end of the hose. Air is introdu-
ced from the compressor and the mortar applied at the desired coat
thickness.
A compressor needs to be provided for spraying works.
02_0166_0603GB 3 — 13
General layout of the On its mixer side, the machine can be combined with a flow-type
flow-type mixer mixer. The flow-type mixer forms a unit in its own right, and will work
independently of the machine.
The flow-type mixer is suitable for mixing premixed dry mortar, either
from a sack or a silo.
The flow-type mixer is fitted on to the machine.
The electrical connection is made at the control cabinet of the control

unit. The machine is connected to the control cabinet of the control
unit, using a connector cable. Thus only a single cable is required for
the two machines.
Depending on the model, the flow-type mixer can be filled with

cement from a sack or from a silo. The premixed dry mortar passes
via the hopper and the measuring pipe into the mixing pipe. In the
mixing pipe, the desired material consistency is produced though
the controlled addition of water. The consistency can be set using
the flow meter. At the end of the mixing pipe, the pumpable material
is continuously emptied into the machine hopper.
The flow-type mixer is equipped with a fill-level sensor. This is

located in the machine hopper and is used to control the flow-type
mixer automatically.
3 — 14 02_0175_0603GB
General layout of the On its mixer side, the machine can be combined with a plate mixer.
plate mixer The plate mixer forms a unit in its own right, and will work indepen-
dently of the machine.
The plate mixer is used for premixed dry mortars, which must be
mixed either particularly intensively or for longer periods.
The plate mixer is fitted on to the machine.
The electrical connection is made at the machine control cabinet.
The plate mixer is filled from the mixing drum, where the mortar is
mixed to the required consistency. The pumpable material is then
emptied through the flap into the machine hopper.
02_0176_0603GB 3 — 15
3.11 Control cabinet The machine is controlled and operated via the control cabinet.
Heavy current
The control cabinet’s wiring, earthing and connections comply with

VDE codes of practice.
1 2 3
Item Designation Function/display

1 EMERGENCY STOP Switches off the machine in
button an emergency
(optional)
2 Double pushbutton Pump ON/OFF
3 Main switch Power supply ON/OFF
4 CI external device socket Compressor connection
5 CI external device socket Disc mixer connection
6 CEE external device plug Power supply connection
7 Dummy plug Remote control connection
3 — 16 02_0035_0607GB
3.12 Control unit control The control unit is operated using the control cabinet.
cabinet
Heavy current

1
4
2
5
9 8 7 6

2 Double pushbutton Mixer ON/OFF
3 Signal lamp Ready
4 CEE external device socket S 5 connection
5 Socket Water pump connection
6 CEE external device socket Fill-level sensor connection
7 CEE external device socket Flow-type mixer connection
8 CEE external device socket Vibrator connection
02_0164_0603GB 3 — 17
3.13 Plate mixer control The plate mixer is operated using the control cabinet.
cabinet
Heavy current


3 — 18 02_0173_0603GB
3.14 Drive S 5 EV The machine is driven by an electric motor.
1 2 3
Item Designation
2 Variable drive
3 Drive motor
4 Gear unit
The drive motor has different connection values, depending on the

model. Please refer to the rating plate, the machine card or to the
”Transport, Setup and Connection” chapter in the ”Electrical connec-
tions” section for the connection values for your machine.
Notes
Further information regarding the drive motor may be found in the
manufacturer’s documentation.
The delivery rate can be infinitely varied by means of the handwheel

adjuster(1).
02_0034_0510GB 3 — 19
3.15 Flow-type mixer drive The flow-type mixer is driven by an electric motor.
1
3 4
Item Designation
1 Drive motor
2 Hopper
3 Intake and measuring pipe
4 Mixing pipe

”Transport, set-up and connection” chapter in the ”Electrical
connections” section for the connection values for your machine.
Note
3 — 20 02_0161_0603GB
3.16 Plate mixer drive The plate mixer is driven by an electric motor.
1 2
Item Designation
1 Drive motor
2 Mixing drum

”Transport, set-up and connection” chapter in the ”Electrical connec-
tions” section for the connection values for your machine.
Notes
02_0162_0603GB 3 — 21
3.17 Auger pump The auger pump built into the machine is called a displacement
pump. An auger (rotor) rotates inside a fixed auger barrel (stator).
The auger consists of a highly wear-resistant, very hard metal alloy
and the auger barrel of a multi-notched steel sleeve with vulcanised
elastic rubber core. The tensioning casing is used to retension the
auger pump.
3
2
1
Item Designation
1 Auger
2 Auger barrel
3 Clamping sheath
4 Tensioning screws
3 — 22 02_0057_0511GB
3.18 Cable remote control The machine comes equipped with cable remote control as stan-
dard.
Its socket is located in the control cabinet.
2
1
Item Designation
1 Remote control cable
2 Toggle switch ”ON -- OFF”
3 ”Remote control” coupler plug
02_0167_0603GB 3 — 23
3.19 Vibrator (optional) As an option, the machine can be equipped with a riddler and a vi-
brator.
5
4 3
Item Designation
1 Riddler
2 Vibrator
3 ”Vibrator ON/OFF” rotary switch
4 CEE ”Power supply connection” external device plug
5 CEE ”Vibrator connection” wall socket
The vibrator which is fitted to the riddler should be connected to the

”Vibrator connection” wall socket(5). The ”Power supply connection”
external device plug(4) should be plugged into the control cabinet.
The vibrator can be switched on or off with the ”Vibrator ON/OFF”

rotary switch(3).
3 — 24 02_0168_0603GB
3.20 Remote control by As an option, the machine can be equipped with a compressed-air
compressed air remote control system.
(optional)
1
3 2
Item Designation
1 Pressure switch
2 Coupler plug connector -- control cabinet
3 Hose coupling -- connection to compressor
4 Hose coupling, air tapping
When work is being done using the spray gun, the pump is switched
on and off by means of the pressure switch(1) in the compressed-air
remote control system.
Pressure switch setting values:
Switching on point: 2.0 bar

Switching off point: 3.0 bar
Maintenance card: Adjusting the pressure switch
Coupler plug connector(2) is plugged in at the control cabinet in-

stead of the cable remote control unit.
Air for spraying is fed from the compressor provided and fed to the
spray gun via the compressed--air remote control system.
02_0169_0603GB 3 — 25
3.21 Fill-level sensor As an option, the machine can be equipped with a fill-level sensor.
(optional) The fill-level sensor is used to control the flow-type mixer automati-
cally.
Item Designation
1 Fill-level sensor
3 — 26 02_0170_0603GB
Transport, Set-up and Connection
4 Transport, Set-up and Connection
In this section you will find information concerning safe transport of

the machine. Furthermore, work is described in this section, which is
also necessary for the installation and connection of the machine.
Starting up the machine will not be described until the chapter ”Star-
ting up”.
4.1 Unpacking the ma- Before shipment, the machine is packaged for transportation. Un-
chine pack the machine and dispose of the packaging material.
Recyclable materials are used for packaging the machine.
Dispose of the packing material in compliance with the nationally va-
lid environmental protection regulations.
04_0006_0508GB 4—1
4.2 Transporting the The machine does not have any attachment points and should there-
machine fore loaded onto a suitable transport aid (euro pallet). Use a suitable
crane with lifting gear or a fork-lift truck to lift the machine.
Danger of crushing
Lift the machine carefully with a fork-lift truck and move with great
care.
When lifting with the crane, determine the centre of gravity of the ma-
chine by lifting carefully. All cables or chains on the lifting gear must
be tensioned evenly and the machine must be raised evenly at all
support points.
Suspended Load
4—2 04_0007_0508GB
4.3 Selecting the set-up The set-up site of the machine is usually determined and appropria-
site tely prepared by the site management.
Notes
The responsibility for setting up the machine safely falls on the ope-
rator.
4.4 Set-up site Inspect the proposed site carefully and reject the set-up site if you
requirements have any doubts in respect of safety.
The set-up site must:

-- be horizontal,
-- have level, firm supporting ground,
-- be large enough to allow you to open all flaps and hoods unhinde-
red. You should therefore leave a clearance of at least 1 metre
around the entire machine,
-- such that the machine is accessible from all sides for servicing
and repairs.
Caution
The machine be situated outside the danger zone of elevated work-
sites, or protective roofing must be provided for the machine at its
operating sites.
Supporting ground The support ground must be firm enough to absorb the forces pas-
sed on from the machine into the ground. There must be no hollow
spaces or ground unevenness under the machine.
If the machine is to remain at a set-up site for a long period, it is ad-

visable to select a site with a concrete base.
In the case of machines which operate with at high pressure and

high delivery rate, it is advisable to anchor the machines to the
ground.
Lighting Ensure that there is adequate lighting at the set-up site.
04_0003_0505GB 4—3
Angle of inclination The following maximum angles of inclination are permissible when
the machine is in operation:
-- In pulling direction 7_ upwards.
-- Sides, 7_ in both directions.
7_
7_ 7_
Permissible angles of inclination
4—4 04_0038_0603GB
4.5 Fitting the flow-type Fit the flow-type mixer on the S 5 connection in the following way:
mixer
12
10 2
11
3
9
8 4
7 6 5
Item Designation
1 Flow-type mixer
2 Fastening bolts
3 Fill-level sensor
4 CEE ”Power supply connection” external device plug
5 CEE ”Fill-level sensor connection” external device socket
6 CEE ”Flow-type mixer connection” external device socket
7 Control unit
8 CEE ”S 5 connection” external device socket
9 ”Flow-type mixer” water connection
10 Connector cable
11 Rubber cover
12 Bracket
Notes
As a protective measure, the rubber cover(11) must remain on the
machine.
" Fit the bracket(12) on to the frame of the machine and screw it
down tightly.
04_0039_0603GB 4—5
Danger of crushing
Use only suitable lifting equipment for lifting components.
Lifting equipment, lifting tackle, support trestles and other auxiliary
equipment must be reliable and safe in operation.
Make sure that the load-bearing capacity is sufficient.
Suspended Load
" Place the flow-type mixer on the bracket.
" Attach the flow-type mixer tightly with the fastening screws.
" Insert the flow-type mixer external device plug into the ”Flow-
type mixer connection” external device socket on the control
unit.
" Fit the fill-level sensor inside the machine hopper.
" Insert the fill-level sensor external device plug into the ”Fill-level
sensor connection” external device socket on the control unit.
" Connect the ”Power supply connection” external device plug at

the machine control cabinet to the ”S 5 connection” external
device socket at the control cabinet. Do this using the connec-
tor cable.
" Connect the flow-type mixer water cable to the ”Flow-type mi-
xer” water connection on the control unit.
" Reinstall all disassembled safety devices correctly.
" To remove, repeat the process in reverse order.
4—6 04_0039_0603GB
4.6 Fitting the plate mixer Fit the plate mixer on the S 5 connection in the following way:
2
5
4 3
Item Designation
1 Plate mixer
2 Fastening bolts
3 CEE ”Plate mixer connection” external device socket
4 CEE ”Plate mixer” external device plug
5 Rubber cover
" Remove the fastening screws(2) from the frame of the ma-
chine.
Notes
As a protective measure, the rubber cover(5) must remain on the
machine.
04_0040_0603GB 4—7
Danger of crushing
Use only suitable lifting equipment for lifting components.
Lifting equipment, lifting tackle, support trestles and other auxiliary
equipment must be reliable and safe in operation.
Make sure that the load-bearing capacity is sufficient.
Suspended Load
" Place the plate mixer on the frame of the machine.
" Attach the plate mixer tightly with the fastening screws.
" Insert the ”Plate mixer” external device plug into the ”Plate mi-
xer connection” external device socket at the control cabinet.
" Reinstall all disassembled safety devices correctly.
" To remove, repeat the process in reverse order.
4—8 04_0040_0603GB
4.7 Water connections The following section describes how to connect the flow-type mixer
to the water supply.
Item Designation
1 Flow-type mixer control unit
2 Connecting to the mains water supply
The water supply may only be connected as per DIN 1988 -- Techni-
cal Rules for Water Installations, i.e. by means of installation type 1
backflow preventers or an independent outlet (buffer tank with a boo-
ster pump).
Please ensure that you check preconditions for connection to the wa-
ter supply before beginning connection work.
-- The pipe must be at least 3/4” in diameter.
-- The available water pressure must be at least 4 bar.
Water pipes must be laid visibly, taking local conditions into conside-
ration, and protected against damage. They must not be allowed to
obstruct operating personnel.
04_0013_0510GB 4—9
Caution
The water used must be clean and of drinking water quality.
Never use: salt water, sea water, completely desalted water or water
with added chemicals.
If there is a risk of freezing, the pipes must be laid so as to exclude

the possibility of the water freezing.
" Couple the water hose to the water connection(2).
4 — 10 04_0013_0510GB
4.8 Electrical connection The electrical connections vary for each machine model. Please re-
fer to the rating plate or the technical specifications in the chapter
”General Technical Description” for the electrical connection values.
The following versions are available:
Material no. Model Type Connector plug Fuse

111452010 S 5 EV 400/230V 50Hz CEE 5--pin, 400 V, 32 A 25 A
111452020 S 5 EV/CM 400/230V 50Hz CEE 5--pin, 400 V, 32 A 32 A
111452030 S 5 EV/TM 400/230V 50Hz CEE 5--pin, 400 V, 32 A 25 A
Heavy current
The electrical connection must be made on the basis of the electrical

circuit diagram supplied.
Caution
Do not turn the main switch on at this stage.
The main switch must remain locked until the entire system has been
completely assembled.
04_0014_0607GB 4 — 11
Prerequisites Electrical installation prerequisites should be checked by a qualified

electrician before connection work begins. Refer to the Directives
stipulated in BGI 608.
-- The connected load of the existing electrical installation must be
sufficient for the machine.
-- Connection may only be carried out at a specific feed point (e.g.
site power distribution point complying with VDE 0612). Please re-
fer to the technical data for the maximum back-up fuse values.
-- Operating voltage may not fall below the loads permissible under
-- Please refer to the technical data for the external device plug type.
-- All 3 phases and the PE (Potential Earth) protective conductor
must be present.
Laying electrical supply Supply cables must be laid visibly, taking local conditions into consi-
cables deration, and secured against damage.
Danger
There is a danger of electric shock which may have lethal conse-
quences by:
– contact with electrical cables;
– contact with machines with electrical drives, if the electrical con-
nection has not been properly made or the supply cable is dama-
ged.
4 — 12 04_0014_0607GB
Connection to the mains On construction sites, the machine should only be connected via a
power supply special-purpose feed point in accordance with VDE 0612 (generally
a site power distribution point with residual current circuit breaker).
S 5 EV, S 5 EV/TM
Item Designation
1 Plug connector
2 On-site cable
" Connect cable(2) to plug connector(1) on the machine.
04_0014_0607GB 4 — 13
S 5 EV/CM
Item Designation
1 Plug connector
2 On-site cable
" Connect cable(2) to plug connector(1) on the machine.
4 — 14 04_0014_0607GB
Starting up
5 Starting up
In this chapter you will find information on starting up the machine.

The work steps for initial operation of the machine are described as
well as how to prepare the machine for operation after a long break.
There is also a description on how to check the condition of your ma-
chine and how to carry out a test run with function checks.
Notes
The operating personnel should be trained on the machine during
initial operation.
Every time the machine is in operation, the operator accepts full re-
sponsibility for the safety of anyone located in the machine’s danger
zone. He is therefore obliged to ensure absolute operating safety of
the machine.
The operator must familiarise himself with the machine during ma-
chine handover.
This means:
-- He must have read and understood the Operating Instructions (es-
pecially the chapter on Safety Regulations).
-- He must be in a position to carry out the correct measures in case
of emergency and switch off and secure the machine.
The entire system must be observed during the initial hours of opera-
tion to identify possible malfunctions.
09_0001_0505GB 5—1
Starting up
5.1 Checks Each time the machine is used at a construction site, you should
check the condition of your machine and carry out a test run inclu-
ding function checks. If you identify any faults during the checks,
you must eliminate these (or have these eliminated) immediately.
Visual checks Some important visual checks should be carried out before starting
up the machine.
" Always check the machine thoroughly for apparent defects be-
fore starting work.
" Check that all safety equipment is in place and is fully operatio-
nal.
Electrical connection Using faulty electrical components or connecting components incor-

rectly may result in serious injury (possible fatal) or severe damage
to the machine.
" Always check all electrical components carefully for apparent

defects before starting work.
" Check whether the required power supply is available.
5—2 09_0012_0510GB
Starting up
5.2 Test run Carry out a test run before operating the machine.
Switch-on conditions The following switch-on conditions must prevail before the pump is
switched on:
-- The machine should be in a horizontal position.
-- The machine must be connected to the correct power supply.
Read the ”Electrical connection” section in the chapter ”Transport,
Setup and Connection”.
For the test run, first switch on the main switch, followed by the
pump.
Notes
Any defects found during these tests must be rectified immediately.
A fresh inspection is necessary after every repair. The machine may
only be put into operation once all the inspections described below
have been concluded satisfactorily.
Switching on pump
2 1
Item Designation
1 Main switch
2 Double push-button ”Pump ON/OFF”
" Switch on the main switch(1).
" Switch the pump on at double push-button(2).
09_0013_0510GB 5—3
Starting up
Checking direction of Check that the direction of rotation of the pump is correct:
rotation
Procedure:
" Switch the pump on at the doublepush-button ”Pump ON/

OFF”. Refer also to the section: ”Switching on the pump”.
" Check the direction of rotation of the Cardan shaft. Note the
directional arrows on the gearbox.
Notes
The Cardan shaft must turn in the direction of the arrow(s).
If the direction of rotation is incorrect, the pump cannot deliver mate-
rial. Change the direction of rotation.
The direction of rotation varies according to the auger pump type.
To change the direction of rotation:
Item Designation
1 Main switch
2 Reversing switch
5—4 09_0045_0603GB
Starting up
" Switch the pump off at the double push-button ”Pump ON/
OFF”.
" Switch off the main switch (position ”0”).
" Switch the reversing switch over.

⇒ The ”I” symbol changes automatically to the opposite direc-
tion of rotation.
Notes
The direction of rotation is fixed using the integrated main reversing
switch.
Never operate the reversing switch when the main switch is in posi-
tion ”l”. The rotary field mechanics are locked - any forcible turning
will damage the switching mechanism.
" Switch the main switch on.
" Check the correct direction of rotation once again as described

above.
09_0045_0603GB 5—5
Starting up
Checking function of Depending on the version and country of use, your machine may be
EMERGENCY STOP fitted with an EMERGENCY STOP button.
button (optional)
Check the operability of the EMERGENCY STOP button.
Press: lock EMERGENCY STOP

Rotate: unlock EMERGENCY STOP
" Switch the pump on. Refer also to the section: “Switching on
the pump”.
" Press the EMERGENCY STOP button.

⇒ The pump comes to a halt.
⇒ The agitator stops.
⇒ All control and switch boxes are electrically disabled.
" Unlock the EMERGENCY STOP button by turning it.
Caution
The machine is no longer safe to operate if the EMERGENCY STOP
button is defective, as you will no longer be able to switch off the
machine quickly enough if danger threatens.
If the EMERGENCY STOP button does not respond during the
check, the machine must not be started up.
You must therefore check the functioning of the EMERGENCY STOP
button each time you start work.
5—6 09_0076_0607GB
Starting up
5.3 The delivery line Only use original Putzmeister delivery lines which meet prescribed
operating and burst pressures.
Notes
Only Putzmeister couplings and fittings are guaranteed to comply
with the values specified in the German Accident Prevention Regula-
tions.
You must secure delivery lines with threaded spouts by gluing. You
must ensure that you use a seal which is designed for the purpose to
secure any new coupling against being opened. You must screw the
coupling to the stop. After this, it should no longer be possible to
undo it by hand.
Only use delivery lines with a suitable internal diameter.
Caution
Only couple delivery line couplings which have been cleaned and
have fully operational gaskets. Soiled couplings are not properly sea-
led and allow water to leak out under pressure. This leads inevitably
to blockages.
09_0046_0512GB 5—7
Starting up
5.4 Shutting down the After the function check, you can shut down the machine.
machine after
operation Caution
The handwheel adjuster must only be used when the pump is wor-
king.
Otherwise, the drive may be damaged.
When there are breaks in pumping or the machine is being shut

down, always adjust the delivery rate to the lowest setting.
" With the pump running, adjust the delivery rate to the lowest
setting using the handwheel adjuster.
2 1
Item Designation
1 Main switch
2 Double pushbutton ”Pump ON/OFF”
" Switch the pump off at the double pushbutton ”Pump ON/
OFF”(2).
" Switch the machine off at the main switch(1).
5—8 09_0047_0603GB
Operation
6 Operation
In this section you will find information on machine operation. You will
learn what operations are required for setting up the machine, opera-
tion and for cleaning.
6.1 Requirements Before starting to use the pump, you must carefully carry out the
working steps for commissioning and installing the machine. Before
you fill material into the machine and pump it through the delivery
line you must be sure that
-- the machine functions correctly,
-- the delivery line is designed to withstand the intended delivery
pressure and
-- the delivery line has been laid professionally.
Notes
Should a malfunction occur when the pump is in operation, first con-
sult the Chapter ”Fault, Cause and Remedy”. Contact Putzmeister’s
After Sales department for advice, if you are unable to rectify the
fault yourself.
05_0018_0510GB 6—1
Operation
6.2 Emergency shut-down Make sure you are completely familiar with the procedures for
procedures shutting down the machine in an emergency situation before you
start operating the machine.
Danger
Proceed immediately as described below if an emergency occurs
while you are operating the machine.
" Close the air valve on the spray gun.
" Switch the main switch on the control cabinet to “0”.
" Switch the compressor off.
" Take emergency measures, where necessary.
" Note the incident and report in accordance with company

procedures.
" Look for the cause of the fault and rectify it completely.
" Start up the machine in accordance with the commissioning

instructions.
EMERGENCY STOP Depending on the version and country of use, your machine may be
button (optional) fitted with an EMERGENCY STOP button.
It should be fitted in the control cabinet.
Danger
In the event of impending danger, press the EMERGENCY STOP
button!
Should your machine not have an EMERGENCY STOP button, it

should be switched off at the main switch when an impending
danger arises.
Caution
Familiarise yourself with the position of the EMERGENCY STOP
buttons on your machine.
6—2 05_0107_0607GB
Operation
Press: lock EMERGENCY STOP

Rotate: unlock EMERGENCY STOP
" If possible, close the air valve on the spray gun.
" Press the EMERGENCY STOP button.

⇒ The pump must come to a halt immediately.
⇒ The agitator stops.
⇒ All control and switch boxes are electrically disabled.
" Take emergency measures, where necessary.
" Note the incident and report in accordance with company

procedures.
" Look for the cause of the fault and have it rectified/rectify it
completely.
" Unlock the EMERGENCY STOP button by turning it.
Note
To cancel the EMERGENCY STOP status, you have to unlock the
depressed EMERGENCY STOP button by turning it.
" Start up the machine in accordance with the rules for starting
up the machine.
05_0107_0607GB 6—3
Operation
6.3 Initial pumping The process from the start of forward pumping to the time at which
a continuous flow of material exits from the delivery line is known as
priming the pump. This can take place at the start of building site
operations, but also after pumping interruptions.
At the beginning of pump operation the entire delivery pipe has to be

wetted.
Pumping must generally be started with the aid of a cement grout.
Notes
The grout lubricates the inside of the delivery line and prevents blok-
kages.
Operating the screw conveyor dry will destroy the conveying hose!
" Rinse the delivery line out briefly with water before connecting
it. Use one or two of the sponge balls provided as standard
accessories soaked in water to do this.
" Approx. 20 -- 40 l of grout are required, depending on the

length of the delivery line.
" Now mix in cement grout and add this to the hopper.
" Switch on the auger pump.
" Pump the grout slowly into the delivery line.
The process of priming with grout finishes when the 2 sponge balls
and a full jet of material exit from the delivery line.
With the first mixture, pump the grout through the delivery line. As it
leaves the delivery line, collect the grout in a suitable container and
dispose of it.
6—4 05_0024_0511GB
Operation
6.4 Adjusting the auger The tensioning casing is used to retension the auger pump. The
pump wear of the auger pump can be compensated by reclamping. The
delivery pressure can also be adjusted by pretensioning or relieving
the auger barrel.
" Use the test pressure gauge to set the delivery pressure of the
auger pump.
" Pressure test the auger pump using water.
Maintenance card: Setting the auger pump
1
2
Item Designation
1 Clamping sheath
2 Tensioning screw
Notes
Set the auger pump with the test pressure gauge to a water pressure
of approx. 15-20 bar.
05_0065_0603GB 6—5
Operation
6.5 Pumping operations Carefully carry out the operations for starting up the machine and
setting up the machine and ensure that it is functioning perfectly be-
fore you fill the hopper with medium and begin pumping it through
the delivery line.
Notes
Should a malfunction occur when the pump is in operation, first con-
sult the Chapter ”Fault, Cause and Remedy”. Contact Putzmeister’s
After Sales department for advice, if you are unable to rectify the
fault yourself.
Notes
To prevent blockages in the delivery lines, the inside of the line must
be prelubricated with a laitance.
At the start of pumping, the entire delivery line must be lubricated

with a laitance.
" Prelubricate the delivery line with a laitance. Refer also to the
section: ”Starting pumping”.
The pump is generally started at a low speed of rotation. Once the

delivery line has been lubricated, pumpable material is first delivered
at the lowest possible speed of rotation. If the pump is working
soundly, the delivery rate can be increased.
Caution
Never pump demixed medium or medium that is lumpy due to the
commencement of congealing into the delivery line with force. Blok-
kages are very easily caused by this.
" Add pumpable material to the hopper.

⇒ The material in the hopper is mixed together.
6—6 05_0064_0603GB
Operation
6.6 Mixing with the plate The plate mixer mixes the dry mortar to make pumpable material
mixer when water is added.
1
2
Item Designation
1 Cover
2 Mixing drum
3 Flap
Fill the plate mixer in the following way:
" Close the flap(3).
Item Designation
1 ”Power supply ON/OFF” main switch

⇒ The mixing mechanism begins to operate.
05_0074_0603GB 6—7
Operation
Caution
The mixing mechanism must turn in an anticlockwise direction.
If the mixer turns in the wrong direction when full, it may be dama-
ged. Change the direction of rotation.
" Fill the mixing drum with water.
You may now fill the mixer with dry mortar. Use the bag-opener in the
top of the cover to open the bag.
Fill the mixer evenly, avoiding spreading unnecessary dust.
Danger
Wear respiratory protection and a face mask in all work in which par-
ticles of building materials can enter the body through the respiratory
passages. Comply with the information issued by the manufacturer
of the building material. Keep first aid equipment available. Follow
emergency first aid procedures. All injuries must be reported to a
supervisor.
Notes
In order to achieve optimum mixing effectiveness, the mixing drum
should only be filled up to the middle of the upper mixing arm.
" Pour dry mortar into the mixing drum until the desired consi-
stency is achieved.
" Mix the material until it is of a good consistency for pumping.
Danger
Mortar spraying out of the drum poses a danger.
You must wear protective goggles.
Turn your face away when opening the flap.
" Open the flap.

⇒ The pumpable material empties out.
6—8 05_0074_0603GB
Operation
6.7 Mixing with the flow- The flow-type mixer produces pumpable material by mixing. The fill-
type mixer level sensor is used to control the flow-type mixer automatically.
The flow-type mixer is operated in the following way:
Item Designation
1 ”Power supply ON/OFF” main switch
2 ”Pump ON/OFF” double pushbutton
3 ”Ready for service” indicator lamp

⇒ The ”Ready for operation” signal lamp(3) lights up.
" Switch on the flow-type mixer using the double pushbutton(2).

⇒ The flow-type mixer begins to operate.
Caution
The mixing shaft must turn in the direction of the arrow.
If the mixer turns in the wrong direction when full, it may be dama-
ged. Change the direction of rotation.
You may now fill the mixer with dry mortar. Use the bag-opener in the
top of the cover to open the bag.
Fill the mixer evenly, avoiding spreading unnecessary dust.
05_0073_0603GB 6—9
Operation
Depending on the model, the flow-type mixer can also be filled di-
rectly from a silo.
Danger
Wear respiratory protection and a face mask in all work in which par-
ticles of building materials can enter the body through the respiratory
passages. Comply with the information issued by the manufacturer
of the building material. Keep first aid equipment available. Follow
emergency first aid procedures. All injuries must be reported to a
supervisor.
2 3
Item Designation
1 Hopper (depending on the model)
2 Intake and measuring pipe
3 Mixing pipe
" Fill the hopper(1) with dry mortar.
The dry mortar passes via the hopper and the measuring pipe(2)
into the mixing pipe(3). In the mixing pipe, the desired material con-
sistency is produced though the controlled addition of water.
You can alter the water flow rate by turning the rate regulation valve.
This is done successively via minor alterations to the water flow rate
(20--40 l/h). This may be seen from the float which displays the rate
achieved on the scale in the inspection glass.
6 — 10 05_0073_0603GB
Operation
6.8 Pumping After you have added the pumpable material to the hopper, you can
pump the material from the hopper into the delivery line.
Item Designation
1 Double push-button “Pump ON/OFF”
" Switch the pump on at the double push-button ”Pump ON/

OFF”.
⇒ The Cardan shaft and the auger pump start delivering.
Caution
When the pump is to be continually switched on and off, this must
only be done using the double pushbutton or the remote control. If
the pump is switched several times in succession using the main
switch, this may cause malfunctions.
Notes
Start with a low output and increase this continuously.
You may change rate of output using the output regulator. If the au-
ger pump comes to a halt due to overload, this can be improved by
reducing the delivery rate. Further improvement is possible by redu-
cing the load on the auger pump (reduction of delivery line length,
larger diameter).
" Set the required delivery rate. Refer also to the section: ”Deli-
very rate adjustment”.
05_0066_0603GB 6 — 11
Operation
6.9 Delivery rate The delivery rate can be adjusted by means of the handwheel adju-
adjustment ster on the drive.
Caution
The handwheel adjuster must only be used when the pump is run-
ning.
+ --
Item Designation
" With the pump running, turn the handwheel adjuster towards
”+”.
⇒ The delivery rate is increased.
" With the pump running, turn the handwheel adjuster towards
”--”.
⇒ The delivery rate is reduced.
Notes
Start with a low output and increase this continuously.

6 — 12 05_0068_0603GB
Operation
6.10 Reverse pumping To depressurise the delivery line, carry out reverse pumping in the
following manner:
Item Designation
1 Main switch
2 Reversing switch
" Switch the main switch off(1) (position ”0”).
" Switch the reversing switch(2) over.

⇒ The ”I” symbol changes automatically to the opposite direc-
tion of rotation.
Notes
The direction of rotation is fixed using the integrated main reversing
switch.
Never operate the reversing switch(2) when the main switch is in po-
sition ”l”. The rotary field mechanics are locked - any forcible turning
will damage the switching mechanism.
" Allow the machine to pump in reverse for a short time to relieve
pressure.
05_0067_0603GB 6 — 13
Operation
6.11 Breaks in pumping You should avoid breaks in pumping as far as possible, as the mate-
rial in the delivery line can start to set, or become segregated.
Note the following points if breaks are unavoidable:

-- Never leave the delivery pipe under pressure.
-- Relieve the delivery line of its load during short pumping breaks
by briefly reverse pumping.
-- Switch the machine off during long breaks.
-- Adjust the delivery rate to the lowest setting.
" Stop material feed.
" Pump the hopper empty.
Caution
ning.

setting using the handwheel adjuster. Refer also to the section:
”Delivery rate adjustment”.
" Allow the machine to pump in reverse for a short time in order
to depressurize. Refer also to the section: ”Reverse pumping”.
OFF”.
" Switch off the machine. Refer also to chapter ”Initial Opera-
tion”, section ”Shutting down the machine after initial opera-
tion”.
6 — 14 05_0069_0603GB
Operation
6.12 Blockages Blockage can occur inside the pump itself as well as in the delivery
line. When a blockage occurs, the flow of material at the end of the
line stops and the pressure gauge indicates a rising pressure. If a
blockage occurs inside the pump, the drive motor may also stall.
Blockages can be avoided. However, they do still occur from time to

time and are usually caused by:
-- As a result of insufficient lubrication of the delivery line.
-- As a result of mortar which is hard to pump and segregates easily.
-- As a result of leaks in the delivery line couplings.
Rectifying blockages Rectify blockages as follows:
" Pump in reverse for a short time to decrease the pressure in

the delivery line.
" Switch off the drive motor.
Danger
You should only uncouple the delivery line when you have checked
on the pressure gauge that the system is fully depressurised.
" Uncouple the delivery line and clear the blockages in the line
by shaking and tapping it.
" With stubborn blockages, rinse the line with water.
" When you start the engine up again, add a cement grout to the
delivery line.
05_0029_0511GB 6 — 15
Operation
6.13 Using the cable To use the cable remote control, proceed in following manner:
remote control
Item Designation
1 Remote control cable
2 ”Remote control” coupler plug
3 ”Remote control” dummy plug
" Pull out the ”remote control” dummy plug(3) on the control ca-
binet.
" Plug the ”remote control” connector plug(2) into the remote
control socket.
" Switch the pump on at the double push-button ”Pump ON/

OFF”.
" Switch the pump on using the cable remote control.

Notes
In the event of a power cut, a restart can be avoided.
First of all, switch off the cable remote control. Then switch the pump
back on at the double push-button. The cable remote control is now
enabled again.
6 — 16 05_0070_0603GB
Operation
6.14 Using the spray gun Depending on the version, your machine may be equipped with
compressed-air remote control and a compressor.
Notes
Work with the spray gun is only possible with the compressor swit-
ched on. The compressed-air remote control unit must be used.
To use the spray gun, proceed in following manner:
6 2
3
4
Item Designation
1 Compressed-air remote control
2 Connector plug for ”Compressed-air remote control”
3 Air valve
4 ”Compressor” air line connector
5 ”Remote control” dummy plug
6 CEE socket for ”Compressor connection”
" Pull out the ”remote control” dummy plug(5) from the control
cabinet.
" Plug the ”compressed-air remote control” connector plug(2)

into the remote control socket.
" Connect the compressor to the ”Compressor connection” sok-

ket(6).
" Connect the air hose(4) to the compressor.
05_0071_0603GB 6 — 17
Operation
" Connect the delivery line to the spray gun.
" Connect the air hose to the air valve unit(3) and the spray gun.
2
1
Item Designation
1 Remote control valve
2 Spray gun
3 Air cock
" Close the remote control valve(1) on the spray gun.
Danger
The machine must not be started if the remote control valve is open.
Risk of injury from material sprayed from spray gun.
" Switch the compressor on.
" Switch the pump on. Refer also to chapter: ”Initial Operation”,
section: ”Switching on the pump”.
Notes
The pump is switched on or off by opening or closing the remote
control valve on the spray gun.
If the machine is switched off via the remote control valve, the ma-
chine is still ready for operation and can be started again at any time
by reopening the remote control valve.
6 — 18 05_0071_0603GB
Operation
" Open the air cock on the spray gun.

" Adjust the air to the required quantity with the air cock.
Adjusting the air nozzle

tube
>A
ØA
Item Designation
1 Air nozzle tube
2 Mortar nozzle
The distance from the air nozzle tube(1) to the mortar nozzle(2) must
be greater than the diameter of the mortar nozzle(2). The larger the
distance selected, the fewer blockages occur between the air nozzle
tube(1) and the mortar nozzle(2). The smaller the distance setting,
the more cleanly and evenly the spray gun sprays.
05_0071_0603GB 6 — 19
Operation
Practical tip Guide the spray gun back and forth at an even pace using uninter-
rupted horizontal movements. Circular movements are ineffectual.
Direct the jet slightly upwards when plastering walls, but in all other
cases always spray at right angles to the surface to be plastered.
The distance between nozzle and wall should be between 20 and
30 cm. The closer the nozzle is to the wall, the sharper the jet is outli-
ned, spray with less air here if necessary.
Guide the spray gun back and forth in smooth movements
6 — 20 05_0071_0603GB
Operation
6.15 Cleaning the machine At the end of work, the machine and delivery line must be cleaned. A
clean machine and delivery line are therefore indispensable to per-
mit fault--free delivery when they are next used.
Material residues and contamination deposited in the machine and

delivery line can impair operation!
During all cleaning work, observe the waste disposal regulations that
apply to your region.
Cleaning additives or diesel fuel must not be permitted to enter the
sewage system.
Information on cleaning Prior to cleaning the machine with water or a steam jet (H.P. cleaner)
or other cleaning agents, cover or seal all openings which water/
steam or cleaning agents must not penetrate, for safety or operating
reasons. Especially at risk are electric motors, control cabinets and
electrical plug connectors.
Caution
The machine must only be cleaned on the outside with a steam jet/
high-pressure cleaner.
No water into electric systems
05_0077_0603GB 6 — 21
Operation
Notes
In the first six weeks of operation, clean all painted surfaces with
cold water only at a maximum water pressure of 5 bar. Do not use
any aggressive cleaning additives. Only after this time will the paint
have hardened completely, allowing you to use steam jet equipment
or similar tools.
Under no circumstances use sea water or any other salty water for
cleaning purposes. Should sea water get onto the machine you must
rinse it off without fail.
Water which sprays the machine from all directions does not have
any damaging effect. The system is splash-proof but not waterproof.
Notes
Completely remove the covers / seals after the cleaning process!
Caution
The machine and lines must be drained fully of residual water if there
is a risk of freezing.
6 — 22 05_0077_0603GB
Operation
Machine Clean the machine first, then the delivery line.
" Pump the hopper empty.
Caution
ning.
setting using the handwheel adjuster. Refer also to the section:
”Delivery rate adjustment”.
" Allow the machine to pump in reverse for a short time to relieve
pressure. Refer also to the section: ”Reverse pumping”.
" Switch off the machine. Refer also to chapter ”Initial Opera-
tion”, section ”Shutting down the machine after initial opera-
tion”.
" Disconnect the delivery line.
Danger
on the pressure gauge that the system is fully depressurized.
Turn your face away when opening the line coupling.
" Now wash the machine clean with water. To do this, rinse out
the hopper until it is clean.
" Fill the hopper with water.
" Now pump water from the hopper through the pump until the
water begins to exit the pressure connection cleanly once
more.
⇒ The machine is now fully cleaned out.
" Remove the pressure gauge from the pressure connection and
clean it with water.
" Drain the leavings at the drainage connection and rinse the
hopper out once more with water.
" Now clean the delivery line
05_0019_0510GB 6 — 23
Operation
Delivery line Material deposits inside the delivery line can cause damage and can
continue to accumulate and thereby reduce the line cross-section. To
allow problem-free operation at the next use, it is vital that all delivery
lines are clean.
Danger
on the pressure gauge that the system is fully depressurized.
" Release the delivery line at the pressure connection.
Item Designation
1 Sponge ball
2 Delivery line
" Soak a PUTZMEISTER sponge ball(1) in water.
" Push the well-soaked sponge ball into the delivery line.
6 — 24 05_0072_0603GB
Operation
The delivery line is cleaned by water pressure.
" Reconnect the delivery line to the pressure connection.
" Half fill the hopper with water.
" Start the pumping process and pump water through the deli-
very line until the sponge ball exits the end of the delivery line.
" Repeat the cleaning process until only clean water exits the
delivery line.
Caution
The machine and lines must be drained fully of residual water if there
is a risk of freezing.
Clean all seals and the seal seats. Grease the seals before reassem-
bling them. Dirty couplings are not sealed and will inevitably lead to
blockages.
14700101
Item Designation
1 Pressure connection
2 Rubber seal
05_0072_0603GB 6 — 25
Operation
Plate mixer Clean the plate mixer in the following way:
1
2
Item Designation
1 Cover
2 Mixing drum
3 Flap
" Empty the mixing drum(2).
" Switch the main switch to OFF.
" Disconnect the machine from the mains.
" Open the flap(3).
" Open the cover(1).
Danger
Never reach into moving machine components, whether the machine
is running or switched off.
" Clean the plate mixer inside and out with water.
Notes
Pay particular attention to the cleanliness of the seal surfaces on the
cover(1) and the flap(3).
" Close the cover(1) and screw back on.
6 — 26 05_0075_0603GB
Operation
Flow-type mixer Clean the flow-type mixer in the following way:
" Let the flow-type mixer run until water comes out of the mixing
pipe.
" Switch off the flow-type mixer using the double pushbutton.
" Switch the main switch to OFF.
5 4
Item Designation
1 Mixer shaft
2 Hopper (depending on the model)
3 Flange cover
4 Mixing pipe
5 Dosing tube
" Remove the front flange cover.
" Remove the mixer shaft from the mixing pipe.
" Clean the mixing shaft with water.
" Refit all cleaned parts.
Notes
The hopper and the measuring pipe do not need to be cleaned se-
parately.
05_0076_0603GB 6 — 27
Operation
Spray gun Clean the air cock and air nozzle tube on the spray gun. In addition,
use the probe to clean the air nozzle tube.
15100102
Item Designation
1 Air cock
2 Air nozzle tube
3 Probe
6 — 28 05_0054_0511GB
Faults, Cause and Remedy
7 Faults, Cause and Remedy
This section gives you a summary of faults and their possible cau-
ses, and also ways in which you may rectify them.
Observe the safety regulations when troubleshooting.
Heavy current
be carried out by a qualified electrician or by instructed personnel
under the supervision and guidance of a qualified electrician and in
06_0005_0508GB 7—1
7.1 Machine, general The following section provides a description of possible causes of
faults and their remedies.
Material flow is interrupted.
Cause Remedy
The material is reaching the Check whether the hopper is nearly empty thus allowing air to be
end of the delivery line irregu- sucked in. For this reason, always ensure that there is sufficient
larly and is sprayed with force. material in the hopper.
The flow of material is being Check whether the delivery line forms a loop or is kinked.
constantly interrupted without
spraying.
No mortar emerging at end of delivery line.
Cause Remedy
No material feed. Add pumpable material to the hopper.
Drive direction of rotation Change the direction of rotation.

incorrect.
Blockage in the delivery line The pump should be carefully started up initially before any
and shutdown of the pump material is actually pumped Refer also to chapter: ”Operation”,
due to the overpressure device section: ”Starting pumping”. This is the best way to prevent
tripping. blockages.
Caution
Do not disconnect the delivery line until you have
checked on the pressure gauge that the system is
fully depressurised.
Turn your face away when opening the line
coupling.
Turn off the machine. Release pressure from delivery line. Discon-
nect the delivery line and release the obstruction by tapping and
shaking. Flush out the delivery line with water if necessary. Start
initial pumping slowly following removal of a blockage.
7—2 06_0013_0607GB
Pump has insufficient output.
Cause Remedy
Delivery rate adjustment not

Increase delivery rate.
fully turned on.
Deceasing delivery pressure.
Cause Remedy
Worn auger components Retension auger components or replace.
Mortar is not sufficiently stirred.
Cause Remedy
Mixer (option) mixing vanes Replace worn components.

heavily worn.
06_0013_0607GB 7—3
7.2 Spray gun Possible causes of defects which relate to using the spray gun are
described below, together with their remedies.
The machine will not start up despite activated compressor.
Cause Remedy
A blocked air nozzle tube in Clean air nozzle tube and air line.
the spraying device causing
an insufficient drop in pressure
in the remote control.
No air at the spray gun.
Cause Remedy
The pump is operating and Check whether the rubber seals are present on the delivery line
material is arriving in the spray couplings and ensure that the connections are tight.
gun. However, there is only Check whether the delivery line is leaking or broken.
very limited air or no spray air Check whether the air hose from the compressor to the air battery
at all. is leaking.
Mortar flow interrupted.
Cause Remedy
The flow of material is being Check whether the air tap on the spray gun is completely open.
constantly interrupted without Check on the spray gun to see if the air nozzle pipe is clear. If it is
spraying. blocked, it must be cleaned with the spike included in the
accessories.
7—4 06_0024_0606GB
7.3 Electrical system The following is a description of possible causes of faults, which af-
fect the electrical system, and their remedies.
Heavy current
On power failure If there is a site power failure, and the cause cannot be remedied
immediately, you should clean the machine and the delivery lines at
once.
For further details, please refer also to the chapter: ”Operation” --

section: ”Cleaning the machine”.
Clean the machine and delivery lines with mains water as described
there.
Danger
Before you disconnect the delivery line, check on the pressure
gauge to ensure that the system is fully depressurised.
" Loosen the tension rod of the auger pump and remove the
pump.
" Press the auger out of the auger barrel and clean it.
" Clean the whole machine and reassemble it ready for opera-
tion.
" Locate and remedy the cause of the power failure.
06_0025_0606GB 7—5
The machine does not start
Cause Remedy
No power present. Check the electric lead.
The drive motor does not run in Check the electric lead.
three phases.
The fuse on the machine is too Use the correct fuse.

small.
The electrical fuse protection was tripped
Cause Remedy
The fuse on the machine is too Use the correct fuse.

small.
The fuse triggers too readily. Use the correct fuse.
The diameter of the electric Use a supply lead with a larger diameter.
supply lead is too narrow.
7—6 06_0025_0606GB
The motor protection switch was tripped
Cause Remedy
The diameter of the electric Use a supply lead with a larger diameter.
supply lead is too narrow.
The electric supply lead is Unwind the supply lead.

wound up,
e.g. on a cable drum.
The electrical connection is Compare the mains frequency with the machine frequency
not compatible with the mains specified on the rating plate. The two frequencies must
frequency. correspond.
Ventilation for the drive motor Position the machine so that sufficient air circulates around the
is insufficient. drive motor.
06_0025_0606GB 7—7
Maintenance
8 Maintenance
In this chapter you will find information on the maintenance work ne-
cessary for the safe and efficient operation of the machine.
Following the general maintenance information, you will find the

maintenance cards necessary for this machine. A summary of the
maintenance cards listed by number is included in the table of con-
tents.
We should like here to emphasise expressly that all prescribed

checks, inspections and preventative maintenance work must be
conscientiously carried out. Otherwise we will refuse any liability or
warranty claim. Our After Sales department is available to you with
advice and help at any time should you be in doubt.
07_0001_0505GB 8—1
Maintenance
8.1 Maintenance intervals The following table shows the intervals for the various maintenance
tasks.
Notes
Have the initial after-sales service carried out by a Putzmeister
Mörtelmaschinen GmbH After Sales service engineer or by a dealer
authorised by Putzmeister Mörtelmaschinen GmbH.
Inspection
Interval Assembly Measure Reference
criteria
daily Safety Visual Repair the safety
equipment inspection device.
Electric cabling Visual Replace the electric
inspection cabling.
Delivery line Visual Replace as neces-
inspection: sary.
Suitability and
wear; designed
for concrete
pressure; cor-
rectly installed
and sufficient
wall thickness.
Machine Lubricate until you can see grease Observe the lubricant
escaping. recommendation!
Maintenance chart:
Lubrication diagram
weekly Axle and Check lubrica- Lubrication Observe the lubricant
wheels tion points for recommendation!
sufficient lubri-
cation.
8—2 07_0007_0510GB
Maintenance
Inspection
Interval Assembly Measure Reference
criterion
annually Threaded Torque Check and set Use a torque wrench
connections threaded and refer to the
connections using a tightening torque
torque wrench and table.
refer to the torque
table.
Entire machine Industrial safety Industrial safety Use industrial safety
inspection inspection by inspection form.
(APR) qualified person.
every Gear unit Change transmission oil.
3 years
07_0007_0510GB 8—3
Maintenance
8.2 Operating materials This section lists all the operating materials used in your machine.
You must carefully collect all operating materials, e.g. used oil, filters
and auxiliary materials and dispose of them separately from other wa-
ste. Observe the national and regional regulations applicable to your
area.
Only work with waste disposal companies who are approved by the
responsible authorities.
Geared motor The gearbox is filled at the works with 0.8 l of lubricant CLP ISO
VG 220, which must be changed every 10000 h, or at least every
3 years.
Manual lubrication Use a lithium soap based multipurpose grease marked DIN 51 502:
K2K, NLGl Class 2.
Auger For assembly of the auger, use only Putzmeister silicone oil.
Putzmeister silicone oil is available in an aerosol and can be obtai-
ned under part number 210923.003.
8—4 07_0008_0510GB
Maintenance Chart
40--030
Page 1 of 1
40-030 Maintenance tasks, general
This maintenance chart describes general maintenance tasks and

contains notes that apply to all maintenance work using maintenance
charts.
Caution
Maintenance work must only be carried out by authorised personnel
with special knowledge and experience.
Preparation The following tasks must be carried out prior to maintenance work:
" Set the machine up horizontally on level ground.
Danger
Shut down the machine before starting maintenance work and
secure it against unauthorized or accidental starting.
If it is necessary to start up the machine in the course of its mainte-

nance, this is specially indicated in the maintenance charts.
" Switch off the machine.
" Secure the machine against unauthorised starting.
" Secure your working area and fix notices to the locked controls
and setting devices.
WK40_030_0507GB 8—5
Maintenance Chart
40--001
Page 1 of 1
40-00Visual
1 checks
This maintenance chart describes visual checks which you must

carry out before each maintenance task. You will find the mainte-
nance intervals in the maintenance summary at the start of this
chapter.
No further maintenance charts required.
No special tools required.
Danger
Inspect the electrical cables particularly closely and carefully. There
is a danger of flash over from damaged cables, particularly when
there is high air or ambient humidity.
General The general visual inspections which follow should be carried out
before each job as well as before all maintenance work.
" Check that all safety equipment is available and in a fully func-
tioning condition.
Electrical system Should you locate any damage to the electrical system, you must
have the damage rectified immediately by a qualified electrician.
" Check that all electrical connections are secure and free from
corrosion.
" Check that the electrical cables have no breaks.
" Check the insulation on the electrical cables.
8—6 WK40_001_9512GB
Maintenance Chart
40--036
Page 1 of 1
40-036 Lubrication diagram S 5
This maintenance chart shows you the location of the lubrication nip-
ples for lubricating with a grease gun. You will find the maintenance
intervals in the maintenance summary at the start of this chapter.

General maintenance work

Grease gun
Notes
Use only an oil specified in the lubricant table.
The specified lubrication interval applies to normal operation. Under
extreme operating conditions, more frequent lubrication may be ne-
cessary.
All the lubrication nipples have a red protective cap. There may be
further lubrication nipples at the positions marked in the illustrations.
At some points the lubrication nipples are located on the opposite
side of the machine or inside the machine. Always lubricate until
grease begins to escape.
Lubricate the machine at the lubrication nipples
WK40_036_0603GB 8—7
Maintenance Chart
40--037
Page 1 of 1
Flow-type mixer lubrication diagram

40-037
This maintenance chart shows you the location of the lubrication

nipples for lubricating with a grease gun. You will find the main-
tenance intervals in the maintenance summary at the start of this
chapter.


Grease gun
Note
extreme operating conditions, more frequent lubrication may be
necessary.
1 2
8—8 WK40_037_0603GB
Maintenance Chart
40--038
Page 1 of 1
40-038 Plate mixer lubrication diagram
This maintenance chart shows you the location of the lubrication nip-
ples for lubricating with a grease gun. You will find the maintenance
intervals in the maintenance summary at the start of this chapter.


Grease gun
Notes
extreme operating conditions, more frequent lubrication may be ne-
cessary.
WK40_038_0603GB 8—9
Maintenance Chart
44--088
Page 1 of 2
44-08Setting
8 the pressure switch
This maintenance card describes how to set the pressure switch.

You will find the maintenance intervals in the maintenance summary
at the start of this chapter.
Before you can set the pressure switch, you must remove the casing
cover.
" Remove the central screw on the casing cover with a screwdri-
ver.
" Pull the casing cover upwards to remove.
Pressure switch setting values:
Switching on point: 2.0 bar

Switching off point: 3.0 bar
8 — 10 WK44_088_0603GB
Maintenance Chart
44--088
Page 2 of 2
Set the pressure switch in the following way:
-- --
4
+ + 3
1
5
Item Designation
1 Pressure switch
2 Pressure display for the upper switching value
3 Adjusting screw for the upper switching value
4 Adjusting screw for the lower switching value
5 Pressure display for the lower switching value
" Set the upper switching value you require using the adjusting
screw(3).
⇒ The setting value is displayed on the scale in the pressure
display(2).
" Set the lower switching value you require using adjusting
screw(4).
⇒ The setting value is displayed on the scale in the pressure
display(5).
Notes
You can obtain precise settings if you use the pressure gauge for
comparison.
" Refit the casing cover to the casing with the screw.
WK44_088_0603GB 8 — 11
Maintenance Chart
46--021
Page 1 of 2
46--021
Replacing the screw conveyor
This maintenance chart describes how to replace the auger. You will
find the maintenance intervals in the maintenance summary at the
start of this section.

Demounting and fitting the auger pump
No special tools required.
Notes
Use only genuine Putzmeister spare parts.
Use original spare parts marked with the Putzmeister logo.
34000300
8 — 12 WK46_021_0503GB
Maintenance Chart
46--021
Page 2 of 2
5
4
3
2
1
1 Auger
2 Auger barrel
3 Clamping sheath
4 Tensioning screws
5 Bolt
" Loosen the tensioning screws(4).
" Pull the screw conveyor barrel(2) out of the tensioning ca-
sing(3).
As a rule the screw conveyor barrel can be pulled out of the tensio-
ning casing. If this is too difficult, the tensioning casing can be pres-
sed open.
" Take a suitable screw(5) and turn it into the open threaded bo-
ring.
⇒ The tensioning casing will be pressed open.
" Remove the screw conveyor barrel(2) from the tensioning ca-
sing(3).
" Put the screw conveyor barrel in a vice and turn the screw con-
veyor(1) counter-clockwise.
Caution
The screw conveyor and screw conveyor barrel may treated only
with Putzmeister silicone spray before being fitted. Do not use waste
oil!
Used oil attacks the rubber.
" Turn the new conveyor screw(1) clockwise into the clamped
screw conveyor barrel(2).
" Adjust the end face of the screw conveyor and the screw con-
veyor barrel so that they are flush.
WK46_021_0503GB 8 — 13
Maintenance Chart
46--027
Page 1 of 4
46-02Disassembly
7 and assembly of the auger pump
This maintenance card describes how to replace the auger pump.


Replacing the screw conveyor.
Notes
You must replace the wear parts, if wear is established by a visual
inspection or if there is inadequate pressure build-up in the delivery
line.
Dismantling the auger

pump
2
4 3
Item Designation
1 Tensioning nut
3 Tension rod
4 Auger pump
8 — 14 WK46_027_0603GB
Maintenance Chart
46--027
Page 2 of 4
" Unscrew the clamping nuts(1) on the tie bolt(3).
" Pull off the pressure joint(3).
2 1
2
3
Item Designation
1 Auger pump
2 Through bolts
3 Cardan shaft
" Unscrew the through bolts(2) from the cardan shaft(3).
" Pull the auger pump(1) from the hopper.
Notes
Replace the screw conveyor barrel and/or the screw conveyor with a
new unit, if there is wear.
WK46_027_0603GB 8 — 15
Maintenance Chart
46--027
Page 3 of 4
Assembly of auger
pump
2 3
1
Item Designation
1 O-ring
2 Spacer ring
3 Auger pump
" Clean the O-ring(1) as required, replace if worn.
" Grease the O-ring(1) slightly before placing in the spacer

ring(2) and then insert both into the side of the hopper.
" Insert the auger pump(3) into the spacer ring(2), then slide the
pressure connection onto the tie bolt and the auger pump(3)
and align.
8 — 16 WK46_027_0603GB
Maintenance Chart
46--027
Page 4 of 4
2 1
2
3
Item Designation
1 Auger pump
2 Through bolts
3 Cardan shaft
" Fit the cardan shaft(3) and auger pump(1) together and secure
with the through bolts(2).
Caution
Only use new self-locking hexagon nuts.
2
1
Item Designation
1 Washer
2 Tensioning nut
" Place the washers(1) onto the tie bolts and screw on the clam-
ping nuts(2), tightening the whole unit evenly.
WK46_027_0603GB 8 — 17
Maintenance Chart
46--028
Page 1 of 3
46-02Adjusting
8 the auger pump
This maintenance chart describes how to adjust the auger pump.


Auger pump, dismantling and assembly
Replacing screw conveyor

Putzmeister pressure check gauge, part no. 208745.002
The performance of the auger pump is checked by means of water

pressure with the machine running.
" Check whether the drain connection on the hopper is closed.
" Fill the hopper with water.
8 — 18 WK46_028_0603GB
Maintenance Chart
46--028
Page 2 of 3
Item Designation
1 Pressure gauge
3 Delivery line
4 Pressure check gauge
5 Shutoff valve
" Connect a delivery line(3) to the pressure connection(2).
" Connect the pressure gauge(4) to the end of the delivery line.
" Switch the machine on.
" Start operating the pump.
" Slowly close the shut-off valve(5) on the checking pressure

gauge(4).
⇒ Note that the pressure will increase.
Notes
If water pressure of approx. 20 bar is not reached at the pressure
gauge, increase the tension of the clamping sheath.
WK46_028_0603GB 8 — 19
Maintenance Chart
46--028
Page 3 of 3
1
2
Item Designation
1 Clamping sheath
2 Tensioning screw
" By tightening the clamping screws(2) evenly, you increase the

pretensioning.
⇒ The pressure increases.
Caution
If the clamping sheath(1) is tightened excessively, increased wear to
the auger parts may result.
Pretension the tensioning casing only enough to achieve the requi-
red pressure.
If the required pressure cannot be achieved even at high pretension,
you must dismantle the auger pump and check it for wear.
Notes
Repeat the test procedure to achieve an accurate measured result.
" Switch off the machine.
" Release the water pressure on the pressure testing gauge.
" Disconnect the pressure testing gauge.
8 — 20 WK46_028_0603GB
Decommissioning
9 Decommissioning
This chapter contains information on decommissioning the machine.
9.1 Temporary If the machine is to be shut down temporarily, take the following mea-
decommissioning sures.
" Run the hopper until it is empty.
OFF”.
" Switch the machine off at the main switch.
" Clean the machine. Refer also to the chapter: ”Operation” --

section: ”Cleaning the machine”.
Danger
Never reach into moving machine components, whether the machine
is running or switched off.
10_0009_0510GB 9—1
Decommissioning
Shutting the machine If you wish to take the engine out of service or place in storage, it
down must be greased and preserved as necessary.
Notes
Preservation and greasing the machine prevents corrosion and pre-
mature ageing. It is necessary, if the machine:
– is not used for longer periods;
– is exposed to corrosive atmospheres during storage or transporta-
tion.
" Carry out all steps described in the section on temporary de-
commissioning. Refer also to the section: ”Temporary decom-
missioning”.
" Lubricate the machine.
" Shut down the machine only in current-free condition.
" Protect the machine with a suitable agent.
Frost protection If there is a danger of frost, carry out the following measures.
" Drain the machine completely of residual water.
Caution
The machine and delivery lines must be fully drained of residual wa-
ter if there is a risk of freezing.
9—2 10_0009_0510GB
Decommissioning
9.2 Final decommissio- The final decommissioning and disposal requires complete disas-
ning, disposal sembly of the machine into its individual components.
When disposing of all machine components, ensure that there is no
possibility of damage to health or the environment.
Final disposal of the machine is carried out by a qualified specialist
company.
Danger
When decommissioning the machine permanently, there may be a
risk of injury from escaping lubricants, solvents, preserving agents,
etc.
They can cause chemical burns in the event of direct skin contact.
Risk of injury at sharp-edged machine components.
Electric machines
Caution
Uninstallation work on electric machines must only be carried out by
qualified electricians.
10_0010_0510GB 9—3
Decommissioning
Material used The main materials used for machine construction were:
Material Use for / in

Copper -- Cables
-- Machine frame
Steel -- Hopper parts
-- Pump units
-- Gaskets
-- Hoses
Plastic, rubber, PVC
-- Cables
-- Wheels
Tin -- PCBs
Polyester -- PCBs
Parts requiring separate The following components and working materials must be separated
disposal prior to disposal:
Designation Applies to ....

-- Electrical supply
-- PCBs with electrical
Electronic scrap components
-- Drive motor (E-version)
9—4 10_0010_0510GB
Appendix
10 Appendix
10.1 General tightening Tightening torques depend on bolt grade, thread friction and bolt
torques head bearing area. The values given in the following tables are for
guidance. These values should only be used if no other values are
specified in the relevant chapters of the Operating Instructions or in
spare parts sheets.
Caution
Bolts must always be replaced with bolts of the same size and
grade.
Bolts with adhesive in the locking threads and self-locking nuts must
always be replaced after removal.
Continuation next side
11_0003_0507GB 10 — 1
Appendix
The tables below give the maximum tightening torques (maximum

torque) in Nm for a friction factor of mtotal = 0.14, with the thread
lightly-oiled or lightly-greased.
Notes
All tightening torques X 1.1 apply for bolts with cement in the thread.
Set screws -- metric triangular thread, DIN 13, Part 13

Dimensions Tightening torque
[mm] Md [Nm]
M SW 8.8 10.9 12.9
M 4 7 3.0 4.4 5.1
M 5 8 5.9 8.7 10
M 6 10 10 15 18
M 8 13 25 36 43
M 10 17 49 72 84
M 12 19 85 125 145
M 14 22 135 200 235
M 16 24 210 310 365
M 18 27 300 430 500
10000900
M 20 30 425 610 710
SW = Width across flats (A/F) M 22 32 580 820 960
X.X = Grade 8.8, 10.9, 12.9 M 24 36 730 1050 1220
M 27 41 1100 1550 1800
M 30 46 1450 2100 2450
Set screws -- metric precision thread, DIN 13, Part 13

Dimensions Tightening tor-
[mm] que Md [Nm]
M SW 8.8 10.9 12.9
M 8¢1 13 27 39 46
M 10 ¢ 1.25 17 52 76 90
M 12 ¢ 1.25 19 93 135 160
M 12 ¢ 1.5 19 89 130 155
M 14 ¢ 1.5 22 145 215 255
M 16 ¢ 1.5 24 225 330 390
M 18 ¢ 1.5 27 340 485 570
M 20 ¢ 1.5 30 475 680 790
10000900
M 22 ¢ 1.5 32 630 900 1050
SW = Width across flats (A/F) M 24 ¢ 2 36 800 1150 1350
X.X = Grade 8.8, 10.9, 12.9 M 27 ¢ 2 41 1150 1650 1950
M 30 ¢ 2 46 1650 2350 2750
10 — 2 11_0003_0507GB
Index of Key Words
Index of Key Words
This chapter contains the main key words with the number of the
page on which they are to be found as a header in the left-hand
margin. This Index of key words is listed alphabetically by the main
concepts. These are subdivided into associated sub-concepts,
marked with a dash.
i
Index of Key Words
A D I
Accessories, 2 — 15 Decommissioning, Shutting the ma- Icons, 1 — 4
Auger pump, 3 — 22, 8 — 18 chine down, 9 — 2 Inclination angle, 3 — 6
- Adjusting the auger pump, 8 — 18 Delivery line, 5 — 7 Initial operation
- Assembly, 8 — 16 - Cleaning, 6 — 24 - Shutting down the machine, 5 — 8
- Dismantling, 8 — 14 - Extending, 2 — 4 - Switching on pump, 5 — 3
- Screw conveyor, 8 — 12 Delivery pressure, 3 — 8 Initial pumping, 6 — 4
Delivery rate adjustment, 6 — 12
B Designated use, 2 — 3
L
Designation of machine, 3 — 1
Blockages, 6 — 15
Disposal, 9 — 3 Liability, 2 — 5
- Rectification, 6 — 15
- Exclusion of liability, 2 — 5
Drive
- Flow--type mixer, 3 — 20 Lubrication
C - Plate mixer, 3 — 21 - Gearbox, 8 — 4
- S 5 EV, 3 — 19 - Manual, 8 — 4
Cable remote control, 3 — 23, 6 — 16
Lubrication diagram
Checking, Direction of rotation, 5 — 4
- Flow--type mixer, 8 — 8
Checks, 5 — 2 E - Plate mixer, 8 — 9
Cleaning, 6 — 21 - S 5, 8 — 7
Electrical connection, 4 — 11, 5 — 2
- Delivery line, 6 — 24 - Connector plug, 4 — 11
- Flow--type mixer, 6 — 27
- Machine, 6 — 23
- Fuse, 4 — 11 M
Emergency, 2 — 13
- Plate mixer, 6 — 26 Machine number, 3 — 2, 3 — 8
- Spray gun, 6 — 28 Emergency shut--down, EMERGENCY
STOP button, 6 — 2 Machine versions, 3 — 2
Connecting to the mains electricity
EMERGENCY STOP button, 3 — 11, Maintenance intervals, 8 — 2
supply
5 — 6, 6 — 2 - Assembly, 8 — 2
- S 5 EV, 4 — 13
- Function check, 5 — 6 - Inspection criteria, 8 — 2
- S 5 EV/CM, 4 — 14
- Measure, 8 — 2
- S 5 EV/TM, 4 — 13
Mixing
Connection, Cables, 4 — 12 F - Flow--type mixer, 6 — 9
Connection to the mains power sup- - Plate mixer, 6 — 7
ply, 4 — 13 Fault, 2 — 13
Fault, cause and remedy Model, 3 — 8
Control cabinet, 3 — 16
- Control unit, 3 — 17 - Electrical system, 7 — 5 Modifications, 2 — 4
- Plate mixer, 3 — 18 - Machine, general, 7 — 2
- Spray gun, 7 — 4
Fill--level sensor, 3 — 26
N
Final decommissioning, 9 — 3 Noise, 2 — 14
Flow--type mixer, 3 — 14, 4 — 5
Foreword, 1 — 2
Frequency, 3 — 8
Frost protection, 9 — 2
Function checks, EMERGENCY STOP
button, 5 — 6
Functional description, 3 — 13
ii
Index of Key Words
O R T
Onwards sale, 2 — 2 Rating plate, 3 — 8 Technical data, 3 — 6
Operating materials, 8 — 4 Remote control by compressed air, - Connectors, 3 — 6
3 — 25 - Dimensions, 3 — 6
Operator
- Inclination angle, 3 — 6
- Accessories, 2 — 13 Residual risk, 2 — 9
- Machine, general, 3 — 6
- Machine, 2 — 13 Risk of crushing and bumping, - S 5 EV, 3 — 7
Options, 3 — 10 2 — 10
- S 5 EV/CM, 3 — 7
- EMERGENCY STOP button, 3 — 11, - Auger pump, 2 — 11
- S 5 EV/TM, 3 — 7
6—2 - Transporting the machine, 2 — 10
- Sound pressure level, 3 — 6
- Fill--level sensor, 3 — 26 Risk of injury, 2 — 9 - Weights, 3 — 6
- Remote control by compressed air,
3 — 25 Test run, 5 — 3
- Vibrator, 3 — 24 S Tightening torques, 10 — 1
Overview of the components Transporting the machine, 4 — 2
Safety devices, 2 — 4
- S 5 EV, 3 — 3 - Fork--lift truck, 4 — 2
Safety equipment, 2 — 8, 3 — 11
- S 5 EV/CM, 3 — 4
- Protective grille, 3 — 12
- S 5 EV/TM, 3 — 5
Safety installations, EMERGENCY U
STOP button, 3 — 11
P Scope of supply, 3 — 2
Unauthorised use, 2 — 16
Unpacking the machine, 4 — 1
Personnel, 2 — 6 Screw conveyor, Replacement,
Use contrary to the designated use,
8 — 12
Personnel selection and qualifica- 2—4
tions, 2 — 6 Set--up site
- Qualified electrician, 2 — 6 - Requirements, 4 — 3
- Training, 2 — 6 - Selection, 4 — 3 V
Place of work, 2 — 13 - Supporting ground, 4 — 3
Vibrator, 3 — 24
Plate mixer, 3 — 15, 4 — 7 Setting up, Angle of inclination, 4 — 4 - Riddler, 3 — 24
Power, 3 — 8 Shut--down, 6 — 2 Visual checks, 5 — 2, 8 — 6
Pressure switch, 3 — 25 Shutting down, After operation, 5 — 8 Voltage, 3 — 8
- Setting values, 8 — 10 Sound emissions, Noise, 2 — 14
Sound power level, 3 — 9
Pump, Switching on, 5 — 3
Sound pressure level, 3 — 6
W
Pumping operations, 6 — 6
- Blockages, 6 — 15 Sources of danger, 2 — 7 Water connection, 4 — 9
- Breaks in pumping, 6 — 14 - Coupling system, 2 — 7 - Mains water supply, 4 — 9
- Initial pumping, 6 — 4 Water quality, 4 — 10
Spare parts, 2 — 15
- Pumping, 6 — 11 Working area, 2 — 13
- Requirements, 6 — 1 Spray gun, 6 — 17, 7 — 4
- Reverse pumping, 6 — 13 Storing the machine, 2 — 15
Summary of components, 3 — 3 Y
Supporting ground, 4 — 3 Year of manufacture, 3 — 8
Switch--on conditions, 5 — 3
Symbols, 1 — 4
iii
Index of Key Words
iv
Putzmeister Putzmeister Limited Putzmeister France
Mörtelmaschinen GmbH Chesterfield Trading Estate Zone Industrielle
Max--Eyth--Straße 10 Carrwood Road Rue Jean Jaurès
72631 Aichtal Sheepbridge/Chesterfield/ 91861 Epinay sous Sénart
Postfach 21 52 Derbyshire S41 9QB Tel. (1) 69 39 69 39
72629 Aichtal Tel. (0 12 46) 45 45 46 Fax (1) 60 47 20 68
Tel. (0 71 27) 599--0 Fax (0 12 46) 126 00 77
Fax (0 71 27) 599--743
Putzmeister Iberica S.A. Putzmeister (SA) (Pty) Ltd. Putzmeister America
Camino de Hormigueras 173 1485 Citrus Street. Mortar Maschine
28031 Madrid Honeydew/Johannesburg 1733 90th Street
Tel. (1) 428 81 00 PO Box 5146 Sturtevant, WI 53177
Fax (1) 428 81 06 2118 Cresta / South Africa Phone: (262) 886 3200
Tel. 0027--(0)11--794--3790 Fax: (262) 886 3212
Fax 0027--(0)11--794--4119
Weitere Werksvertretungen mit Kundendienst in:
Ägypten Griechenland Katar Österreich Syrien

Algerien Guatemala Kolumbien Pakistan Taiwan
Argentinien GUS Korea Panama Thailand
Australien Hong Kong Kroatien Paraguay Tschechien
Bahrain Indien Kuba Peru Tunesien
Belgien Indonesian Kuwait Philippinen Türkei
Bolivien Irak Libanon Polen Ukraine
Bosnien Iran Luxemburg Portugal Ungarn
Chile Island Malaysia Rumänien Uruguay
China Israel Malta Rußland USA
Costa Rica Italien Mauritius Saudi--Arabien Venezuela
Dänemark Japan Mexiko Schweden- Vereinigte
Ecuador Jemen Neuseeland Schweiz Arabische Emirate
El Salvador Jordanien Niederlande Singapur Vietnam
Finnland Jugoslawien Norwegen Slovakei Zypern
Frankreich Kanada Oman Slovwenien
Putzmeister Mörtelmaschinen GmbH
Postfach 2152
D--72629 Aichtal
Telefon (07127) 599--0
Telefax (07127) 599--743
Internet: http://www.moertelmaschinen.de
E--mail: pmm@pmw.de

S5 EV - CM - TM Betriebsanleitung 01-0407 GB

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Operating Instructions

for machine operator and maintenance staff

Auger pump S 5 EV/CM/TM

Rev. 01--0407 PMM_365188013

The paper on which this document is printed is 100% chlorine free

1 About these Operating Instructions

3 General Technical Description

4 Transport, Set-up and Connection

7 Faults, Cause and Remedy

Index of Key Words

1 About these Operating Instructions

Putzmeister Mörtelmaschinen GmbH

or the branch or services agent responsible for you.

The Operating Instructions contain important information on how to

The Operating Instructions must be supplemented by the relevant

The Operating Instructions must always be available wherever the

The generally recognised rules of technology for safe and proper

Continuation next side

These operating instructions do not include a description of the drive

Modifications are made from time to time in the interests of constant

These operating instructions are not covered by the Amendment Ser-

The contents of this document may not be reproduced, even in part,

Example: Page 3--2

" Action symbol

Refer also to the maintenance charts:

The following special tool is required:

The appropriate symbol will be used if it is possible to identify the

This chapter summarises the most important safety regulations. This

The following safety instructions should be regarded as a supple-

Existing accident prevention regulations and laws must be observed

2.1 Principle Use only machines in a technically perfect condition, as designated

Make sure that

If defects or faults are found or suspected during operation, opera-

Pass on to the new operator all the accompanying documentation

Reporting an onwards sale or acquisition to Putzmeister ensures

The machine must only be used as specified in the Operating In-

The machine is exclusively designed to deliver pumpable plastering

The maximum delivery pressure must be no higher than that speci-

The machine is filled via the hopper.

All items of the machine’s protective panelling must be fitted or con-

Specified inspection work should be carried out at regular intervals.

Never make any modifications, additions or conversions to the ma-

The machine must be inspected for operational safety by a technical

A new delivery line is only suitable for pressures entered on the

Modifications Never make any modifications, additions or conversions to the

The control and safety settings made at Putzmeister Mörtel-

The machine must not be operated with deactivated, modified or

Safety devices must only be repaired, adjusted or replaced by

The safety and accident prevention regulations from the following

Exclusion of liability We state here expressly that Putzmeister Mörtelmaschinen accepts

Training The machine must only be operated, serviced or maintained by per-

In the event of malfunctions, stop the machine immediately and se-

Never release or tighten threaded unions that are under pressure.

Any safety devices removed for set-up, maintenance or repair purpo-

Safety devices must only be repaired, adjusted or replaced by tech-

All equipment required for safety and accident prevention (warning

The machine must only be loaded onto a suitable transport vehicle

Risk of crushing in the end stop area of the auger pump

All electrical assemblies are protected as standard, as per

2.13 Conduct in an Switch off the machine immediately in an emergency situation.

We recommend wearing ear defenders for noises louder than

Wear your personal ear defenders.

All soundproofing equipment must be present and in perfect