5-Section B - Safety

SECTION B – SAFETY
USER MANUAL
3.SAFETY…..…………………………………………………………………………………………………………………………….…..21
3.1 SAFETY CONTROL……..…………………………………………………………………………………………………………….21
(EMERGENCY STOP)…………………….……………………………………………..……………………………………………….21
3.2 PROPER USE…………………….…………………………………………………………………………………………………….22
3.2.1 MISUSE…………………………..……………………………………………………………………………………………………22
3.2.2 EXTENDING END HOSE……………..………………………………………………………………………………………….23
3.3 MUTILATION RISK…………………………………………………………………………………………………………23-24-25
3.3.1 DANGER ZONE….………………………………………………………………………………………………………………… 26
4.0 EQUIPMENTS………………………………………………………………………………………………………………………….27
4.1 PROTECTIVE EQUIPMENT ….…………………………………………………………………………………………………..28
4.2 CORPORATE PRECAUTIONS.……………………………………………………………………………………………………29
4.3 ADDITIONAL INSTRUCTIONS..…………………………………………………………………………………………………29
4.3.1 OTHER ADDITIONAL INSTRUCTIONS ……………………………………………………………………………………30
4.3.2 INSTRUCTION………………………………………………………………………………………………………………………30
4.3.3 USERS….……….……………………………………………………………………………………………………………………..30
4.3.4 OPERATOR…………………………………………………………………………………………………………………………..30
4.3.5 CONTROLS….……………………………………………………………………………………………………………………….30
4.3.6 SAFETY INSTRUCTIONS..………………………………………………………………………………………………………31
4.3.6 EXPLANATION OF SAFETY INSTRUCTION..……………………………………………………………………….32-33
4.3.7 FAILURES …………………………………………………………………………………………………………………………….34
4.3.8 CHANGES……..…………………………………………………………………………………………………………………34-35
4.3.9 MACHINE CARD…………………………………………………………………………………………………………………. 36
4.4 CONFIGURABLE DEVICES………………………………………………………………………………………………………..37
4.5 SPARE PARTS…….……………………………………………………………………………………………………………………37
4.6 PERIOD OF SERVICE AND INSPECTION..……………………………………………………………………………..37-38
BOOM MAKİNA TİC SAN LTD ŞTİ.

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USER MANUAL
5. WORKPLACE EQUIPMENTS.………………………………………………………………………………………………………39
5.1 PROTECTION FROM FIRE…………………………………………………………………………………………………………39
5.2 OBLIGATION……………………………………………………………………………………………………………………………39
5.3 EDUCATION.……………………………………………………………………………………………………………………………40
5.4 QUALIFICATION OF HYDRAULIC CONCRETE DISTRIBUTOR BOOM OPERATOR.………………………..40
5.5 RESPONSIBILITY………………………………………………………………………………………………………………………41
5.6 QUALIFIED PERSONNEL.………………………………………………………………………………………………………….41
5.7 WELDERS……..…………………………………………………………………………………………………………………………41
5.8 QUALIFIED ELECTRICIANS.………………………………………………………………………………………………………42
5.9 HYDRAULIC ENGINEERS…………………………………………………………………………………………………………42
5.10 DANGER ZONES…..……………………………………………………………………………………………………………… 42
5.10.1 PLACING BOOM……..………………………………………………………………………………………………………….43
5.10.2 PLACING BOOM …….………………………………………………………………………………………………………….43
5.10.3 END HOSE…….……………………………………………………………………………………………………………………44
5.10.4 START-UP………………………………………………………………………………………………………………………….45
5.10.5 FUNCTIONAL LIQUIDS……………………………………………………………………………………………………….46
5.10.6 TEST-PURPOSE OPERATING……………………………………………………………………………………………….46
5.10.7 ACİL DURUM KAPAMA DÜŞMESİ……………………………………………………………………………………….47
5.10.8 EXTENDING PLACING BOOM……….…………………………………………………………………………………… 48
5.10.9 BAD WEATHER CONDITIONS……………………………………………………………………………………………. 48
5.10.10 EYEBALL ESTIMATE………………………………………………………………………………………………………….48
5.10.11 LOADS…………………………………………………………………………………………………………………………….49
5.10.12 SPOTTER………………………………………………………………………………………………………………………….49
5.10.13 BOOM MOVEMENTS..……………………………………………………………………………………………………..50
6. DANGER ZONE….………………………………………………………………………………………………………………………50

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USER MANUAL
6.1 HIGH VOLTAGE LINES……..………………………………………………………………………………………………………51
6.2 CLEARANCE ……………………………………………………………………………………………………………………………52
6.3 FLASH OVER.………….……………………………………………………………………………………………………………….53
6.4 STATIC CHARGE………………………………………………………………………………………………………………………53
6.5 OBSTACLES.…………………………………………………………………………………………………………………………….54
6.7 OVERLAPPING WORKING RANGES .…..……………………………………………………………………………………54
6.8 IMPERMISSIBLE WORKING RANGES ……………………………………………………………………………………….55
6.9 CONCRETING OPERATION……………….………………………………………………………………………………………55
6.10.RESPONSIBILITY……………………………………………………………………………………………………………………56
6.11 NOISE…………………………………………………………………………………………………………………………………..56
6.13 REMOTE CONTROL….……………………………………………………………………………………………………………57
6.14 EMERGENCY STOP…….………………………………………………………………………………………………………….57
6.15 UNAUTHORIZED WORKING…………………………………………………………………………………………………..58
7. TURNING DELIVERY PIPES…………………………………………………………………………………………………………59
7.1 MINIMUM WALL THICKNESS.………………………………………………………………………………………………….59
7.2 BLOCKADES.…………………………………………………………………………………………………………………………..59
7.3 DELIVERY PIPE OPENING…………………………………………………………………………………………………………60
8. END HOSE…….…………………………………………………………………………………………………………………………..61
8.1 DANGER ZONE….…………………………………………………………………………………………………………………….61
8.2 BENDING………………………………………………………………………………………………………………………………..62
8.3 SECURING……………………..……………………………………………………………………………………………………....62
8.4 EXTENDING.……………………………………………………………………………………………………………………………63
8.5 SEPERATED DELIVERY LINE …………………………………………………………………………………………………….64
8.6 STATIONARY CONCRETE PUMPS..…………………………………………………………………………………………..64
8.7 CLEANING……………………………………………………………………………………………………………………………….64

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USER MANUAL
8.8 TRANSPORTING……………………………………………………………………………………………………………………..65
8.9. TRANSPORT VEHICLE…………………………………………………………………………………………………………….65
8.10 MAINTENANCE AND SAFETY RULES .………………….………………………………………………………………..66
8.9.1 SPECIAL WORK……………………………………………………………………………………………………………………67
8.9.2 SECURING THE ARE …………………….………………………………………………………………………………………67
8.9.3 STABILITY .………………………………………………………………………………………………………………………….68
8.9.4 LIFTING EQUIPMENTS ….…………………………………………………………………………………………………….68
8.9.5 CHANGING DELIVERY LINES.…………….…………………………………………………………………………………68
8.9.6 WORKPLACE……………………………………………………………………………………………………………………….69
8.9.7 WATER..…………………………………………………………………………………………………………………….……….69
8.9.8 CLEANING…….…………………………………………………………………………………………………………………….70
8.9.9 CLEANING DELIVERY LINES……………..………………………………………………………………………………….70
9. WARNING DEVICES.………………………………………………………………………………………………………………..71
9.1 INSPECTION.…………………………………………………………………………………………………………………………71
9.2 SAFETY EQUIPMENTS……………………………………………………………………………………………………………71
9.3 ENVIRONMENT………..…………………………………………………………………………………………………………..71
9.4 ELECTRICAL POWER.…..…………………………………………………………………………………………………………72
9.5 HIGH VOLTAGE LINES…….………………………………………………………………………………………………………72
9.6 CLEARANCE..…………………………………………………………………………………………………………………………73
9.7 SWITCH OFF OVERHEAD CABLES……………………………..…………………………………………………………….74
9.8 STATIC CHARG.………………………………………………………………………………………………………………………74
9.10 EMERGENCY PRECAUTION..…………………………………………………………………………………………………74
9.11 QUALIFIED PERSONNEL..……………………………………………………………………………………………………..75
9.12 BEFORE START THE WORK.………………………………………………………………………………………………….75
9.12 CLEANING WORK…………………………………………………………………………………………………………………75

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USER MANUAL
10. MAINTENANCE WORK………………………………………………………………………………………………………….76
10.1 INSPECTION….…………………………………………………………………………………………………………………….76
10.2 SECURING THE ELECTRICAL POWER ………………….………………………………………………………………..76
10.3 GAS,DUST,STEAM,SMOKE…………………………………………………………………………………………………..76
10.4 RESPIRATION PROTECTION AND FACE MASK .…………………………………………………………………….76
10.5 WELDING..………………………………..………………………………………………………………………………………..77
10.6 DUST.………………………………………………………………………………………………………………………………….77
10.7 HYDRAULIC SYSTEM AND PNEUMATIC SYSTEM DELIVERY LINES ..……………………………………… 78
11 INSPECTION….………………………………………………………………………………………………………………………..78
11.1 PRESSURE FLUCTUATION..…………………………………………………………………………………………………..79
11.2 PIPES…………………………………………………………………………………………………………………………………..80
11.3 SWEAT………………………………………………………………………………………………………………………………… 80
12. NOISE……………………………………………………………………………………………………………………………………..80
12.1 EAR PROTECTIVE…………………………………………………………………………………………………………………..80
13. OILS,GREASES AND OTHER CHEMICAL MATERIALS………………………………………………………………….81
13.1 HOT MATERIALS .………………………………………………………………………………………………………………….82
13.2 ENVIRONMENTAL PROTECTION.…………………………………………………………………………………………..82
14. LOADING, TRANSPORTING AND OPERATING AGAIN ..……………………………………………………….83-84
14.1 DRIVING..……………………………………………………………………………………………………………………………..85
14.2 OPERATING AGAIN…………..…………………………………………………………………………………………………..85

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USER MANUAL
GENERAL SAFETY RULES ‘’ BEFORE USE’’
— Read the user manual carefully.

— Take the personal security and protective measures.
— Control all machine guards and change the damaged parts with ORIGINAL Spare Part.
— Be sure there are no objects on the machine.
DURING USE
— Do not wear clothes that can be attached to moving parts.

— Do not put hands and objects to the movement area of machine.
AFTER USE
— Stop the engine and be sure all power is stopped.
EXPLANATIONS
DANGER: A situation or thing that can cause major damage or destruction. Bad situation
which is undesirable but possible. Potential injury or health hazard source.
DANGEROUS AREA: Any zone in or around the machine where people may be exposed to
risk in terms of health and safety.
OPERATOR: The person or persons responsible for setting up, cleaning, repairing or moving
the machine, or performing normal maintenance. Before operating the machine, operator
must read and understand the manual. As required, the BOOM MAKINA technicians will
assist you in providing all the information needed for proper use of the machine.
OPERATOR ASSISTANT: They are the personnel who help the operator in various business
operations, especially for the use of the boom with remote control.
RISK: Possibility of occurrence of the incident and the possibility of injury or damage to
health.

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USER MANUAL
3.SAFETY
 Employers are responsible for teaching the instructions in the user manual.
 Employees using the machine (authorized operator) must have been trained in
advance and have read the manual.
Wear personel protective equipment: Hard hat, Goggles,

Protective gloves, Ear protector, Safety footwear.
Change the damaged labels with new one.
3.1 Safety Control
The machine must be handled in accordance with the instructions specified in the
User Manual under technically appropriate conditions. In the event of any fault,
especially in situations which endanger the safety of work, it must be intervened
immediately.
 Be sure that the safety equipment is not removed or replaced.
 Always keep a fire extinguisher at accessible distance.
 Do not use controls or pipes for holding.
 Use the handles and ladders when climbing and exiting the machine.
 Keep the platforms away from oil and petrol.
 In addition to the lack of equipment, safety and protection equipment, inform
the authorized person immediately of any deficiencies you have noticed.
Report the precautions or working status you have applied to your colleague or foreman
who will come after you, to continue working safely.
Press the EMERGENCY STOP on machine or remote control when fault or emergency
situation.
(EMERGENCY STOP)

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USER MANUAL
3.2 Proper Use
The machine had designed for distribution of concrete up to 2,300 kg/m³ bulk
density. Working area must be limited with construction site. Maximum delivery
pressure must not be exceed value specified in the rating plate or inspection log
book.
In addition, proper use the machine within its usage limits, you must observe the
Operating Instructions and conform the maintenance periods.
Placing boom must inspect by an expert. Inspections must be done in accordance

with inspection log book at the period specified in the checklist.
Inspection results must be saved to inspection log book and must be confirmed by
signing. Inspection log book always must be kept with machine.
3.3 Misuse
Our hydraulic distributors accept as delivery machines in construction sites.

The machine must not be used like a crane for lifting loads.
BOOM MAKINA does not accept any liability for damage caused by such use. The risk
of such misuse is entirely operator dependent.

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USER MANUAL
3.4 Extending End Hose
(Extending the end hose is not allowed.)
It is strictly forbidden to extend placing boom and the end hose except the lenght
specified in the machine info card.
3.5 Mutilation Risk
The machine must be operated in accordance with safety rules. Periodic controls and
maintenances must be done bu authorized service. Violating safety rules of
construction site may cause death or injury to user or third parties and may damage
to the machine and other equipments.
 Some of the mutilations may occur due to misuse of the machine listed
below;
Eye injuries occur due to by splashing of concrete, water and chemicals.
Eye or skin injuries caused by hydraulic fluid escaping under pressure when threaded
fittings are opened without the accumulator pressure having been dumped
beforehand or without prior dumping of the pressure in the entire system.
Risk of scalding due to hot hydraulic fluid escaping under pressure.
Injuries caused by tipping of the machine due to collapsing of support floor.

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USER MANUAL
Injuries occur due to fitting explosion, explosion of pipes or dislocation of the plugs
from the delivery line, end hose and pump chamber.
Electric shocking occur if the power connection is not properly connected or if the
phase cable is damaged or if it contacting with other electrical cables, which could
result in contact with electric motors (which may have fatal results).
Injury or death occur due to unintentional operation of the boom in the construction
site and therefore the unintentional movement of the boom.
Injuries occur due to falling parts of the pipe as a result of unconnected fitting or
partially loose connections. Tools left on the boom may fall.
Head and shoulder injuries as a result of concrete falling down from the end hose
(even if the pump is off) when the placing boom is turned over the construction site
at a high distance.
Injuries caused by falling boom arms if isolators are opened without first ensuring
that the appropriate boom arm is secured.
Injuries to the hose operator being struck by the end hose if this has become trapped
in the reinforcement and suddenly jumps out on further movement of the boom.
This danger also occurs when the concrete blockage is suddenly released. There is
also a significant risk of starting pumping by the swinging end hose due to jammed
air or sudden movement of the boom.

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USER MANUAL
Eye injuries due to hydraulic fluids escaping under pressure.
Injuries due to impact of the end hose.

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USER MANUAL
3.6 Danger Zone
When the pump is started, the danger zone is the perimeter of the end hose, where
the end hose can be swung out. The diameter of the hazardous area is twice the
length of the end hose.
End hose lenght maximum 3 meters.

Danger zone= 2 x End hose lenght= 6meters.
Cordon off the pouring area if there will be viewers.

Do no enter the danger zone.
Injuries occur due to opening pressurized delivery line. (E.g: After blockage).
Never open pressurized delivery line!
 Injuries caused by slipping from greasy machines.

 Injuries caused by falling because of cables.
 Injuries caused by slipping or falling of unconnected delivery lines.

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USER MANUAL
4.1 Equipments The following protective equipment is defined by rules without any
exceptions in the working area to limit the risks to the life and limb
of persons.
Your hard hat protects your head against, for example, falling
-Hard Hat concrete or parts of the delivery line hose.
Safety footwear protect your feet against falling objects or

protruding nails.
-Safety footwear
The ear protectors protect you against the noise created by

-Ear protector the machines while you are standing near the machines.
-Protective Gloves
Protective gloves protect your hands against hard or
chemical materials, mechanical movements (eg impact) and
shearing injuries.
-Protective Goggles
Protective goggles protect your eyes from splashing in

concrete or other particles.
-Safety Belt
The safety belt protects you from falling when working on

scaffolding, bridges or similar structures.
-Protective mask
The protective mask protects you against particulates (eg
cement mixtures) that can penetrate your body through
breathing of building materials.

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USER MANUAL
4.2 Protective Equipment
Always use personal protective equipment as required by law or the situation.

Personal protective equipment must be worn in the area where the machine is used,
especially if the machine is working with cement or chemical mortar mixtures, in
accordance with the instructions of the work safety units.

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USER MANUAL
4.3 Corporate Precautions
Always keep the user manual at the place of use the machine.
In addition to the user manual, observe and inform the application of all other
applicable statutory or compulsory regulations on accident prevention and
environmental protection.
These mandatory regulations may also be related to the transport of dangerous

materials and the wearing of personal protective equipment and traffic
regulations.
4.4 Additional Instruction
It is important to follow the Boom Makina’s user manual. Failure to follow these
instructions can result in serious death / injury, damage to your equipment or
shortening the life of your equipment. Machines that are determined not to
comply with the usage criteria and maintenance instructions are excluded from the
warranty by Boom Makina.
Observe the laws, regulations and directives of the country where the machine is
used.
According to the regulations of the country where the machine will be used, it may
be necessary to adapt the second hand / used hydraulic concrete distributor for
export according to the country regulations.
The machine operator must ensure that all instructions are followed.

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USER MANUAL
4.4.1 Other Additional Instruction
This user manual should be supplemented by additional instructions that

specify specific organizational characteristics, such as work organizations,
work procedures or the personnel with whom the work is being carried out,
and which covers the tasks contained in the inspection.
4.4.2 Instruction
Personnel entrusted with work on the machine must read the Operating
Instructions and in particular the Safety instructions section before starting
work. It is too late to read the instructions after the work begins. This is
especially the case for people who only work on the machine from time to
time. (eg during adjustment or maintenance) Please contact Boom Makina for
the instructions of your new machine.
4.4.3 Users
At least from time to time, check that the staff does their work in accordance
with the user manual and that they pay attention to risk and safety factors.
4.4.4 Operator
Employees should never use long hair, loose clothing or jewelry.
4.4.5 Controls
Have information about the machine. Read and follow the operating
instructions, maintenance criteria and inform your supervisor if there is
anything you do not understand. Start working after familiar with all
documentation.

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USER MANUAL
4.4.6 Safety Instructıon

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USER MANUAL
4.4.7 Explanation of Safety Instruction
1.BOOM SHOWS WITH A.
2.BOOM SHOWS WITH B.
3.BOOM SHOWS WITH C.
PLATE OF WEAR HARD

HAT
PLATE OF DON’T LIFT

WITH BOOM
PLATE OF MAXIMUM END

HOSE LENGHT 3 M.
Lifting Points
PLATE OF TURNING,
1.BOOM, 2.BOOM, 3.BOOM,

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USER MANUAL
4.4.8 Failures
All safety instructions and hazard warnings on the machine must be fully
readable. As the owner and operator of the machine, it is your responsibility
to change any safety instructions or warning signs that are damaged or
unreadable on the machine without delay.
Check the safety of the operation every time you start working. Any changes
to the machine that affect the functionality of the machine, or only suspected
changes, must be repaired immediately; the inspector should be notified if
necessary, or where operations endanger operational safety. If there are
faults affecting the safe operation of the machine, the machine must not be
used until the malfunctions have been corrected. The correction of faults
must be verified by a second periodic inspection.
4.4.9 Changes
Changes, additions, and conversions to the machine without first getting the
supplier's approval may affect security. This also applies to the installation and
adjustment of safety devices and valves as well as for welding work on load-bearing
elements.

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USER MANUAL
This requirement is especially relevant to:
— Extension of end hose and placing boom;

— Adjust the safety pressure, movement speeds, power outputs, turning speeds and
other settings set during work;
— Installation to placing boom delivery line with a larger diameter or greater weight;
— Installation to placing boom a load bearing or lifting equipment.
— Changes made to the support system or anywhere in the boom;
— Changes made to hydraulic cyclinders;
— Changes made to cable or radio remote control systems; etc.
Never do any of them.

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USER MANUAL
5. Machine ID Card
The values displayed on the machine nameplate and machine board (eg
Model, Production Year, Hydraulic Pressure, etc.) are the maximum
permissible values.
Numara AÇIKLAMA
1 Model: Specify type of machine.(Name-Model)
2 Serial Number: Displays the machine registration number.
3 Production Date: Displays the machine’s manufacturing date.
4 Power: Displays the machine’s power (kW).
5 Voltage: Displays the machine’s voltage (V).
6 Current: Displays the machine’s current (A).
7 Frequency: Displays the machine’s frequency (hz).
8 Vertical Distance: Displays the machine’s maximum vertical range.
9 Horizontal Boom Length: Displays the machine’s maximum horizontal range.
10 Pipe Diameter: Displays the diameter of the concrete pipes (mm).
11 Hydr. Power Unit Serial Nr.: Display’s the registration number of hydraulic power unit.
12 Max Hydraulic Pressure: Displays the maximum pressure expressed in Bar.
13 Max. End Hose Distance: Displays the maximum lenght of the end hose expressed in mm.
14 Rotation Degree: Displays the Wheel lock angle of boom.
15 Weight: Displays the net weight of the machine.

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USER MANUAL
5.1 Configurable Devices
Configurable devices (hydraulic pressures, electrical voltage settings, etc.) must only be set
by the authorized Boom Makina services.
The Hydraulic Concrete Distributor must be approved by the Boom Makina’s Engineer for its
ability to be reworked after the following important changes.
Some of the major changes:
--After assembly,
--After raising,
-- After revisions,
-- After any changes is done on equipment,
Mechanical Engineer and service personnel authorized by the Authorized Service may only
intervene, adjust or modify the hydraulic concrete distributor.
4.5 Spare Parts
Spare parts must comply with the technical requirements specified by Boom Makina. Use only
original spare parts. Boom Makina shall not be responsible for damages caused by the use of
non-original spare parts.
4.6 Period of Service and Inspection
Replace hydraulic hoses within stipulated and appropriate intervals, even if no safety relevant
defects have been detected.
The service life of hoses should not exceed six years, including a maximum storage period of
two years.
Check the delivery line, elbows, clamps at the end of the pouring, check the wear conditions
according to the amount of concrete casting, especially the end hose elbow must be checked
first.
If you are worried about the elbows and the concrete pipeline, take the necessary changes
into account. Turn concrete pipes over time. Check the thickness of the concrete pipes with
the help of thickness gauges or a hammer.

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USER MANUAL
Observe the prescribed intervals or those specified in the operating instructions for routine
checks and inspections.
Machines which are not maintained or serviced in accordance with the instructions are not
safe in operation and use.
The placing boom must be inspected for operational safety by a subject expert. The operator
must commission such inspection at the following intervals;
— Every month,
— Every 500 operating hours or after 20,000 m3 pump output,
— Every time the machine is replaced or re-assembled or after each upgrade, it must be
checked by a qualified engineer and a workable report must be reported.
Note:
The inspection shall be carried out even if one year has not passed since the last inspection as
soon as one of the two criteria
— 500 operating hours or 20,000 m3 pump output

— is achieved, in addition an inspection shall be carried out before a new installation.
The outcome of the inspections must be recorded in the check book and confirmed by a
signature. The check book must be made available on request. The inspection and check book
are specified by law in the Republic of Turkey. Please observe the regulations in the country in
which the machine is being used. Every inspection must be notified to the Boom Makina on the
forms provided for this purpose.

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USER MANUAL
5. Workplace Equipments
Workshop equipment appropriate to the task in hand is absolutely necessary for the execution
of maintenance work, You should commission the Boom Makina After Sales Department with
the maintenance and repair of your machine if you do not have the qualified personnel,
suitable workshop equipment etc, available.
5.1 Protection from Fire
Ensure that personnel are aware of the location and operation of fire extinguishers. Observe
the fire alarm and firefighting procedures.
5.2 Obligation
The operator is obliged to act in accordance with the Operating Instructions.

Accidents which can be ascribed to the failure to comply with safety and accident prevention
regulations:
— issued by the Industrial Employers’ Obligation Insurance Associations;
— The commercial liability insurance company;
— The legislation of your country; or to deficient supervision, will be made the responsibility of:
— The machine operator; or (where he cannot be held responsible due to lack of training or
basic knowledge),
— his supervisors, under the law.
Please therefore ensure that the necessary caution prevails.

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USER MANUAL
5.3 Education
Operators with professional qualification certificates are authorized to use hydraulic concrete
distributors. Operators who do not have a Professional Qualification Certificate must contact
the Boom Belgelendirme.
Operate only trained personnel, clearly identify the individual responsibilities of staff for
operation and installation, maintenance and repair.
Make sure that the machine is only operated by authorized personnel.
The machine must be used, repaired or maintained only by persons who have been trained to
do these tasks and are authorized to do so.
5.4 Qualification of Hydraulic Concrete Distributor Boom Operator
Any work on or with the machine must be carried out by reliable personnel only. Statutory
minimum age limits must be observed.
The machine may only be operated or maintained without supervision by persons
(maintenance staff, machine, operators) who
— are aged 18 years and older,
— are physically and mentally suitable (Study G 25 ~driving, control and monitoring
activities”),
— are physically capable (rested and not under the influence of alcohol, drugs or medication);
— have been instructed in the operation and maintenance of the machine;
— have demonstrated their competence to the owner and
— can be expected reliably to execute the tasks they are charged with.
Reliability also includes the machine operator informing his employer of illnesses or
indisposition on his own responsibility.

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USER MANUAL
5.5 Responsibility
Define the machine operator’s responsibility, giving him the authority to refuse instructions
issued by third parties that would be prejudicial to safety. Amongst other duties, the machine
operator must inspect the proposed site of operations and must refuse to place the truck at
this site if he has any doubts in respect of safety.
5.6 Qualified Personnel
Operation, maintenance and repair must only be carried out by persons trained and
commissioned to undertake such operations.
Define the responsibilities of the personnel clearly.
Safety equipment must only be repaired, set or replaced by subject experts.
Work on the hydraulic and electrical systems must only be carried out by persons who can
produce to us appropriate certificates of competence (training certificates).
Couplings must only be fitted to hoses by persons having the necessary experience and
possessing the equipment necessary for this task.
5.7 Welders
Only welders commissioned by the manufacturer and in possession of the necessary

welding qualification may carry out welding work on the placing boom, on the supports
or on other components of importance for safe operation. The work must be inspected
by an authorized inspector.
Danger of explosion
Welding work on fuel and oil tanks may only be carried out by trained welders observing
the relevant safety regulations.

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USER MANUAL
5.8 Qualified Electricians
The electronic components of the remote radio and cable control systems may be
damaged by external voltages generated during electrical welding processes. For this
reason:
— disconnect the remote control cable from the control console:
— disconnect all cables leading to the receiver of the radio remote control system.
Close connector sockets with caps;
— disconnect the positive and negative leads from the battery and equipment of the
machine must be carried out only by a skilled electrician or by instructed persons
under the supervision and guidance of a skilled electrician and in accordance with
electrical engineering rules and regulations.
Only such qualified personnel may install, connect, disconnect and open electrical
control cabinets.
If necessary, have a qualified electrician isolate the power supply. Only qualified
electricians may work on electrical systems with an operating voltage in excess of 25
volts alternating current or 60 volts direct current.
5.9 Hydraulic Engineers
Only persons having special knowledge and experience in hydraulic systems must work on
hydraulic equipment. Adjustable equipment (pressure limiting valve, potentiometer, fluid flow
limiter, hydraulic cylinders, etc) must only be adjusted by technically qualified After Sales
engineers or servicing personnel Modifications to the machine ratings (for example, increasing
pressures, modifying speeds, etc) are not permitted.
5.10 Danger Zones
Unauthorized presence in the danger zone of the machine is forbidden. Warn persons present
in the danger zone. Cease operations if such persons do not leave the danger zone despite a
warning. The machine operator must be capable of seeing the danger zone at all times and
under all circumstances. If necessary he shall appoint an assistant supervise the danger zone.
The machine operator is responsible for safety in the working area (danger zone) of the
machine whilst the machine is in use.

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5.10.1 Placing Boom
Unauthorized access to the danger zone of the machine is forbidden.

Warn people in danger zone. If they do not leave the danger zone despite warning, stop
operation. The machine operator must always be able to see the danger zone at all times and
under all circumstances. If necessary, you must authorize an assistant to check the danger
zone.
The machine operator responsible from danger zone when using machine.
5.10.2 Placing Boom
The danger zone when working with the boom is the zone over which the boom is slewed.

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5.10.3 End Hose
The danger zone when starting to pump is the zone around the end hose in which the end hose can
swing out.
The diameter of the zone is twice the length of the end hose.
1 Maximum end hose length 3 m
2 Danger zone =2 x end hose length = 6 m
Danger
There is a risk of injury in the zone around the end hose if the end hose swings out violently when
pumping is started or after a blockage has been cleared. This zone is twice the end hose length in
diameter.
The end hose must be allowed to hang freely.

Ensure that no—one is standing in the danger zone. Keep the working area under constant
observation.
You must stop work immediately and press the EMERGENCY SHUTDOWN button if anyone
should enter the danger zone.

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5.10.4 Start Up
Check safety of operation every time you start work. Any defects or safety relevant changes to
the machine/plant or its functioning found, or merely indicated, shall be repaired immediately;
if necessary, the supervisor should be notified or, where defects endanger operational safety,
operations should be ceased.
Take the necessary precautions to ensure that the machine or plant is only used when in a
safe and reliable condition.
Operate the machine only if all protective and safetyoriented devices, such as removable
safety devices, emergency shutdown equipment, sound proofing elements and exhausters are
in place and fully functional.
Take care to ensure that:
— the machine is only ever operated in a faultless condition;
— no safety equipment has been removed, rendered nonfunctional or modified (EMERGENCY SHUT
DOWN, grille on the pump filling hopper, etc.);
— safety equipment removed for the purposes of maintenance work is refitted immediately the work is
completed.
The machine shall be free from visible defects (cracks. damage, loose or missing bolts, missing safety
pins, rust on loadbearing components, leaks, etc.). Every lost drop of oil pollutes the ground water.
Check the tightness and secure closure of the oil and water tanks (environmental protection).

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5.10.5 Functional Liquids
Making ready for operation also includes topping up the functional fluids.
Danger
Oils, fuel and other functional fluids may be a health hazard on contact with the
skin, etc.
You must, therefore, always wear personal protective clothing and equipment
when you are handling toxic, caustic or other functional fluids that are injurious
to health and and always take note of the manufacturer’s instructions.
5.10.6 Test-Purpose Operating
Check the machine/plant for obvious damage and defects at least once per working shift.
Report any changes (including changes in the working characteristics) to the competent
organization or person immediately. If necessary, stop the machine immediately and lock it.
The machine operator shall inspect the machine each time before commencing work.
Furthermore, he should check for correct functioning of all operating and safety equipment,
especially the EMERGENCY SHUT DOWN functions.

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5.10.7 Emergency Stop
Press to lock EMERGENCY STOP

Turn to unlock EMERGENCY STOP
— All equipment required for safety and accident prevention (warning signs and
informative notices, cover grids, covers, etc.) snail be in place. Such equipment may
not be removed, modified or damaged.
— All control and monitoring equipment should be functional.
— Set all the control and monitoring devices to the “0” position before you change the
mode of control (control block, operating console or remote control).
— Press EMERGENCY STOP button. Otherwise the machine might execute unintended
movements.
If this cannot be avoided in exceptional cases, press in the EMERGENCY STOP
button, disconnect the remote control (cable control) and lock the remote control unit
away.
Remote Control Emergency Stop
Unlock the EMERGENCY STOP button by turning it in the direction shown by the
arrow to bring the machine back into service.

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5.10.8 Extending Placing Boom
Only erect the placing boom after proper assembly and only in the sequence
described in the operating instructions. The correct sequence is dependent on the
“folding system” (roll-and-fold system, Z-fold system etc).
5.10.9 Bad Weather Conditions
Return the placing boom to the transport position in the event of storms or bad
weather. The placing boom may not be used in winds stronger than wind force 8
(wind speed 62 km/h and higher), Greater wind speeds jeopardize stability. There
is a risk of lightning strike in the event of storms.
Tower cranes on construction sites generally have wind speed measuring
equipment, so that you can ask about the wind speed at any time. You can use
the following rule of thumb to make an approximate estimate of what the wind
speed is if no wind speed measuring device is available.
5.10.10 Eyeball Estimate
From wind force 8 and greater, small branches break from trees and walking
outside is made significantly more difficult.

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5.10.11 Loads
The placing boom must never be used as lifting equipment (crane) for lifting loads.
The placing boom must never be used for lifting loads.
5.10.12 Spotter
Always ask the site management to supply you with an assistant to act as a
spotter. Agree clear hand signals or other signals with the spotter so that you can
communicate with each other. A spotter is particularly important for you if you are
operating the placing boom with a remote control unit.
You should, therefore, position the spotter such that he can always observe the
whole of the placing boom.
Your primary duty as the machine operator is to observe the site of concrete
placement.

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5.10.13 Boom Movements
Only slew the placing boom over persons when the end hose is empty. There is a
danger from falling concrete. Injuries to the head and shoulder can be caused by
concrete falling out of the end hose when the placing boom is slewed over the
construction site at a great height (even when the pump is switched off). Injuries to
workers may result from unintentional operation of the boom control and thus
unintended movement of the boom.
Press the EMERGENCY STOP button immediately if the boom executes unexpected
movements. You intended, for instance to execute the SLEW function and the boom
instead executes a different function you had not selected. The cause for this may be
an electrical fault (sticking relay or moisture in the plug-in contacts) or sticking gates in
the valves. In these cases, you must cease working and have the precise cause of the
fault rectified by your workshop personnel or our After Sales Department.
6. Danger Zone
The danger zone when working with the boom is the zone overwhich the boom is slewed.

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6.1 High Voltage Lines
Work with care where there are high voltage lines. Direct contact with a power line under a
voltage is always dangerous. A spark can jump across from high voltage lines even if you just
approach them and this will energize the machine and the surrounding area. Whenever
voltage flashes over there is a lethal danger for all persons either on the machine or in its
vicinity or who are connected to it (remote control, end hose etc). In the event of a flash over,
what is known as a discharge voltage pattern” is formed under the machine and in its vicinity.
The voltage declines as you move away from the machine. Any step within this voltage funnel
is dangerous! A current corresponding to the difference in potential flows through the body if
you bridge different voltages (potential differential).
Caution in the vicinity of high voltage lines
High Voltage
A spark can jump across from high voltage lines even if you just approach them and this will
energize the machine and the surrounding area. You must therefore always maintain the
specified safe clearance.

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6.2 Clearance
Rated voltage [V] Safe clearance [m]
Up to l kV 1.0
1 kV to 11O kV 3.0
110 kVto22OkV 4.0
220 kV to 380 kV 5.0
unknown rated voltage 5.0
Beware: Clearances are generally incorrectly estimated. Take no risks.
The same minimum clearances are necessary when driving under overhead cables. The
possibility of the overhead cable and the placing boom swaying in the wind must also be taken
into consideration here. You should further note that where air humidity is high, distances
greater than the minimum distances shown above are always necessary. Comply with the
requirements of the country in which the machine is being used. You must immediately
consult with the electricity utility responsible if it is not possible to maintain this minimum
clearance under all possible working positions. If you have any doubts it is better to forego the
use of the placing boom and to lay a separate delivery line, for instance Should a flash over
occur, despite all caution. stay calm, do not move (potential differential), touch nothing. Tell
any persons standing outside the funnel not to approach: beware of potential differential! Ask
these persons to have the cable isolated.
6.3 Flash Over
High voltage
Electricity works are a/ways equipped with automatic switch-on devices, If a circuit breaker
trips, the shortcircuited cable will be switched back on again after a brief interval. Brief
intervals when the voltage is absent give rise to a false sense of safety.
You should only move and rescue injured persons once a representative of the electricity
utility has notified you that the cable has been switched off Start first aid measures for
accidents caused by electrical current.

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Note also:
A radio remote control system only protects the machine operator when he is standing outside
the discharge voltage pattern. There is a lethal danger to all persons in all other cases.
You should therefore have the responsible qualified electricians switch off the overhead
cables if you are working in the vicinity of any overhead cables .
6.4 Static Charge
Faults can be caused in the radio remote control system and dangerous electrical charging of
the machine when working in the vicinity of transmitters (radio transmitter etc). Persons who
bridge the charged parts to the earth are heavily charged on contact. Stationary booms
operating in the vicinity transmitters must be earthed. Fasten the earthing strap to a bright
metal point on the machine and anchor it in the ground with an electrically conducting metal
rod.
6.5 Obstacles
Maintain safe distances from obstacles (booms, scaffolding, tower Crane, etc.) without fail.

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6.7 Overlapping Working Ranges
Beware of overlaps
You must stand as close as possible to the extended placing boom if you wish to estimate
correctly the movements of the boom and, above all, the distance between the placing boom
and obstacles or overhead cables. Directly beneath the placing boom there is a danger of
parts of the delivery line falling. Beneath the end hose there is a danger of falling concrete.
Avoid excessive force. The following actions (examples) will overload the placing boom and
will lead to damage and jeopardize persons:
— lifting and :transporting loads;
— pushing with the placing boom, in order to move an obstacle out of the way. :or instance;
— allowing the placing boom to strike an obstacle;
— tearing away a trapped end hose by force.

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6.8 Impermissible Working Range
Placing booms the boom hinges of which allow considerable flex angles, have a very large
useful working range. Because of this high mobility, various placing booms can, however, also
be shifted into positions that are of no interest for the job in hand. Under certain circumstances
it is even possible to overload or cause damage to the placing boom. We have indicated such
unacceptable working ranges by the use of warning plates on the machine and appropriate
notes in the Operating Instructions.
6.9 Concreting Operation
Make sure that nobody is at risk from the running machine before starting up the machine or setting it
in motion. Always watch the control displays in accordance with the Operating Instructions during
start-up and shut-down procedures.

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6.10. Responsibility
The machine operator is responsible for the entire operational area while the machine is in
use. It must be possible for him to observe this area in its entirety, otherwise a signaller is
required. Avoid any method of operation that might be prejudicial to safety. Secure yourself
against falls by means of a safety harness and similar securing devices during any work on
scaffolding, bridges and other parts of a building. Avoid any method of operation that might be
a risk to machine stability.
6.11 Noise
Keep all access covers, maintenance flaps, etc closed and locked during operation. There is a
risk of injury on moving parts of the machine and a risk of damage caused by the increased
noise stress.
6.12 Faults
You should be constantly observing the machine for any damage or faults while is in use. The
machine operator must suspend operations until any defects which jeopardize the safe
operation of the machine have been rectified if it is not possible to rectify them immediately.
Stop the machine immediately and secure it in the event of malfunctions. Have any faults
rectified immediately. Suspend operations immediately any faults occur which may be
prejudicial to safe working.

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6.13 Remote Control
When the machine is in ready mode, the machine operator must

always and under all circumstances carry on his person the plugged-in
cable remote control unit or the switched on radio remote control unit.
Only in this way can it be guaranteed that the machine operator can
press the EMERGENCY SHUT—DOWN button in the event of an
emergency situation. The EMERGENCY SHUT—DOWN button may only
be unlocked (turned in the direction shown by the arrow) to re-start the
machine once the cause or the emergency situation has been remedied.
6.14 Emergency Stop
Press to lock EMERGENCY STOP
Turn to unlock EMERGENCY STOP
Never put the remote control unit down when it is in ready mode. Carry the remote control unit in such
a way that no control element is actuated unintentionally. Replace any damaged cable on a cede
remote control immediately.
You must unplug the cable remote control unit during breaks in pumping, interruptions and repairs.
You must switch off the radio remote control unit and additionally press the EMERGENCY
SHUTDOWN button. You must lock the cable remote control unit / radio remote control unit away
during interruptions in work, eg in the tool— box, thus preventing unauthorized operation.

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6.15 Unauthorized Working
You must always secure the machine against unauthorized operation when you leave it.
Never leave the machine when the engine is running or when the engine could be started by
an unauthorized person. Always secure the machine against unauthorized use before you
leave it.
This means:
— moving the placing boom to the rest position;
— locking away the remote control;
— locking the control console;
— switching off the main switch.

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7. Turning Delivery Pipes
Rotate all delivery pipes clockwise through 120° and the bends through 180° after
approximately 6000 m³ pumped volume to prolong the service life of the delivery line. Note the
minimum wall thickness and operating pressure.
7.1 Minimum Wall Thickness
Replace pipes and bends if the wall thickness has fallen below the minimum. The minimum
wall thickness depends on the maximum possible concrete pressure delivered by the pump.
Fit only as new delivery pipes near the pump, as the concrete pressure is highest here. High
pressure delivery (concrete pressure over 85 bar) through the delivery line on the placing
boom is forbidden. Connect the concrete pump only to an inspected, separate high pressure
delivery line for high pressure delivery. High pressure delivery applications demand particular
care, knowledge and special equipment.
They may only be executed under the instruction of a subject expert. In any event, you should
request additional information material from us. Take note that the entire delivery line system
is subjected to maximum pressure in the event of a blockage in the end hose.
7.2 Blockages
Avoid blockages. A properly cleaned delivery line is the best insurance against the formation
of blockages. Blockages increase the risk of accidents.
1. Wedged aggregate
2. Cement paste
3. Boundary layer
Never try to blast a blockage out using compressed air. This causes a danger to life
and limb.
Injury caused by the force of bursting couplings, bursting pipes or plugs being rapidly ejected
from delivery lines, end hose and pump hopper.
Always try to remove the blockage by reverse pumping and then re—starting forward
pumping.
If the blockage is not removed, dump the pressure in the entire system, and particularly on the
delivery line, and then remove the section of delivery line concerned.

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7.3 Delivery Pipe Opening
You must never open delivery lines under working pressure, nor attempt to knock blockages
off. Concrete exiting under pressure can cause personal injury. Relieve the pressure on the
concrete column by a brief period of reverse pumping before opening. Be aware that not every
blockage can be released by reverse pumping. Stand on the side of the line clip when opening
the line. Never work bending directly over the coupling. Remove persons not involved from the
danger zone. Separate delivery lines must be covered with timber cladding or metal casing or
similar if persons are working in their danger zone (less than 3 m away).
Never open delivery lines under working pressure.

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8. End Hose
The end hose must be able to swing freely each time pumping is started or when pumping is
re-started after a blockage. No one may stand within a radius of the length of an end hose. Do
not guide the end hose when pumping is started. The end hose can swing out or stones may
be ejected and cause an accident.
8.1 Danger Zone
The danger zone when starting to pump is the zone around the end hose in which the end
hose can swing out. The diameter of the zone is twice the end hose length.
1. End hose length, maximum 4 m
2. Danger zone = 2 x end hose length = 8 m
DANGER
There is a risk of injury in the zone around the end hose if the end hose swings out violently
when pumping is started or after a blockage has been cleared. This zone is twice the end
hose length in diameter. The end hose must be allowed to hang freely Ensure that no one is
standing in the danger zone. Keep the danger zone under constant observation. You must halt
work immediately and press the EMERGENCY STOP button if anyone enters the danger
zone. Injuries may be caused to the hose operator by his being struck by the end hose if this
has become trapped in the reinforcement and suddenly jumps out on further movement of the
boom. This danger also exists it a blockage is suddenly released. There is also a considerable
risk of injury from the end hose swinging out violently when pumping is started. A hose guide
on the end hose makes the work easier and protects against injuries.

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8.2 Bending
Never bend the end hose over. Never attempt to straighten a bent end hose by increasing the
pressure.
Do not bend the end hose. The end hose must not be inserted in the concrete.
8.3 Securing
The end hose must be secured against falling.

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8.4 Extending
Extension of the placing boom and end hose beyond the length specified on the boom rating
plate is forbidden.
Extending the end hose is not permitted.
End hoses may not be fitted with any extension coupling, outlet shoes or other dangerous outlet
fitting. Further pipes connected to the end hose must not impose a load on the boom. Couplings
must only be fitted to hoses by persons having the necessary experience and possessing the
equipment necessary for this task. Secure couplings against spontaneous opening with safety
clips.
8.5 Seperated Delivery Line
Delivery lines, in particular riser lines which are not led along placing booms, must be securely
fastened in order to transfer the forces generated in them into the structure or other parts of the
building. The lines must be laid so as to avoid kinks, sharp bends, stresses and damage during
operations. Support horizontal delivery lines in order to make installation of the couplings easier.
Separate delivery lines must be covered with timber cladding or metal casing or similar if persons
are working in their danger zone (less than 3 m away).

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8.6 Stationary Concrete Pumps
Do not ascend the ladder during pumping operations.
Heavily worn delivery lines can burst at any time under high operating pressure (eg in the event of
blockages). For this reason. ascending the ladder during pumping operations is forbidden.
8.7 Cleaning
Take care with aggressive cleaning agents. Wear protective clothing.

Acid will attack rubber articles.
Do not use any readily flammable agent (petrol, etc.) for cleaning purposes.
Danger of fire.
Do not use sea water or water containing salt for cleaning, in the water tank or in the water
box.
Keep your working area and tools clean.
Use the hand rails and steps when climbing on and off the machine.
Do not jump from the machine.
Keep steps. platforms, control and indicating devices. etc. free from dirt. oil. snow and ice.
There is a danger of falling and a danger from defective functioning.
Injuries caused by slipping over or slipping from the oily or greasy machine.
Injuries caused by tripping over cables. hoses or reinforcing steel.

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8.8 Transporting
Shift the placing boom into the transport position. Observe the correct sequence of boom arm
movements. Failure to comply can lead to damage being caused.
8.9. Transpor Vehicle
The following applies for the transport vehicle:
When traveling on public roads, ways and places. always observe the valid traffic regulations
and, if necessary, make sure beforehand that the machine is in a condition compatible with
these regulations.
Before starting work or traveling with the machine, check that the braking, steering, signalling
and lighting systems are fully functional. Always switch on the lighting in conditions of poor
visibility and in darkness.
The maximum loading or the maximum permissible gross weight shall not be exceeded. The
tractor unit must have sufficient engine power. Comply with the axle loads and other
information provided by the truck manufacturer.

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Before transporting the machine, always check that the accessories are stowed in such a way
that they cannot cause an accident. Stow loose accessory components away safely for road
travel. Comply with the permissible gross weight of the transport vehicle.
8.10 Maintenance and Safety Rules
Comply with the adjusting, maintenance and inspection activities and intervals set out in the
Operating Instructions, including information on the replacement of parts and equipment.
These activities may be executed by qualified personnel only.
Machines which are not maintained or serviced in accordance with the instructions are not
safe in operation and use.
We warn urgently against inexpert repairs. The Boom Makina After Sales department will
carry out repairs. Carefully save the inspection certificates supplied. The operator is
responsible for the proper operation of the hydraulic accumulator and for compliance with the
inspection intervals laid down by the law.
Brief operating personnel before beginning special operations and maintenance work. Appoint
a person to supervise these activities.
- Replace the safety labels if they are missing, missing, damaged or unreadable.
- Do not use the guards if the safety devices have been removed for maintenance.
- Refer to the manual for maintenance procedures and intervals.
- Check the end hose and mounting hardware regularly, replace if worn, worn or rusted.
- Keep the machine clean! Oil, loose-connected tools can cause accidents.
- When adding new pipes to the machine, ensure that it is capable of removing the
maximum concrete pressure.
- Do not change the maximum discharge valve settings on any hydraulic circuit without the
manufacturer's permission.
- Do not make changes to structural elements and pressure circuits without prompting the
manufacturer.
- Damaged hydraulic and concrete pipes, hoses should not repair the replacement.
- Repairs must only be carried out by qualified personnel.
BEFORE INTRODUCING ANY REPAIR, READ AND UNDERSTAND THE HANDBOOK.

IN ANY DOUBT, CONTACT THE BOOM MAKINA.

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8.9.1 Special Work
Always observe the start-up and shut-down procedures set out in the Operating Instructions and the
information on maintenance work any work concerning the operation, conversion or adjustment of the
machine and its safety oriented devices or in any work related to maintenance, inspection and repair.
Only welders authorized by the BOOM MAKINA may work on loadbearing components. Their work
must be checked by an authorized inspector.
8.9.2 Securing the Area
Ensure that the maintenance area is adequately secured. Take care when cleaning the
placing boom that no unauthorized person can start the machine up.
Switch the engine off before commencing any work on the machine, and secure the machine
against unauthorized starting. Disconnect the remote control (cable remote control) and lock
the remote control units away.

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8.9.3 Stability
A machine completely shut down for maintenance and repair work must be secured against
inadvertent starting by;
 Locking the main control devices and removing the key and/or,
 Fixing a warning notice to the main switch.
 Hang a warning notice on the control console when you are working on the machine. Prevent
unauthorized persons from approaching the machine.
 Only carry out maintenance and repair work when the machine is parked on level ground
capable of bearing its weight and is secured against tilting.
 Only carry out maintenance and repair work on the placing boom with the placing boom
retracted or properly supported and with, the motor switched off.
8.9.4 Lifting Equipments
To avoid the risk of accidents, individual parts and large assemblies being moved for
replacement purposes should be carefully attached to lifting equipment and secured. Use only
suitable and technically perfect lifting gear and suspension systems with adequate lifting
capacity. Never work or stand under suspended loads.
Fastening of loads and instruction of crane operators should be entrusted to experienced
persons only. The person giving the directions must be within visual range of or in speech
contact with the operator.Observe the appropriate accident prevention regulations when
working with lifting equipment.
Support the boom arms before starting work on the valves, cylinders or hydraulic lines on the
boom.There is a risk of injury from falling boom arms if isolators are opened without first
ensuring that the corresponding boom arm is secured.
8.9.5 Changing Delivery Lines
The delivery lines were installed without tension with the placing boom in the driving position
and can only be changed without difficulty in this condition. Stresses may be generated on
reassembly if delivery lines are changed when the placing boom is extended.

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8.9.6 Workplace
Always use specially designed or otherwise safety—oriented ladders and working platforms
when carrying out assembly work above head height. Never use machine parts as a climbing
aid. Wear a safety harness when carrying out maintenance work at greater heights. Keep all
hand grips, steps, handrails, platforms, landings and ladders free from dirt, snow and ice.
Use the hand grips and steps for climbing on and off the machine. It is forbidden to stand on
the grille.
8.9.7 Water
Before cleaning the machine with water, steam jet (high-pressure cleaning) or other cleaning
agents, cover or tape up all openings which, for safety and functional reasons, must be
protected against water, steam or detergent penetration. Special care must be taken with
electric motors and control cabinets.
Do not direct the water or steam jet onto electrical components of the machine or cover or lock
away electrical devices (remote control units).
Never spray remote control units or control cabinets with barrier agents (anti-tack oil or similar)
to protect them against contamination. This causes significant corrosion damage to the
electrical system.
No water in the electrical system.
Water spraying on the machine from arbitrary directions has no damaging effect. The machine
is protected against spray water. but is not water tight. When cleaning is finished, completely
remove all covers and tapes applied for this purpose.

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8.9.8 Cleaning
Clean the machine, especially connections and threaded fittings, of any traces of oil, fuel or
preservatives before carrying out maintenance or repair work.
Never use aggressive cleaning agents. Use lint free cleaning rags.
Take care with aggressive cleaning agents. Wear protective clothing.
Acid will attack rubber articles.
Do not use any readily flammable agent (petrol, etc) for cleaning purposes.
8.9.9 Cleaning Delivery Lines
Do not use sea water or water containing salt for cleaning purposes. After cleaning, examine
all fuel, lubricant and hydraulic fluid lines for leaks, loose connections, chafe marks and
damage. Any defects found must be rectified without delay.
The preferred methods for cleaning the delivery line are reverse pumping or forced cleaning
with water.
Boom Makina does not recommend compressed air cleaning for concrete pumps with placing
booms. Boom Makina accepts no liability for damage resulting from cleaning with compressed
air.

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9. Warning Devices
Threaded fittings undone for the purposes of maintenance and repair work shall always be
tightened with the specified torques.
9.1 Inspection
There is a risk of injury from falling pipeline parts caused oy threaded fittings which have been
partially loosened or couplings that have not been secured.
9.2 Safety Equipments
All equipment required for safety and accident prevention (warning signs and information
notices cover grilles, covers, protective covering etc) must be in place. Such equipment may
not be removed, modified or damaged.
Any safety devices removed for set-up, maintenance or repair purposes must be refitted and
checked immediately upon completion of the maintenance and repair work. Secure the covers
and flaps opened for the purposes of maintenance work.
Do not open gas-tilled spring elements, as are used on maintenance flaps, for instance. The
spring elements are filled with gas under high pressure which can escape explosively if you
attempt to open them.Relieve the tension on systems under mechanical stress.
9.3 Environment
Ensure that all consumables and replaced parts are disposed of safely and with minimum
environmental impact

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9.4 Electrical Power
As a standard finish, the control cabinet, engine and control elements are protected in
accordance with degree of protection P 54 as specified in DIN 40 050 and IEC 144, i. e.
complete protection against contact with live parts or internal moving parts. Protection against
hazardous dust accumulations.
Boom Makina pumps and placing booms are equipped as standard with electrical motors
complying with ISO Class B. The voltage tolerance for variations in the rated voltage is ±5%.
Other degrees of protection, voltage tolerances, etc. can be supplied on request.
Use only original fuses with the specified current rating. The electrical system can be
destroyed by over-rated fuses or bridging, Switch off the machine/plant immediately if trouble
occurs in the electrical system.
The power on the construction site shall be supplied from a special feed point (construction
site power distribution point).
9.5 High Voltage Lines
Whenever voltage sparks over there is a lethal danger for all persons either on the machine or
in its vicinity or who are connected to it (remote control, end hose etc.). When voltage sparks
over, what is known as a “voltage funnel” is formed beneath the device and around it. The
voltage here decreases as you move away from the centre. Every step inside this funnel is
dangerous! A current corresponding to the difference in potential flows through the body if you
bridge different voltages (step voltage).

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9.6 Clearance
Maintain a safe distance from electrical overhead cables when working with the machine/plant. If work
is to be carried out close to overhead lines, the working equipment must be kept well away from them.
Caution, lethal danger! Check out the prescribed safety distances. The possibility of the overhead line
and the placing boom swaying in the wind shall also be taken into consideration here. You should
further note that where air humidity is high, distances greater than the minimum distances shown
above are always necessary. Comply with the requirements of the country in which the machine is
being used. Most common minimum distances from overhead cables as follows:
Rated voltage N) Safety clearance [m]
Up to 1 kV 1.0
1 kV to 110 kV 3.0
110 kV to 22O kV 4.0
220 kVto38OkV 5.0
unknown rated voltage 5.0
High voltage
A spark can jump across from high voltage lines even if you just approach them and this will
energize the machine and the surrounding area. You must therefore always maintain the
specified safety clearance.

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USER MANUAL
9.7 Switch off Overhead Cables
You should therefore have the responsible qualified electricians switch off the overhead
cables if you are working in the vicinity of any overhead cables.
If you have any doubts it is better to forego the use of the placing boom and to lay a separate
delivery line, for instance.
You must immediately consult with the electricity utility responsible if it is not possible to
maintain this minimum clearance under all possible working positions.
Faults can be caused in the radio control system and dangerous electrical charging of the
machine when working in the vicinity of transmitters (radio transmitter etc.). Persons who
bridge the charged parts to the earth are heavily charged on contact.
9.8 Static Charge
Machines in use in the vicinity of transmitters must be earthed. Fasten the earthing strap to a
bright metal point on the machine and anchor it in the ground with an electrically conducting
metal rod.
9.10 Emergency Precautions
Should a sparkover occur, despite all caution, stay calm, do not move (step voltage), touch
nothing.
Tell anyone outside the area not to approach you because of the risk of step voltage. Ask
these persons to have the cable isolated.
You should only move and rescue injured persons once a representative of the electricity
generator has notified you that the cable has been switched off.
Start first aid treatment for accidents caused by electrical current.
High voltage
Electricity works are always equipped with automatic switch-on devices. If a circuit breaker
trips, the short-circuited cable will be switched back on again after a brief interval. Brief
intervals when the voltage is absent give rise to a false sense of safety.
DANGER!
A radio remote control system only protects the machine operator if he is standing outside
voltage funnel. There is a mortal danger to all persons in all other cases

74
USER MANUAL
If your machine comes into contact with heavy current lines:
— Do not leave the machine
— Drive the machine out of the danger zone
— Warn those outside against approaching and touching the machine
— Have the power switched off
— Only leave the machine once you are sure that the line you have touched or damaged has
been de-energized.
9.11 Qualified Personnel
Work on the electrical system and equipment of the machine/plant must be carried out only by
a skilled electrician or by instructed persons under the supervision and guidance of a skilled
electrician and in accordance with electrical engineering rules and regulations. Only qualified
electricians may work on electrical systems with an operating voltage in excess of 25 volts
alternating current or 60 volts direct current. Only such qualified personnel may install,
connect, disconnect and open electrical switching cabinets.
9.12 Before Start the Work
Disconnect the negative strap from the battery before starting any work on the electrical
system. When reconnecting, connect the positive terminal first, and then the negative terminal.
Before starting work on high voltage assemblies and after cutting the power supply, connect
the supply cable to earth and short-circuit the components such as capacitors with an earthing
rod.
9.12 Cleaning Work
Never direct a water or steam jet towards the electrical components of the machine.
High voltage
There is a lethal danger from sparkover.

75
USER MANUAL
The electrical system can be damaged. The electrical system is protected against spray water,
but is not waterproof. You must always lock the remote control unit away in the driver’s cab
during cleaning work, and cover the electrical equipment.
10. Maintenance Work
Work on the electrical system and equipment of the machine/plant must be carried out only by
a skilled electrician or by instructed persons under the supervision and guidance of a skilled
electrician and in accordance with electrical engineering rules and regulations.
The power supply to parts of machines and plants oh which inspection, maintenance and
repair work is to be carried out shall be isolated, if provided for in the regulations. Before
starting any work, check the de-energized parts for the the presence of power and earth or
short-circuit them in addition to insulating adjacent live parts and elements.
10.1 Inspection
The electrical equipment of machines/plant shall be inspected and tested at regular intervals.
Defects such as loose connections or scorched cables must be rectified immediately.
High voltage
An electric shock (possibly with fatal consequences) may be the result of touching machines
with electric motors or contact with other electrical cables if the electrical connection has not
been made properly or the supply cable is damaged.
10.2 Securing the Electrical Power
Necessary work on live parts and elements shall only be carried out in the presence of a
second person who can cut off the power supply in the event of danger by actuating the
emergency shut-down button or main power switch. Secure the working area with a red and
White safety chain and a warning sign. Use insulated tools only.
10.3 Gas, Dust, Steam, Smoke
Observe the regulations in force for the site at which you are working.

76
USER MANUAL
10.4 Respiration Protection and Face Mask
Wear respiratory protection and a face mask in all work in which particles of building material
can enter the body through the respira tory passages (concrete spraying, for example).
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 a
supervisor.
10.5 Welding
Only carrying out welding, flame cutting and grinding operations on the machine if this has
been expressly authorized, as there may be a danger of fire and explosion.
Before carrying out welding, flame cutting and grinding operations, clean the machine/plant
and its surroundings of dust and other flammable substances and make sure that the
premises are adequately ventilated (danger of explosion).
Only trained and qualified welders must weld fuel and oil tanks, and these must comply with
the elevant safety regulations there is a danger of explosion.
Welding must only be carried out by qualified persons
10.6 Dust
The machine is not dust proofed, although penetration by quantities of dust sufficient to impair
operations are prevented.

77
USER MANUAL
10.7 Hydraulic System and Pneumatic System Delivery Lines
Work on hydraulic equipment may be carried out only by persons having special knowledge
and experience in hydraulic systems, who can demonstrate to us appropriate certification of
competence (certificates of training).
Wear a face mask and gloves whenever you work on the hydraulic system. Escaping fluid is
toxic and can penetrate the skin.
11 Inspection
Check all lines, hoses and screwed connections regularly for leaks and obvious damage.
Repair damage immediately. Splashed oil may cause injury and fire.
Regular inspections are specified as part of the safety inspections of the machine, Bursting
lines represent a risk of personal injury. The manufacturer accepts no responsibility resulting
from the use of worn or defective components.
Replace, do not repair, damaged hydraulic or delivery pipes. Replace damaged or soaked
hydraulic hoses immediately.
Even if no external damage is detected, hydraulic hoses shall be replaced every six years
(including a storage period of no more than two years). For this purpose, the period shall be
calculated from the marking on the fitting (date of manufacture of the hose).

78
USER MANUAL
11.1 Pressure Fluctuation
Depressurize, in accordance with the specific instructions for the unit concerned, all system
sections and pressure pipes (hydraulic system, pneumatic system. delivery line) to be
removed before carrying out any repair.
Never open delivery lines under working pressure.
Work only on depressurized systems. Fluid escaping under pressure represents a danger.
Open the accumulator relief valve, if a hydraulic pressure accumulator is fitted, to prevent any
movements of the machine caused by the residual pressure. Modifications to the hydraulic
accumulator are forbidden.
There is a risk of eye or skin injuries caused by hydraulic fluid escaping under pressure if
threaded fittings are opened without first relieving the accumulator pressure or first relieving
the pressure in the entire system.
Furthermore, there is a risk of injuries caused by opening pressurized delivery lines (after
blockages). Concrete escaping under pressure can cause personal injury.

79
USER MANUAL
11.2 Pipes
Lay and fit hydraulic compressed air and delivery lines properly. Ensure that no connections
are interchanged. The fittings, lengths and quality of the hoses must comply with the technical
requirements.
Danger of explosion
If lines are not installed properly, there is a risk of injury caused by the force of bursting
hydraulic lines, bursting couplings, bursting pipelines or blockages being ejected at speed
from delivery lines, end hose and pump hopper
11.3 Sweating
Carefully sweat the hydraulic system after any maintenance or repair work. Otherwise, there is a
risk of injuries caused by swing out and telescopic support legs extending rapidly.
12. Noise
All noise protection equipment shall be fitted and in perfect condition. Close the maintenance
flaps: The high noise level can cause permanent hearing damage.
The regular working position is at the remote control (normal operation). For this reason it is not
possible to lay down a specific working position for the operator of the machine. The workplace—
related emission value at the placement site is below dBA. However, depending on the model and
operating conditions, the value of 85 dBA can be exceeded in the vicinity of the machine. A
distance of less than 5m from the machine is considered to be close.
12.1 Ear Protective
Instruct your personnel always to wear their personal ear protectors. As the owner, you are
responsible for ensuring that your personnel comply with this regulation.

80
USER MANUAL
13. Oils, Greases and Other Chemical Materials
Comply with the safety regulations applicable to the products when handling oils, greases and
other chemical materials.
Building materials containing cement have a highly alkaline effect when they react with water
(and also with perspiration). Admixtures are toxic and caustic.
Take care when handling toxic and caustic functional fluids (brake fluid, battery acid, water
glass, concrete set accelerating admixtures, cement, etc).
Take care with aggressive cleaning agents. Acid will attack rubber articles.
The most frequent injuries are eye injuries caused by concrete splashes. water glass or other
chemical materials.
Danger of poisoning
Cleaning agents. concrete solvents, preservation agents etc propelled by compressed air can
cause very serious damage to the respiratory tract if a respiratory protection mask is not worn.
Spray mist enters the lungs very easily.

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USER MANUAL
13.1 Hot Materials
Take care when handling hot consumables (risk of burning or scalding). Only drain fluids from
depressurized systems at the points provided for this purpose. Take care when draining hot
fluids, there is a risk of scalding.
13.2 Environmental Protection
Have used consumables such as oil, filters, brake fluid, batteries, etc, disposed of properly.
Used cleaning rags should also be disposed of properly.
14. Loading, Transporting and Operating Again
1. Load and transport the machine only in accordance with the Operating Instructions.
2. Cut off the external power supply to the machine or plant even if only minor changes of place
are envisaged.
3. Use only lifting gear and tackle of sufficient capacity for loading
4. Appoint a competent marshaller to assist in the lifting operations.
5. Lift the machine properly in accordance with the information In the Operating Instructions
(slinging points for lifting tackle, etc.), using suitable lifting gear.
6. Never walk under suspended loads.
7. Fasten the load safely. Use suitable fixing points.
8. Before or immediately after completion of the loading operations, the machine/plant must be
secured by means of recommended or supplied devices against unintentional changes of
position. Affix an appropriate warning sign. Before recommissioning these devices must be
properly removed.

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USER MANUAL
Move placing boom into the transport position.
Supporting frames and other equipment shall be safe in operation and use. Ensure that the
loadbearing capacity is adequate.

83
USER MANUAL
14.1 Driving
The maximum loading or the maximum permissible gross weight shall not be exceeded.
Only use suitable means of transport of adequate carrying capacity.
The tractor unit shall have sufficient engine power: comply with the axle loads and other
information provided by the vehicle manufacturer.
Be aware of the height of the truck. Only drive over arches, bridges or other supporting
structures if the loadbearing capacity is adequate. Always keep an adequate distance from the
edges of building pits and slopes, there is a danger of collapse.
Be aware of the elevated position of the truck’s centre of gravity when travelling on a slope
and on ascending or descending routes.
14.2 Operating Again
The recommissioning procedure must be strictly in accordance with the Operating

Instructions.
Carefully refit and fasten all parts to be removed for transport purposes before
recommissioning.
Properly reconnect the machine to the supply mains before recommissioning.

84

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SECTION B – SAFETY

3.1 SAFETY CONTROL……..…………………………………………………………………………………………………………….21

3.2 PROPER USE…………………….…………………………………………………………………………………………………….22

3.2.2 EXTENDING END HOSE……………..………………………………………………………………………………………….23

3.3 MUTILATION RISK…………………………………………………………………………………………………………23-24-25

3.3.1 DANGER ZONE….………………………………………………………………………………………………………………… 26

4.1 PROTECTIVE EQUIPMENT ….…………………………………………………………………………………………………..28

4.2 CORPORATE PRECAUTIONS.……………………………………………………………………………………………………29

4.3 ADDITIONAL INSTRUCTIONS..…………………………………………………………………………………………………29

4.3.1 OTHER ADDITIONAL INSTRUCTIONS ……………………………………………………………………………………30

4.3.6 SAFETY INSTRUCTIONS..………………………………………………………………………………………………………31

4.3.6 EXPLANATION OF SAFETY INSTRUCTION..……………………………………………………………………….32-33

4.3.7 FAILURES …………………………………………………………………………………………………………………………….34

4.3.9 MACHINE CARD…………………………………………………………………………………………………………………. 36

4.4 CONFIGURABLE DEVICES………………………………………………………………………………………………………..37

4.5 SPARE PARTS…….……………………………………………………………………………………………………………………37

4.6 PERIOD OF SERVICE AND INSPECTION..……………………………………………………………………………..37-38

BOOM MAKİNA TİC SAN LTD ŞTİ.

5.1 PROTECTION FROM FIRE…………………………………………………………………………………………………………39

5.4 QUALIFICATION OF HYDRAULIC CONCRETE DISTRIBUTOR BOOM OPERATOR.………………………..40

5.6 QUALIFIED PERSONNEL.………………………………………………………………………………………………………….41

5.8 QUALIFIED ELECTRICIANS.………………………………………………………………………………………………………42

5.9 HYDRAULIC ENGINEERS…………………………………………………………………………………………………………42

5.10 DANGER ZONES…..……………………………………………………………………………………………………………… 42

5.10.1 PLACING BOOM……..………………………………………………………………………………………………………….43

5.10.2 PLACING BOOM …….………………………………………………………………………………………………………….43

5.10.3 END HOSE…….……………………………………………………………………………………………………………………44

5.10.5 FUNCTIONAL LIQUIDS……………………………………………………………………………………………………….46

5.10.6 TEST-PURPOSE OPERATING……………………………………………………………………………………………….46

5.10.7 ACİL DURUM KAPAMA DÜŞMESİ……………………………………………………………………………………….47

5.10.8 EXTENDING PLACING BOOM……….…………………………………………………………………………………… 48

5.10.9 BAD WEATHER CONDITIONS……………………………………………………………………………………………. 48

5.10.10 EYEBALL ESTIMATE………………………………………………………………………………………………………….48

5.10.13 BOOM MOVEMENTS..……………………………………………………………………………………………………..50

BOOM MAKİNA TİC SAN LTD ŞTİ.

6.1 HIGH VOLTAGE LINES……..………………………………………………………………………………………………………51

6.2 CLEARANCE ……………………………………………………………………………………………………………………………52

6.3 FLASH OVER.………….……………………………………………………………………………………………………………….53

6.4 STATIC CHARGE………………………………………………………………………………………………………………………53

6.7 OVERLAPPING WORKING RANGES .…..……………………………………………………………………………………54

6.8 IMPERMISSIBLE WORKING RANGES ……………………………………………………………………………………….55

6.9 CONCRETING OPERATION……………….………………………………………………………………………………………55

6.13 REMOTE CONTROL….……………………………………………………………………………………………………………57

6.14 EMERGENCY STOP…….………………………………………………………………………………………………………….57

6.15 UNAUTHORIZED WORKING…………………………………………………………………………………………………..58

7. TURNING DELIVERY PIPES…………………………………………………………………………………………………………59

7.1 MINIMUM WALL THICKNESS.………………………………………………………………………………………………….59

7.3 DELIVERY PIPE OPENING…………………………………………………………………………………………………………60

8.1 DANGER ZONE….…………………………………………………………………………………………………………………….61

8.5 SEPERATED DELIVERY LINE …………………………………………………………………………………………………….64

8.6 STATIONARY CONCRETE PUMPS..…………………………………………………………………………………………..64

BOOM MAKİNA TİC SAN LTD ŞTİ.

8.9. TRANSPORT VEHICLE…………………………………………………………………………………………………………….65

8.10 MAINTENANCE AND SAFETY RULES .………………….………………………………………………………………..66

8.9.1 SPECIAL WORK……………………………………………………………………………………………………………………67

8.9.2 SECURING THE ARE …………………….………………………………………………………………………………………67

8.9.3 STABILITY .………………………………………………………………………………………………………………………….68

8.9.4 LIFTING EQUIPMENTS ….…………………………………………………………………………………………………….68

8.9.5 CHANGING DELIVERY LINES.…………….…………………………………………………………………………………68