N) eVverDIGm 1 Guide to the Operating instructions 4.4 Foreword ssnannatnnenanennanannanenanies fo 4 1.2 Correction Request Form — Technical Publications ie 1.3 loons and symbols ao 2 Safety regulations 2.1 Basic principle 2.1.4 Lock Out ~ Tag Out Procedures 2.2 Designated use 2.3 Use contrary to the designated use 2.3.1 Lifting loads 2.3.2 Extending the end hose ~ 2.33 End hose with spout 2.3.4 Exclusion of liability ~ 2.4 Risk of injury “ 2 2.4.1 Supporting ground - 8 2.4.2 Danger zone 2-1 2.8 Protective equipment ~~ 14 2.6 Organizational measures - 15 2.6.1 Supplementary instructions - 15 2.6.2 Other supplementary instructions ~ - 16 2.6.3 Instruction se - 16 2.6.4 Users - 16 2.6.5 Operator - 16 2.6.6 Checks + - 16 2.6.7 Protective equipment +--+ -7 2.8.8 Safety instructions - 18 2.6.9 Faults - 19 2.6.10 Moaiifications vse = 20 2.6.11 Machine rating plate - 2 2.6.12 Boom rating plate - 2 2.6.13 Spare parts rn aa 2.6.14 Maintenance and inspection intervals ~~ ene 24 2.6.15 Workshop equipment ~ - 26 2.6.16 Fire protection - 26 2.6.17 Liability - 26Sy 2.7 Selection and qualification of personnel 2. 27 2.7.4 Training 2-2 2.7.2 Responsibility 2- 2B 2.7.3 Technical personnel 2- 29 2.7.4 Welders vrrnnnnnnnenenn 2- 29 2.7.5 Qualified electricians 2- 30 2.7.6 Hydraulics engineers 2- 30 2.8 Danger zones Working Area 2-31 2.8.1 Support legs ~~ 2- 2 2.8.2 Placing Boom sense 2- 32 2.83 End hose 2- 3 2.8.4 impermissible Working Range srr 2-44 2.9 Setting up ~ - 4 2.9.4 Functional fluids se 2-36: 2.40 Test run even 2- 3% 2.40.4 Emergency shut-down button 2- 36 2.41 Setup site - 2- 39 2.41.4 Working area ~ 2- 39 2.41.2 Space requirement senna 2- 40 2.11.3 Minimum clearance from pits 2-41 2.11.4 Safe clearance seen 2- 42 2.11.5 Supporting ground see 2-43 2.11.8 Corner bearing load 2- 44 2.1.7 Supporting area 2- 45 2.41.8 Support block 2- 48 2.41.9 Timber biocks 2- 45 2.11.10 Calculation example 1 - 2- 46 2.41.11 Calculation example 2 ~ 2- 46 2.42 Supporting the machine 48 2.42.4 Danger zone = 49 2.42.2 Interlock 51 2.123 Front axle as fulcrum « 52Se SVeEROIGm 2.13 Extending the placing boom 2.18.1 Bad weather and thunderstorms Rule of thumb 2.13.2 Driving 2.13.3 Loads 2.18.44 Marshaller ~ 2.13.5 Boom movements 2.13.6 Danger zone “ Climbing the Placing Boom ~ 2.13.7 High voltage lines ~ 2.13.8 Clearance ~ 2.13.9 Spark over vue 2 87 2.13.10 Static charging ~ 60 2.13.11 Obstacles 61 2.13.12 Impermissible working range + 62 2.14 Pumping operations 2.14.4 Place of work ~ 2.14.2 Responsibility +--+ 2.1433 Noise « 2.14.4 Moving machine parts ~~ 2.14.5 Faults » 2.146 Remote control - 66 2.14.7 Emergency shut-down button ~ - 66 2.14.8 Unauthorized operation ~ eves - o7 2.14.9 Wall thickness - 68 2.14.10 Tapping the delivery line - 68 Operating Temperature ~~ - 68 2.14.11 Rotating the delivery pipes seen - 69 2.14.12 Minimum wall thickness ~ - 69 2.14.13 Truck mixer drivers - 70 2.14.14 Agitator hopper ~ -1 2.14.18 Blockages - 72 2.14.16 Delivery line opening - 73 High-pressure Delivery ~ - 73 2.14.17 End hose - 74 2.14.18 Danger zone ~ - 74 2.14.19 Bending ~--- - 75 2.14.20 Securing - 75 2.14.21 Extending - 76Sg 2.14.22 Separate delivery line 2.14.28 Stationary pumps 7 78 246 Cles ng 2.18.1 Danger zone ~ 80 2.15.2 Drain off the leavings 80 2.16 Driving position 2.16.1 Accessories 2.46.2. Truok height and weight -vssrn 2.16.3 Descents and slopes 2.16.4 Truck mixer 2.47 Maintenance 2.474 Special work 2.47.2 Battery ~ 2.17.3 Seouring the area 2.17.4 Stability 2.475 Lifting equipment ~ 2.17.6 Replacing delivery pipes 2477 Place of work 2.17.8 Water 2.47.9 Cleaning 2.17.10 Clean delivery pipes - 2.47.11 Alarm systems 2.47.12 Checking 2.17.18 Safety equipment 2.17.14 Environment « 2.17.15 Lockout | Tagout Procedures 2.48 Electical power 2.18.1 High voltage lines ~ 2.48.2 Clearance 2.18.3 Switch off overhead cables 2.484 Static charging 2.48.5 Emergency measures ~~ 2.18.6 Qualified personnel 2.48.7 Before starting any work 2.18.8 Cleaning work 2.18.9 Welding work 2.48.10 Maintenance workSe evVerRoIGm 2.18.11 Inspection "2+ 103 2.18.12 Securing electrical power 2-103 2.19 Gas, dust, steam smoke 2- 104 2.19.1 Respiratory protection and face mask + 2-104 2.19.2 Welding ~ 2-105 2.19.3 Dust 2-105 2-106 2-106 2-107 2-109 2-109 2.20 Hydraulic system, pneumatic system, delivery lines. 2.20.1 Inspection ~ 2.20.2 Release pressure 2.20.3 Pipes 2.20.4 Bleeding 2.21 Noise 2-110 2.21.1 Ear defenders ~ 2-110 2.21.2 Owner 2-110 2.22 Oils, greases and other chemical substances ~ -114 2.22.1 Hot substances sunmnnonnnnnns Bo AZ 2.22.2 Environmental protection ~ 2-12 2.23 Transport and towing ; setting up again 2-113 2.23.4 Loading ~ 2-14 2.28.2 Driving 2-16 2.233 Truck mixer ~ 2-117 2.23.4 Setting up again 2-117 3. General technical description 3.1. Specification 1 3.4.1 Summary 4 Left truck side ~ " Right truck side 12 3.2 Technical data ~ 13 3.2.1. Noise emission measurement 13 3.22 Machine, Boom rating plate ~ 13Sa 14 4 3.3.2 Delivery line 14 3.3.3 Support legs ~ 4 3.3.4 Hydraulic control ~ 3-14 3.3.5 Pump - 15 38.3.6 S transfer tube siren 3- 15 3.4 Symbols for the control system ~ 3- 16 3.4.1 Pump se see oe 3- 16 3.4.2 Engine 3-17 3.4.3 Support and others ~ 3- 18 3.4.4 Boom ~ 3- 19 3.5 Electrical control devices oe 3- 20 3.5.1 Control cabinet ~ 3-21 Local box Front view ssmennenene 3 = 22 Fuse box module front & back view 3- 23 Side view 3-24 3.5.2 Cable remote control ~ 25 3.5.3 Radio control system transmitter 4,Sarms( proportional ) 26 Radio control system transmitter 4,Sarms( 2joy proportional ) 3 - 27 3.5.4 Radio control system receiver ~ 28 3.5.5 Emergency shut-down button cer 29 3.5.6 Inductive switch distributor casing 32 LEDs 32 Assignment serene i Significance of the LEDs ~ 33 Redundant system ~ nme 3 33 3.5.7 Inductive switch connector Significance of the LEDs ~ 3.6 Hydraulic control devices ~ 3- 36 3.6.1 Support control block ~ 3-37 3.6.2 Boom functions control block 3-38 3.6.3 Agitator lever 3- 39 3.6.4 Water pump lever 3 40 3.6.5 Output controller ae 3-41 3.6.6 Accumulator dump cock, transfer tube damping cock 3. 42Sa SVeRDIGM 3.7 Other components 48 3.7.1 End hose 44 3.7.2 Flushing water pump ~ 45 3.7.3 Hydraulic fluid radiator 46 3.8 Safety System - 48 3.8.1 Safety System Operation 48 3.8.2 Operation of Safety system 48 3.8.3 Safety System ON- 49 [1] Outrigger case 1 49 [2] Outrigger case 2 49 [3] Outrigger case 3 seernennnnnn 49 [4] Outrigger case 4 [5] Outrigger case 5 [6] Outrigger case 6 [7] Outrigger case 7 3.8.4 Safety System OFF 3.8.5 Proximity Sensor Setting(npn_type)- 82 3.8.6 Zero Point Setting(sensor no.4): 62 3.8.7 Impemmissible Working range (EVERDIGM all machine) 3-53 3.88 Troubleshooting 54 4 Driving, towing and loading 44 Driving 1 441.1 Hand signals ~ 1 4.1.2 Before moving off = 4.1.3 During the journey 3 4.2 Hand signals for driving 4 4.3 Towing 6 4.4 Loading 7 vilSa eveRoIGM 5 Operation 5.4 Starting up 5.14 Test run = 5.1.2 Functional fuids 5.1.3 Power take-off gearbox ~ 5.1.4 Remote control Hazerd wamings ~~ Proportional racio remote control Starting up Boom speed Restarting the pump - Cable remote control Starting up Boom speed Restarting the pump 5.2 Setup site 5.2.1 Space requirement ~ 6.2.2 Danger zone ~~ 5.2.3 Minimum clearance from pits 5.2.4 Safe clearance from pits 6.2.5 Supporting ground 5.2.6 Support area ‘Support block ~ ‘Comer bearing load ~ Calculation example 1 ~ Calculation example 2 ~ Length of the timber blocks required Example 1 - 2 Example 2 - 2 5.3 Supporting the machine +r reve - 4 5.3.1 Working range ~ - 25 5.3.2 Remote control vvereremrnnerensenn B= 26 5.3.3 Interlock ~ -27 5.3.4 Danger zone 5.3.5 Spirit level 5.3.6 Forward support legs [X-type] 5.3.7 Rear support legs [Xtype] ~ 5.3.8 Forward support feet [X-type] ~ 5.3.9 Rear support feet [X-type] 5.3.10 Forward support feet [Swing-type] vilSe everoism 5.3.11 Forward support legs [Swing-type] 5.3.12 Forward support feet [Swing-type] 5.3.13 Rear support feet [Swing-type] ~ 5.3.14 Rear support legs [Swing-type] 5.3.15 Remote contro! 32 33, 33 34 36 5.4 Function checks. 5.4.1 Pump functions ‘Switchover Magnetic switch Stroke length Stroke time 5.4.2 Filter functions Vacuum fiter Boom fier 5.4.3 Emergency shut-down function Emergency shut-down button ssvrvsesesensese 5.4.4 Function check on the boom control unit SSSLILBBSEBBE 5.5 Boom movements 5.5.1 Uncontrolled boom movement ~ Countermeasures 42 Sinking of the boom and the support feet «+--+ 5- 43 Loss of volume 5.5.2 High-vottage line 5.5.3 Danger zone + 5.5.4 Boom movements Hand signals Prohibited activities 5.5.5 Bad weather and thunderstorms ~ Rule of thumb 5.6 Hand signals for boom and pumping operations ~ 5.7 Extending the 5-2R boom S71 Arm 4 5.7.2 Boom Slewing ~ 57.3 Arm 2 5.7.4 Arm 3 ~ 5.7.5 Am 4 « 5.7.6 Am 5 «a SVERDIGM 5.8 Extending the 5-RZ boom 5.8.1 Arm 1 5.8.2 Boom Slewing 5.83 Am 2 58.4 Am 3 ~ 58.5 Am 4 ~ 5.8.6 Am 5 ~ 5.87 End hose 5.8.8 Impermissible working range 5.9 Extending the 4-2 boom AO 5.9.1 Arm 1 se ae 5.9.2 Boom Slowing ee 5.9.3 Am 2 ~ ae 5.9.4 Am 4 ~ 28 5.9.5 Am 3 ~ ee 5.10 Extending the 5-Z boom - Gao BAO. Arm 1 osrrnn a 5.102 Boom Siewing ~ ae 5.10.3 Arm 2 5. 65 5.10.4 Arm 3 Bo 5.105 Arm 4 a 5.10.6 A 5 oven ate 5.10.7 End hose 5- 69 5.10.8 impermissible working range ~ a 5.11 Net reaches 5 5.12 Using the 12m end hose 5-71 5.12.1 End hose + 5- 72 5.122 Danger zone een 5- 72 5.12.3 Impermissible working range ~ 5-73 5.12.4 Net reaches 5-74 5.13 Install Detachable type 5+ 75 Wire spec 5- 76 Fixed wire 8-77 Safety belt wear 5-78ae SVERDIGM 5.14 Pumping operations - BAA Hazards. sven 5.14.2 Notes on correct pumping ~~ 5.14.3 Starting pumping 5.14.4 Pumping 5.14.5 Possible faults ~~ e Blockages: Overheating 5.14.6 Special cases Continuation delivery tine BAB Cleaning ss Cleaning instructions 5.15.1 Delivery line How to clean which delivery line Suction cleaning sree 5.18.2 Hopper delivery cylinder and S transfer tube 5.15.3 Truck superstructure and post-washing operations 5.16 Transport position come 5-114 5.16.1 Shifting the placing boom to the transport position 5-114 5.46.2 Retract supports 5-115 Interlock 5-115 5.46.3 Remote control 5-116 6 Quick troubleshooting guide 6.1 Concrete pump in general 6.2 Placing boom 6.3 Boom control 6.4 Electrical system ~ 7 Maintenance 7.4 Maintenance intervals 7.2 General tightening torques 3 7.2.4 Flared screwed join, reassembly coer 5 7.2.2 Profiled ring join, reassembly + 5 itSE 7.3 Functional fuids 6 7.3.4 Hydraulic fuid ~ 6 7.8.2 Oil for the powertake-off, rotor and agitator gearboxes 7-7 7.3.3 Manual lubrication sen 7 7.34 Centralized lubrication system ~ ee 7.35 Truck engine oll and transmission oll 7 7.36 Level of contaminant ~ 8 7.87 Lubricant analysis 8 7.38 Storage of lubricants ~ sen 8 7.4 Lubrication recommendation ve 9 Maintenance cards (00-0001 Visual checks ~ 18 General 14 Electrical system: 14 Hydraulic system: 7. 14 Boom & Body: Boom pedestal 03-0001 Changing the hydraulic fluid 19 (03-0002 Function checks “+r 25 03-0008 Checking the accumulator or 04-0001 Filter change 34 04-0002 Hoses tse 39 04-0005 Vacuum meter 43 06-0009 Change of delivery piston with KEP 45 07-0001 Lubricating the § transfer tube ~ 55 07-0011 S transfer tube 57 10-0007 Measuring the wall thickness (Machines with S transfer tube) 81 Twin Pipe - 86 20-0002 Lubricating the placing boom s+ 87 21-0021 Lubricating the boom pedestal (TRS70 Generation 2 ) 23-0002 Gasket set for boom cylinder (with bolted-on guide bush) xilSe SO veri 23-0003 Gasket set for boom cylinder (with threaded guide bush) ~ 7 25-0001 Replacing the delivery line ~ 103 7.5 Resale 110 7.6 Warranty period standard ~ 7-11xiv== Sa €verRDIGm 1 Guide to the Operating Instructions In this section 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: EVERDIGM Corporation After Sales Department 49, Buyeong-all,Jincheon-eup, Jincheon-gun, Choongchungbuk-do, ‘South Korea Telephone -82-(0)43-530-3300 (3412) Telefax +: #82(0)43-530-3318 Or the Branch or Agency that looks after you. Address Telephone: Telefax: Telex21.03.rev00= Se €verDIGm 4.4 Foreword This manual has been prepared with the assistance of service and engineering specialist to provide you, EVERDIGM Corporation mechanics, with the information on the machines. We like to assure you that you will be acquainted with more suitable maintenance techniques. It contains a variety of lustrations and diagrams for the machines to help you easily understand Utilizing adequately this manual for you maintenance operations will not only greatly relieve you from unnecessary effort but also enhance maintenance reliability, ‘Should you have any questions or doubt as to the contents of this manual, do not hesitate to contact us. ‘And we do not describe optional equipments in this manual & parts list. If you choose some optional equipment, we supply manual & parts list ‘each applicable equipment. Finally, we like to advise you that the specifications and other details on ‘our machines and are subject to change without prior notice for the purpose of product upgrading, and also we hope that this manual would be of a great help to you in ‘your maintenance operations. Mar 2021 We EVERDIGM 14 21.03.rev00= = Wg evenoien @ Correction Request Form — Technical Publications If you find a problem with this manual, please make a copy of this page, fill out your contact information, describe the problem and retum it to EVERDIGM, Attn, Technical Publications. Date ofthis request City, State & Zip : Phone no: Model & Serial Number: Description of Problem (wrong Information, unclear or erroneous procedure, clarification, etc.) Corrective Action Taken by You (if any) 12 21.03.rev001.3 ICONS AND SYMBOLS i (" LN 21.03.rev00 yy —— The following icons and symbols are used in the Operating Instructions: Task symbol ‘Text following this symbol describes tasks which you are required to work through, generally from top to bottom in the sequence shown, ‘Text following this symbol describes the result or effect of an action Refer also to the maintenance cards: This symbol is used to refer to the maintenance cards required. possibly as a supplement to the maintenance card you are currently reading, ‘The following special tools are required: This icon identifies the special tools necessary to carry out the work. Normal tools, is commercially-available tools or tools carried in the truck, are not specially listed. Environmental protection Particular information regarding environmental protection is introduced by the icon shown, the words Environmental protection printed in bold, and a line. The associated text is printed in italics and ends with another line. Note Particular information regarding the economic use of the machine is Introduced with the icon illustrated; the word Note printed in bold, and a line. The associated text is printed in italios and ends with another line. Caution Particular information or rules or prohibitions intended to prevent damage are introduced with the icon illustrated, the word Danger Printed in bold, and a line. The associated text is printed in italics and ends with another line. Warning Particular information, rules, or precautions intended to alert ‘against a hazardous situation which could result in death or serious injury. Its introduced with the icon illustrated, the word WARNING printed in bold, and a line. The associated text is printed in bold and ends with another line, cySa €VeRDIGMm 14 21.03.rev00 PP PP F&F Danger Particular information or rules prohibitions intended to prevent injury or significant damage are introduced with the icon illustrated, the word Danger printed in bold, and a line. The associated text is printed italics and ends with another line. ‘The appropriate symbol will be used if itis possible to identify the source of the danger precisely. Danger of fire ‘This symbol is used to Identify tasks for which there is a particular Danger of fire. Danger of explosion €£$ $$___________ This symbol is used to identify tasks during which there is the danger of an explosion. The explosion may also be caused by pressure being released suddenly. Falling items) This symbol is used to identify tasks in which there is a danger of injury caused by parts falling down. Danger of crushing ‘This symbol is used to identify tasks during which there is the danger of being crushed21.03.rev00 Se EVerRDIGm ‘Suspended load This symbol is used to identify tasks in which suspended loads may fall dawn. igh voltage This symbol is used to identify tasks in which there is the danger of electrocution, possibly with lethal consequences. Danger of burning ‘This symbol is used to identify tasks in which there Is a danger of burning from chemical substances which are not specifically described. Danger of burning This symbol is used to identify tasks in which there is a danger of burning from battery acid Danger of poisoning This symbol is used to identify tasks in which there is a danger of Poisoning by inhalation of gases, ingestion of or contact with substances. 1821.03.rev00Se EVeRDIGMm 2 Safety regulations This chapter summarizes the most important safety regulations. This chapter is, therefore, particular suitable for an initial basic instruction of new operators. Naturally, the various rules are also repeated once more at the appropriate points in the Operating Instructions. EVERDIGM cannot anticipate every possible circumstance that might involve a potential hazard. The wamings inthis manual are therefore not all inclusive. If procedure, tool, device, or work method net specifically recommended by EVERDIGM is used, you must satisfy yoursotf that itis safe for you and others around you. You are also responsible for ensuring that the machine will not be damaged or rendered unsafe by the procedures you choose. AIL EVERDIGM equipment undergoes a thorough Quality Control inspection at the factory. Although their design incorporates built-in safety features, ‘operation by unskilled, untrained andlor careless operators can result in dangerous operating situations. Knowing the characteristics of the machine and functionality of all Controls is important for safe and proper operation of the equipment. Becoming familiar with the operation ‘of the controls and practices of concrete pumping will result in improved efficiency and smoother pumping. This chapter summarizes the most important safety regulations. Itis, therefore, particularly suitable as an initial basic instruction Cd for new operators. ‘The various rules are also repeated at the appropriate points in the Operating Instructions. 21.08.rev0021.03.rev00= ) &VeRDIGM 2.1. Basic principle ‘The machine must only be used in technically perfect condition in accordance with its designated use and the instructions set out in the Operating Instructions. Any functional disorders, especially those affecting the safely of the machine, should, therefore, be rectified immediately. Check safety of operation every time you start work. Any defects found or suspected shall be repaired immediately. If necessary, inform the project supervisor. Cease work if defects are found that may prejudice safe Operations. Use only perfect delivery lines, end hoses, couplings etc. suitable for the delivery job and manufactured by the pump manufacturer. Concrete delivery lines are subject to wear which varies according to the pressure and composition of the concrete, the material from which the delivery line is made, ete. Take care to ensure that: = no safety equipment is removed, rendered inoperable or modified (EMERGENCY SHUT-DOWN BUTTON, grill on the pump filling Hopper ete.) ; - safety equipment removed for the purpose of maintenance work is re~ fitted immediately the work is completed. 2.4.4 Lock Out - Tag Out Personnel servicing the unit should be protected from unexpected start— Procedures ups. Use of the following procedures is strongly recommended: Lock Out~Tag Out Procedure U Engage E-Stop push-button on the control panel Where Contact With DDisengage the PTO (if equipped) Moving Parts is, DSwitch engine off and remove the key. The key must be kept by Possible: the individual performing the work Put a Tag Out Notice on the machine near the ignition switch stating ‘D0 NOT REMOVE THIS TAG — UNDER REPAIR - DO. NOT START" Lock Out-Tag Out Engage E-Stop push-button of the control pane! Procedure Where The individual performing the work must engage the ‘E-Stop’ on Contact the remote control unit (0 The individual performing the work must maintain complete Control ofthe remote control unit until the work is completed 21.03.rev00Se evervicm ea ion AA DO NOT REMOVE THIS TAG 22 21.03.rev002.2 Designated use 21.03.rev00 vy) EVeRDIGM EVERDIGM truck-mounted concrete pumps are considered to be industrial machines. The machine may not be used for the transport of ‘goods, except for carrying the accessories used for the machine, such as pipes, hoses, etc. The maximum loading or the maximum permissible gross weight must not be exceeded. ‘You must also observe the specified Operating Instructions and comply with the conditions and intervals for maintenance and inspection to operate the machine within the limits of its designated use. Machine, placing boom and delivery line must be inspected for operational reliability by a subject expert at least once a year. The inspection must be carried out when the first of elther 500 operating hours or 20,000 m* pump output is reached. The operating hours meter ‘on the machine must be used to determine when an inspection becomes due. This operation hours meter records the hours of pumping operations. The operating hours meter must always be kept in a functioning condition, ‘The machine is designed exclusively for the delivery of concrete up to a bulk density of 2,400 kg/m’. Its operation must be restricted to pumping ‘operations on construction sites. The maximum concrete pressure must not exceed that specified on the rating plate or in the check book. 23= Sg €VerRDIGm 2.3 Use contrary to the Use other than that above going such use, such as lifting loads, for designated uso instance, is considered contrary to the designated use. EVERDIGM accepts no liability fir damage resulting from such Use, The risk of such misuse lies entirely with the user. 2.3.4. Lifting loads ‘The placing boom must never be used for iting loads. High-pressure delivery (over 85 bar concrete pressure) through the placing boom-delivery line is prohibited. The delivery line and end hose only suitable for pressures up to 85 bar in their new condition, 24 21.08.rev00a Se €veroicm 23.2. Extending the Extension of the placing boom and end hose beyond the length end hose specified on the rating plate (boom) is forbidden. 4M aS Extending the end hose is not permitted. 2.3.3 End hose with spout End hoses may not fitted with any extension coupling, spout, “ outlet shoes or other dangerous outlet fiting or similar device. m Ne 'No coupling, spout, swan neck or similar on the end of the end hose 25 21.03.rev00Se EverRDIGMm 2.3.4 Exclusion of liability 26 21.03.rev00 We state here expressly that EVERDIGM accepts no liability for damage arising from incorrect or negligent operation, servicing or maintenance or as a result of use contrary to the designated use. This statement is equally valid for modifications to, additions to and customization of the machine which may compromise safety. The {guarantee will no longer be valid in such cases. Please consult EVERDIGM you wish to deliver higher density media. It may be the case that suitable measures, such as reducing the net reach, are necessary.=e Se EVeRDIGm 24 Risk of injury ‘The machine has been built accordance with the state of the art and recognizes safety rules. Nevertheless, its use may constitute a risk to life {and limb of the user or of third parties, or cause damage to the machine and to other property, ‘Some of the injuries that may be caused by improper use of the machine are listed below. Eye injuries caused by concrete spatter or other chemical substances. Eye or skin injuries caused by hydraulic fluid escaping under pressure when threaded unions are opened without the accumulator pressure having been dumped beforehand or without prior dumping of the the entire system. Eye injuries may be caused by hydraule uid escaping under pressure, Risk of scalding by hot hydraulic fluid or other hot functional fluids escaping under pressure. ‘There is a risk of burning on hot machine parts, for example exhaust system and engine, 27 21.08.rev00Se evernicm 2.441 Supporting ground Injuries caused by the machine tipping over as a result ofthe supporting ground giving wey. | \ Eo gags gages |, SE BINER| SE BES seQesecoeseease Ee SBS) ze se EcSassay ES REES Ee a 28 21.03.rev0021.03.rev00 N7) €VeRDIGm Danger of crushing on extension and retraction ofthe supports. Injuries caused by swinging and telescopic support legs extending rapidly, particularly of the hydraulic circuit has not been properly bled Injuries caused by entrapment when extending and retracting the ‘support legs or swinging support legs-including entrapment between ‘support leg or swinging support leg and other obstacles on the construction site.VERO ee 21.03.rev00 Injury may be caused by the force of bursting couplings, bursting pipes or plugs being rapidly ejected from delivery lines, end hose and pump hopper. Electric shock (which may have lethal consequences) by contact with machines with electric motors - ifthe electrical connection has not been properly made; or the supply cable is damaged; or - by contact with other electricity cables. Injuries caused to construction site workers by unintended operation of the boom control and unintended movement of the boom. Injuries caused by pipe sections falling as a result of partially loosened threaded unions or couplings that have not been secured. Tools that have been left on the arm assembly may also fall oe Securing couplings 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)Danger zone 21.03.rev00 a €VverDicm Injuries caused by falling boom arms if isolators are opened without first ensuring that the appropriate boom arm Is secured, Injury may be caused by the hose operator being struck by the end hose Of this has become trapped in the reinforcement and suddenly jumps out ‘on further movement of the boom. ‘This danger also exists if a blockage Is suddenly released. ‘There is also a considerable risk of injury from the end hose striking out when starting to pump and during washing out as a result of entrapped air or sudden boom movements. Injuries caused by the pump rolling because of brakes or Support legs releasing. 1, Maximum end hose length 4 m 2, Danger zone = 2x end hose length = 8 m The danger zone when starting to pump and during washing ‘ut procedures isthe area around end hose in which the end hose can strike out. The diameter ofthe zone is twice the ‘end hose length.Sy EVeRDIGm 242 21.03.rev00 Injuries cased by delivery ines being opened when under pressure (eg after a blockage) Never open delivery line under pressure Injuries may be caused by reaching into or falling into agitator. Newer reach into the agitator hopper. Injuries may be caused by slipping over or slipping from the oily or Greasy machine,21.08.rev00 ry €VeRDIGM Injuries caused by reaching into the water box while the pistons are running, Do not reach into moving parts of the machine Injuries caused by reaching into the rotor housing (ff the maintenance ‘openings are not secured). Injuries may be caused by tripping over cables, hoses or reinforcing Steel. Injuries caused by being trapped by the truck mixer or parts of it (chute). Injuries caused if unsecured delivery lines slip offal 243ay EvVeRDIGm 2.5 Protective equipment —_The following protective equipment is prescribe, with no exceptions, throughout the working area in order to restrict the risks to the lite and limb of persons: Protective helmet A protective helmet protects your head against, for instance, falling ‘concrete or against parts of the delivery line should the hoses burst. Safety shoes Safety shoes protect your feet against falling objects and against penetration by projecting nails. Ear defenders Ear defenders protect you against the noise generated by the ‘machine when you are standing close to it Protective gloves, Protective gloves protect your hands against aggressive or chemical substances, against mechanical effects (e. g. blows) and against cutting injuries. Protective goggles Protective goggles protect your eyes against injuries from concrete splashed or other particles. Safety hamess safety hamess protects you against falling when you are working (on scaffolding, bridges or similar structures, Respiratory equipment and face mask Respiratory equipment and a face mask protect you against parcles of building materials which could enter your body through your respiratory passages (e. g. concrete admixtures). © 9S ®@OOOO 24 21.03.revo0== Sy — everricm 2.6 Organizational measures 2.6.1 Supplementary instructions 21.03.rev00 ‘Always keep the Operating Instructions to hand at the place of use of the machine ( in the tool compartment or container provided for this purpose). In addition to the Operating Instruction, Observe and instruct users in the application of all other generally valid legal and otherwise mandatory regulations relating to accident prevention and environmental protection, ‘These compulsory regulations may also deal with handling of hazardous substances or the issuing and wearing of personal protective equipment or with traffic regulations, Comply with the regulations of the country in which the machine Is being used. When a machine is sold for export as s used machine, it may be necessary to adapt the machine to the regulations of the country in which the machine will be used. ‘Operator and machine operator are responsible for ensuring that all instructions are complied with, 248Se €VerRDIGm 2.6.2 Other supplementary 2.6.3 Instruction 2.6.4 Users 2.6.5 Operator 2.6.6. Checks 216 21.08.rev00 ‘These Operating Instructions must be supplemented by and notifying special organizational features such as job organization, working procedures or the personnel entrusted with the work. Personnel enirusted with work on the machine must have read the Operating Instruction, and in particular the chapter on safety, before beginning work. Regarding the instructions ater work has been is too late, This applies especially to persons working only occasionally on the machine, e.g. during setting up or maintenance. Do come to EVERDIGM for instruction on your new machine. Provide a copy of the Operating Instructions for your personnel and have them confirm in writing that they know, understand and apply the ‘Operating Instructions Safety instructions and Maintenance Instructions. ‘Make yourself familiar with the machine. Read the Operating Instructions ‘and comply with them, and ask questions of there is something you have not understood. Begin operating the machine only once you are fully and clearly familiar with the layout and significance of all the control and monitoring devices and the functioning of the machine in general. Atleast from time to time, check whether the personnel is carrying out the work in compliance with the Operating Instructions and is paying attention tothe risks and safety factors. The operating personnel must nor wear loose long hair, loose garments or jewellery, including rings. Injury may result from being caught up in the machinery or from rings catching on moving parts26.7 Protective equipment 21.03.rev00 Se EVeRDIGM Use personal protective equipment wherever required by the circumstances or by law. Personal protective equipment (protective helmet, protective goggles, protective mask, protective gloves etc) must be worn everywhere within the area in which the machine is being used, in particular if the machine is working with cement or with chemically based mortar admixtures. 0o 0@ @® ‘Wear personal protective equipment. Wherever the machine is in use, a safety helmet and safety shoes must ‘always be worn in addition to the general protective equipment usual on construction sites or protective equipment required for the specific job in hand. The hose operator must always wear protective gloves, Provide these for him if necessary. 247Wy eVeRDIGm 2.6.8 — Safety instructions 2418 21.08.rev00 Observe all safely instructions and waming notices on the machine. Observe safety instructions and hazard warnings. All safety instructions and hazard warnings on the machine must be kept complete and in a perfectly legible condition. Warning plates on the machine Itis your responsibilty as owner and operator of the machine to ensure that any safety instructions or warning plates on the machine. That have been damaged or rendered illegible are replaced without Delay. 52.6.9 Faults 21.08.revoo Sa €VverRDIGm Check safety of operation every time you start work. Any defects or safety-relevant changes to the machine of its functioning found, or merely suspected, must be repaired immediately; if necessary, the supervisor should be notified or where defects endanger operational safety, operations must be ceased. ‘The machine must not be used until defects which are of significance for ‘safe working with the machine have been rectified. Rectification of the defects must be verified by a subsequent retest. 249i) €VeRDIGMm 2.6.10 Modifications 220 21.03.rev00 Never make any modifications, additions or conversions to the machine which might affect safety without first obtaining the supplier's approval This also appliers to the installation and adjustment of safety devices and valves as well as to welding work on load bearing elements. 4M BS Extending the end hose is not permitted. 1m particular, this requirement relates to: = extension of the placing boom or end hose - adjustment of safety pressures, speeds of movement, power outputs, ‘speeds of rotation and other settings to valves other than those set in the works. - _fiting a delivery line with a greater diameter or of greater self-weight to the placing boom. ~ programming changes (software) in computer systems. - conversions or modifications anywhere in the support system or the boom. + modifications to hydraulic cylinders. - modifications to cable or radio remote control system, - ete.2.6.11 output 21.03.rev00 © _MADE IN KOREA ay €VeRDIGM Machine rating plate The values stated on the rating plate (e.g. hydraulic fluid pressure, tc) are the maximum permitted values. Model Machine No. Manufac.No. Year of Mfg Total weight(kg) [_ Hyd.press(bar) Concr.presa(bar) [__] Max.km/h [=] Mox.rpm Electrical Voltage(V) DC [—__] | px.wzisaeson O Model (machine model) Machine No. (machine number) Manufacture No Year of manufacture Maximum hydraulic pressure [ber Maximum perited speed [Km/h Permitted gross weight (kal Maximum conerete pressure (bar) Maximum rpm (maximum engine speed) Eetical Votage DC 224ee Sa eVeRDIGm 2.6. 12 Boom rating The following plate is attached to the boom plate a | wg GVERDIGM a © ® —_ La] o—_1_a @ te] © Y o——_] no *>— i ° 4. Boom Type 2 Year of manufacture. 3. Pipe-Diameter 4. Olipressure. 5. Operating Length Max 6. Operating Height Max 7. Boom No 8. manufacture No. 9. End Hose. 410. Electical Voltage. OC 22 21.08.rev0021.03.rev00 ae EVeRDIGmM Adjustable devices (pressure limiting valve, potention meter, fluid flow limiter, hydraulic cylinders, etc) must only be adjusted by technically qualified After Service or Service engineers. Following substantial changes, placing booms must be inspected by and authorized inspector before re-commissioning. Substantial changes include e.g, = design changes to increase the load bearing capacity ; = replacement or repair of load bearing components of welding is necessary, Equipment must only be repaired, adjusted or Replaced by subject. experts ‘Al devices of relevance for safety must be in place and fully functioning. Lead seals may only be removed by representatives of EVERDIGM, Never remove seals, 223Se EVeRDIGM 2.6.13 Spare parts 2.6.14 Maintenance and Inspecti 224 21.03.rev00 intervals Use only original spare parts, EVERDIGM accepts no liability for damage resulting from the use of non-original spare parts. Spare parts must comply with the technical requirements specified by the manufacturer. Spare parts from original equipment manufacturer can be relied to do so. Replace hydraulic hoses within stipulated and appropriate intervals, even of no safety-relevant defects have been detected. ‘Adhere to prescribed intervals or those specified in the Operating Instructions for routine checks and inspections. Observe the Operating, Maintenance and Inspection instructions. ‘The service life of hoses should not exceed six years, including a maximum storage time of two years. Pipes and hoses are subject to natural ageing, even when stored properly and subjected only to the permissible stresses. Their storage time and service life is restricted for this reason.Se everRvDicm Machines which are not maintained or serviced in accordance with the Instructions are not reliable and safe in operation. Machine, placing boom and delivery line must be inspected for operational reliability by a subject expert at least once a year. The inspection must be carried out when the first of either 500 operation hours or 20,000 m' pump output is reached. The operating hours meter records the hours meter of pumping operations. This operating hours meter on the machine must be used to determine when an inspection becomes due. This operating hours meter must always be kept in a functioning condition. It must not be interfered with 2.28 21.08.rev00i) EVeRDIGm 2.6.15 Workshop equipment Workshop equipment appropriate to the task in hand is absolutely 2.6.16 Fire protection 2.6.17 Liability 2.28 21.03.rev00 necessary for the execution of maintenance work. I you do not have the qualified personnel, suitable workshop equipment etc available, you should commission the EVERDIGM After service Department with the maintenance and repair of you machine. Ensure the personnel are aware of the location and operation of fire extinguishers. ‘Observe the fire-alarm and fire-fighting procedures. The operator is obliged to act in accordance with the Operating instructions. Accidents which can be ascribed to failure to comply with safety and accident prevention regulations = the commercial lability insurance company or 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.2.7 Selection and 27.4 qualification of personnel 21.03.rev00 Wy €VeRDIGM ‘Any work on or with the machine or plant shall be carried out by reliable personnel only. ‘Statutory minimum age limits must be observed. Reliability also includes the machine operator informing his employer of illnesses or indisposition on his own responsibility. ‘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 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 ower ; and = canbe expected reliably to excute the tasks they are charged with. Employ only trained or instructed personnel and set out clearly the individual responsibities of the personnel for operation, set-up, ‘maintenance and reps The machine shall only be operated, serviced or maintenanced by persons trained to carry out such tasks and commissioned to do so. Make sure that only authorizes personnel work on or with the machine. The driver shall hold a valid driving license if the Machine is to be driven on the public highway. 227EVERDIGM 2.7.2 Responsibility 228 21.08.rev00 Practice all the operating procedures described in the Operating Instructions (extending the supports, operating the placing boom, shifting the placing boom into the transport position, preparing the vehicle for moving, etc.) under the supervision of an expert until you are certain you can execute them safety. I you do not have the qualified personnel, suitable workshop equipment etc. available you should commission the EVERDIGM After Service Department with the maintenance and repair of your machine, Do not allow persons yet to complete training or instruction, or persons taking a general training course, to operate the machine unless under the constant supervision of an experienced person, ‘Amongst other duties, the machine operator shall inspect the proposed site of operations and shall refuse to place the truck at this site if he has any doubts in respect of safety Define the machine operator's responsibilty, including the responsibilty for compliance with traffic regulations, giving him the authority to refuse instructions issued by third parties that would be prejudicial to safety.a C —_____________- everniem 2.7.3 Technical personnel Operation, maintenance and repair shall be carried out by persons trained and commissioned to undertake such operations. Define the responsibilities of the personnel cleariy, Work on the hydraulic and electrical system shall only be carried out by persons who can produce to us appropriate certificates of competence (training certificates). Equipment shail only be repaired, set or replaced by trained experts. Couplings shall only be fitted to hoses by persons having the necessary experience and possessing the tools necessary for this task. Work on chassis, braking and steering system shall only be carried out by qualified personnel trained for such work. 2.7.4. Welders ‘The work shall be inspected by an expert engineer. 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 electronic components of the remote radio and cable control system may be damaged by extemal voltages generated during electrical welding processes. For this reason ; = disconnect the remote control cable from the control panel ; = _ disconnect all cables leading to the receiver of the radio control system. Close connector sockets with caps : = disconnect the positive and negative leads from the battery, = Remove the vehicle ECU connector. = Install welding area and welding ground as close as possible. = Protect hamesses and hoses around the welding section, Danger of explosion Welding work on fuel and oil tanks may only be carried out by trained welders observing the relevant safety regulations. 229 21.08.rev00Sy EVeRDIGM 2.7.5 Qualified electricians 2.7.6 Hydraulics engineers 230 21.03.rev00 Work on the electrical system and equipment of the machine must be carried out only by a qualified electrician or by instructed persons under the supervision and guidance of a qualified electrician and in aocordanoe with electrical engineering rules and regulations. If necessary, have a qualified electrician isolate the power supply. Only qualified electricians may work on electrical systems with an operation 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. Only persons having special knowledge and experience in hydraulic system shall work on hydraulic equipment. ‘Adjustable equipment (pressure-relief valve, potentiometer, fuid flow limiter, hydraulic cylinders, etc.) shall only be adjusted by technically qualified After Service engineers or servicing personnel. Modifications to the machine ratings are not permitted,Cc 2.8 Danger zones, vy] &VeERDIGM Unauthorized presence in the danger zone of the machine is forbidden. Working Area 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 must appoint an assistant to 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. The danger zone changes as the activities change. No Designation Explanation | 1._| Machine operator In normal operation, with the remate contol 2_| Hose man ‘At the end hose, inthe danger zone 3_| Signaler Inthe machine operator's range of sion 5 | Transit mixer driver ‘At the hopper, in the danger zane 6 | Permited ‘Area withthe operating reach radius of the pacing boom + the end hose length 7 | impermissible ‘Tho end hose must not be moved backwards beyond the vertical of the placing boom 8 | Atthe end hose Risk of injury when pumping is started, during pumping operations, ‘hen removing a blockage and during washing out procedures, The diameter ofthe danger zone is twice the end hose length. 9 _| Beneath the placing boom Risk of injury from faling items 10 | Area ofthe support loge and feet or area of the base structure Danger of crushing when the machine is being set up and during tear down 11 | Atthe hopper Risk of injury whenever the machine is operational; such as during washing out procedures, when the hopper is being fled using transit mixer, ete, 21.08.rev00 231We EvVerDIGm 2.8.1 Support legs - "The danger zone when setting out the machines supports isthe zone in which the supports are swung out or extended. Danger of crushing There Is a danger of crushing in the area through which the supports may be swung out or extended. You should therefore secure the danger zone. Keep the danger zone under constant observation. You must halt work immediately and press the EMERGENCY SHUT- DOWN button of anyone enters the danger zone. ai A 2.82 Placing boom ——- ‘The danger zone when working with the boom is the zone aver which the boom Is slewed. 292 21.03.rev002.8.3 End hose 21.03.rev00 wy EverDIGm Falling items There Is a risk of injury from parts of the delivery line falling beneath the slewing circle of the placing boom. There is a risk of injury from falling concrete beneath the end hose. You should therefore secure the danger zone. Keep the danger zone under constant observation. You must halt work immediately and press the EMERGENCY SHUT- DOWN button if anyone enters the danger zone. In adltion, a protective helmet be wom. The danger zone when starting to pump and during washing ‘ut isthe area around the end hose in which the end hose can ‘strike out. The diameter ofthe zone is twice the end hose length. 1 Maximum end hose length 4m 2 Danger zone = 2.x end hose length = 8 m Danger There is a risk of injury in the area around the end hose if the end hose strikes out when starting to pump, after a blockage has been freed or ‘during washing out. 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 SHUT- DOWN button if anyone enters the danger zone. 233= Sa €VeRDIGM 2.8.4 impermissible Working Range i 2.9 Setting up 234 21.03.rev00 Caution on the Impermissible Working Range of the concrete pump, Note Do not operate the boom horizontally in caution area, there is possibilty ‘overtum accident. [A-B caution area.] Check safety of operation every time you set the machine up for work. Any defects or safety-relevant changes to the machine or its functioning found, or merely suspected, must be repaired immediately; if necessary, notify the supervisor or cease operations where defects endanger operational safety ‘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 i all protective and safety-oriented devices, such as removable safety devices, EMERGENCTY SHUT- DOWN devices, soundOproofing elements and exhausters are in place and fully functional (esti) ® A Close access coversCc 2.9.1 Functional fluids 21.08.rev00 ey EVERDIGM - no safety equipment has been removed, rendered non-functional ‘or modified (EMERGENCY SHUT-DOWN, grille on the pump filing hopper, etc); = _ safety equipment removed for the purposes of maintenance work Se ree ea eea The machine must be free from visible defects (cracks, damage; loose of missing bolts, missing securing pins, rust on load bearing components, leaks, et). Every lost drop of oil pollutes the groundwater. Check the tightness and secure closure of the oll and water tanks (environmental protection). Danger of explosion § $$$ Do not fil wth fue! in enclosed spaces. Tum off the engine and heating. Wipe up split fuel immediately. Do not smoke or use @ naked flame when handling fuel. There is a danger of fire and explosion. ‘Making ready for operation also includes topping up the functional fluids. an Water, oll and fuel levels ‘Only check all the fil levels when the machine is stil, set up on level ‘ground and ready for use. Banger § $$ mma Os, fuel and other functional fluids may be injurious to health on contact with the skin, ete, You must, therefore always wear personal protective clothing and ‘equipment when you are handling toxic, caustic or other functional fuids that are injurious to health and always take note of the manufacturer's information. 238wv] €VverDIGm 2.40 Test run 2.10.1 EMERGENCY SHUT- DOWN button 2.36 21.03.rev00 Check the machine/plant for obvious damage and defects at least ‘once per working shift. Report any changes (inciuding changes in the working characteristics) to the competent organization or person immediately. If necessary, stop the machine immediately and lick 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 funetions. Press — lock EMERGENCY SHUT-DOWN. Tum -unlock EMERGENCY SHUT-DOWN All equipment require for safely and accident prevention (waming Signs and informative notices, cover grids, covers, etc.) shall be in Place. Such ‘equipment may not be removed, modified or damaged. All contro! and monitoring equipment shall function.21.08.rev00 iy) €VeRDIGM Set all the control and monitoring devices to the “0” — position before you cchange the node of controt (control block, operating console or remote control), Press EMERGENCY SHUT-DOWN button. Other wise the machine might execute unintended movements. Do not put the remote control unit down when the machine is in the ready mode. Should this be unavoidable in exceptional cases, depress the EMERGENCY SHUT-DOWN switch, remove the remote control (cable control) and lock the remote control unit away in the driver's cab. Lock away the remote control unit Unlock the EMERGENCY SHUT-DOWN button by turning it inthe direction ‘shown by the arrow to bring the machine back into service. 237€VeRDIGM 238 21.08.rev00 Delivery lines, couplings and hoses shall be fastened in the proper manner and secured against spontaneous opening. ‘Securing couplings Never start work unless the agitator gile is closed and bolted or otherwise secured. S Do net remove gilSe eC sss‘ EVER BIG 2.11 Setup site Familiarize yourself with your working environment before commencing barriers separating the construction site from public roads. 2 ‘The working area s the area in which work Is carried out with or on the machine. 2.11.1 Working area Cc As a result, the site management determines the site for the machine and prepares the area for the machine. The machine operator, however, bbears the responsibility for ensuring that the machine is safely set up. He ‘must inspect the proposed site and must refuge to set the machine up at the site ifhe has any doubts in respect of safety. Is there sufficient clearance to any obstacles? Overhead cabled, cranes, buildings, etc restrict the freedom of operation of the placing boom. Can the operator see all the field of operation of the placing boom? It may be necessary to have a signaler to give directions. Is there adequate clearance to any available for extending the supports fully? It must be possible to extend all support legs to their end postions. Intermediate positions are not permitted as they do not afford the necessary stability 230 21.08.rev00Sa Evervicm 2.11.2 Space requirement 240 21.03.rev00 The support legs must alvays be fully swung out and extended. ‘You must also check the approach route to the site where the truck will be set up. Walk the approach route first if you are not certain that it is suitable. It is especially necessary to walk the approach route once in darkness and at dusk or dawn. You should repeat this exercise again before leaving the construction site, You must always ask for a signaler if you have to reverse into the site Where the truck will be set up. If necessary, have the approach road closed off or secured by assistants, Have the site management arrange {for the removal of nay materials or equipment that hinder your approach. Signalers should not stand in the way of the truck.iy EVeRDIGM 2.11.3. Minimum clearance The force transferred into the ground by each support diffuses from pits ‘through the ground in a conical pattern at an angle of 45%, This imaginary cone may not exit through the wall of the pit. ] Minimum clearance a ‘The minimum clearance ‘a’ for machines = upto 12t permissible gross weight, is 1m ; = over 2t permissible gross weight, is 2m. 244 21.03.rev007) EverRDIGm 2.11.4 Safe clearance 242 21.08.rev00 Maintain an adequate safe clearance to pits, slopes, overhead cables and other obstacles. ‘The force transferred into the ground by each support diffuses through the ground in a conical pattem at an angel of 45°. An adequate safe clearance must be maintained according to the soll type. The safe clearance Is measured from foot of the pit. ‘The safe clearance on non-cohesive or backfilled soil is twice the pit depth. ‘The safe clearance on compact, cohesive soil is equal to the pit depth. Safe clearance ASe CO evernicm 2.11.5 Supporting ground The supporting ground must be level. t must be necessary to create a level surface. Timbers must not be laid over cavities. Take care; asphalt, concrete slabs, etc may have been washed out underneath. Floating feet relieve the load on the hydraulic cylinders in the supports as they can compensate for minor irregularities in the supporting ground. ‘They are not intended for setting the machine up on slopes. The support plate can slip from the supporting timber and the machine can tip over. This is also possible if the supporting timber is compressed into the soil at a slant during operation, ‘Always prepare the supporting ground as described, whatever the ‘form of the support plates. Monitor stability continuously during operations. 283, 21.08.rev00Se €verDIGm 2.11.6 Comer bearing load 246 21.03.rev00 | l | | ba Bee) = egress Re: x a Fags BAS SEES al, | SS DITO 92 OF SEBEL OTTO SM eS Hea GSy es ALSa seg (Only on level supporting ground ‘Check the load bearing capacity of the supporting ground. The site management will be able to state the permitted ground pressure. ‘The maximum comer bearing load generated is stated on each of the supports of the machine, This value must always be in place and legible, The corner bearing load is stated on each support leg= vy] €VveroIGm 2.11.7 Support area If necessary, use supporting timbers to increase the support area. ‘The supporting timbers must be undamaged and free from ice, oll, grease etc. The timbers must be laid under the support plates such that the load is distributed uniformly over all the timbers and the support leg 2.11.8 Support block “The support blocks are 60 x 60 em in size, 2.11.9 Timber blocks “Timber blocks (15 x 15 em ) may be used to further increase the bearing surface area. 245 21.08.rev00x] evervicm 2.11.10 Calculation examplet 2.11.11 Calculation example2 2.48 21.03.rev00 ‘max. poss. ground press. = max. machine comer bearing load area of the support plate Permissible ground pressure stated by the site management {600 kN/m ‘Area of the support plate 875 at Machine comer bearing load 160 kN > Maximum possible ground pressure 1829 kN/nf In this example, the maximum possible ground pressure is higher than the permissible ground pressure. You must at least place support blocks under the support feet. Permissible ground pressure 600 KN/mt stated by the site management ‘Support block area 3600 ca Machine corner bearing load 160 KN > Maximum possible ground pressure. 444 kN/n In this example, itis sufficient to place support blocks under the support feet.21.08.rev00 vy) €VeRDIGM Always use timber blocks for placing booms with a net reach over 30 m, ‘Never set the machine up on backfilled ground, Injuries may be caused by the machine tipping over as a result of the supports sinking, ‘Stop operations if stability is not ensured, Factors which reduce stability include, for instance; = charge in the ground conditions, caused by rain or thaw water, for example; = supports sinking on one side; = fluid losses through leaks in the support hydraulics. Before starting work, close the windows, doors and, where fitted, the sunroof in the driver’s cab. 247/] 2.12 Supporting the machine 2.48 21.08.rev00 ‘The placing boom must not be erected until the machine has been ‘supported in accordance with these instructions. Otherwise there is ‘a danger of the truck tipping over. Set up the machine to be horizontal in al directions. The maximum deviation from the horizontal permitted is 3°. Greater deviations from the horizontal overload the slewing gear for the placing boom and jeopardize the stability of the machine. You must re-position the supports if one or ‘more supports lift from the ground when the placing boom is being ‘moved. All supports must always stand firmly on the ground, ‘Maximum deviation from the horizontal of 3° ‘The supports on truck-mounted mixer pump are not suited for iting the front axle clear of the ground, Only extend the support cylinders. sufficiently for the truck to begin lifting. Placing chocks behind the wheels. Allow the vehicle to roll against the Chocks and apply the parking brake. lace chocks2.12.1 Danger zone 21.03.revo0 iy eVeRDIGM There is a risk of injury cause by the pump rolling away as a consequence of a brake or the support legs releasing Extend and telescope the supports to their end positions in sequence. Intermediate positions are prohibited to guarantee stability. There is a danger of crushing in the area through which the support legs move. ‘There is a risk of injuries caused by persons becoming trapped as the ‘support legs or swinging support legs are extended and retracted, and also between the support leg or swinging support leg and other obstacles on the constructions site, ‘The danger zone when setting out the machines supports is the Zone in which the supports are swung out or extended. Danger of crushing There is a danger of crushing in the area through which the supports may be swung out or extended. You should therefore secure the working area Keep the danger zone under constant observation. You must halt work immediately and press the EMERGENCY SHUT- DOWN button if anyone enters the danger zone, There is also a risk of injury caused by the swinging or telescopic ‘support legs extending rapidly, especially if the hydraulic circuit has not been bled properly. 249SS €VeRDIGM Danger zone A ‘Support legs and support feet Placing boom 2.60 21.03.rev00 Danger zones are the areas surrounding the machine, in which people may be at risk of injury from movernents required by the work. Danger zones vary within the working area and depend on the activity being carried out and the position of the placing boom. Danger zones must be secured and clearly identified. The machine operator must be capable of seeing all the danger zones, at al times, and under all circumstances. If necessary he must appoint a signaler to supervise those danger zones he himself is unable to monitor. Depending on the working situation, workplaces may occasionally fall within the danger zone, especially the workplace of the hose man and the transit mixer driver. If a workplace falls within the danger zone, increased caution is required and suitable personal protective equipment is prescribed. Persons who are authorized to be present in such a workplace, must use their own discretion to assess the hazards of the situation and be able to react accordingly. ‘The machine operator is responsible for safety of ALL personnel in the danger zones of the machine whilst itis in use. ‘The machine operator must stop work immediately and press the EMERGENCY-STOP button if an unauthorized person enters the danger zone, ‘There is a danger of crushi in the swing-out, swing-in and extension zones for the supports. ‘The placing boom danger zone is the area over which the placing boom is slewed. In this area there is a risk of injury from falling concrete and delivery line components.4 Sy SVeRDIGM 2.12.2. Interlock Lock all supports mechanically, if this is provided for in the design. Close all shut-off valves in the support hydraulics. Leaks can cause the supports to sink on one side. HwA0s06: (ol6 type) (new type) [Snap lock] Check stability regularly during operation. The elastic distortions to the machine frame occasionally occurring under extreme positions of the placing boom (one suppor lifts from the ground) must be compensated for by resetting the support cylinders until all supports are firmly placed ‘on the ground. ‘The suspension play on the rear axle of two-axle trucks must be locked by the rear axle lock, if provided. 281 21.03.rev00Se €verRpDIGm 2.12.3. Frontaxle as fulerum The front axle is required as the fulcrum on trucks with support feet ‘mounted directly on the truck superstructure or with support legs that can be telescoped perpendicular to the vehicle axis. The stability of the machine is jeopardized if the axle lifts clear of the ground. ‘The mass located in front of the supports when working over the driver's cab would increase the tipping torque if the front axle were raise clear of the ground. For this reason, the forward vertical support cylinders must only be ‘extended until the truck begins to lift itself from the ground, approximately 2~6 om beyond the springs. The types must remain firmly seated on the ground. Front axle as a fulecurn 282 21.03.rev002.13 Extending the placing boom 2.13.1 Bad weather and thunderstorms Rule of thumb 21.08.rev00 Sg €VeRDIGm Only erect the placing boom from the transport position once the ‘supports have been properly positioned and only in the sequence described in the Operating Instructions. The correct sequence depends cn the “folding system" (roll-and-fold system, Z-fold system ete.) Return the placing boom to the transport position in the event of storms or bad weather. = Placing booms with a vertical reach of 42 m or more (M 42 and Greater machines) may not be operated in winds of wind force 7 or more(wind speed 50 km/h(14.14m/s) and greater). = Placing booms with a vertical less than 42 m (< M42) may Not be operated in winds of wind force 8 or more (wind speed 72 km/h(20m/s) and greater). Greater wind speeds jeopardize stability and the safety of structural elements. There is a risk of lightning strike. ‘Tower cranes on construction sites generally have wind speed ‘measuring equipment, so that you can ask about the wind speed at any time. If no wind speed measuring equipment is available, you may enquire at the local meteorological office or estimate the wind speed Using the following rule of thumb. From wind force 7 and greater, green leaves break from trees and walking outside is hindered perceptibly. From wind force 8 and greater, small branches break from trees and walking outside is made significantly more dificut. 2.53,7] everoicm 2.13.2 Driving Never drive with the placing boom in the unfolded condition, the truck might tip over. Never eve the ruck withthe boom unfolded. 2.13.3 Loads The placing boom shall never be used as liting equipment (crane) for iting loads. ‘The placing boom must never be used for iting loads. 2.84 21.08.rev002.13.4 Marshaller 2.13.5 Boom movements 21.03.rev00 Se EverDicm ‘Always ask the site management to supply you with an assistant to act as a marshaller and observer. Agree clear hand signals or other signals with the marshaller/observer so that you can communicate with each other. A marshaller or observer is particularly important for you if you are operating the placing boom with a remote control unit. ‘You should, therefore, position the marshaller/observer such that he can always observe the whole of the placing boom. Your primary duty as the machine operator is to observe the position where the concrete is being placed 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 constructions site at a great height (even when the pump is switched off) Injuries to workers may result from unintentional operation of the boom contro! and thus unintended movement of the boom, Press the EMERGENCY SHUT-DOWN 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 (striking relay or moisture in the connector 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, 255we everpigm —_________—_____ 9 2.13.6 Danger zone | —- ‘The danger zone when working with the boom isthe zone over ‘hich the boom is slowed. Climbing the Placing Boom tis prohibited to climb the placing boom, to stand on top Zz of it, to use it as a working platform or as an aid to climbing, any 2% NN Y 256 21.03.rev002.13.7. High voltage lines 21.03.rev00 == Sa EVerRDIGm ‘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 sparks over there is a lethal danger for all persons Either on the machine or inits vicinity or who are connected to it (remote Control, end hose ete). 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). Caution in the vicinity of high voltage tines High voltage ‘Asspark 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. 287€VerRDIGm 2.13.8 Clearance 258 21.03.rev00 Voltage funnel ‘The minimum distances from overhead cables as follows ; Rated voltage [V) Safety clearance [m] lup to 1 kV. 1.0 kV to 110 kV 3.0 10 kV to 220 kV 40 1220 kV to 380 kV 50 lunknown rated voltage 5.0 Caution Distances are usually incorrectly estimated, Take no risks.2.13.9 Spark over 21.03.revo0 Sa EVeRDIGM The same minimum clearances are necessary when driving under overhead cables, ‘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 humicity is high, distances greater than the minimum distances shown above are always necessary. Comply with requirements of the country in which the machine is being used. ‘You must immediately consult with the electricity utility responsible If itis not possible to maintain this minimum clearance under all possible ‘working positions. If you have any doubis itis better to forego the use of the placing boom and to lay a separate delivery line, for instance. ‘Should a spark over occur, despite all caution, stay calm, do not move (step voltage), touch nothing Tell anyone outside the area not to approach you: step voltage may occur. Ask these persons to have the cable isolated. Step voltage High voltage Electricity works are always equipped with automatic switch-on Devices. Ifa circuit breaker trips, the short-circulted 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. 259€VeRDIGM 2.13.10. Static charging 260 21.03.rev00 ‘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 frst aid treatment for accidents caused by electri current ‘You must also be aware that: ‘Switch off the overhead cables if you are working in the vicinity of any overhead cables. 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. 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.2.13.11 Obstacles 21.03.rev00 a €Vveroicm Maintain safe distances from obstacles (masts, scaffolding, etc.) without fail ‘You must stand as close as possible to the extended placing boom If ‘you wish to estimate correctly the movement of the boom and, above all, the distance between the placing boom and obstacles. 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: = iting and transporting loads; = pushing with the placing boom, in order to move an obstacle out of = the way, for instance; = _ allowing the placing boom to strike an obstacle; - tearing away a trapped end hose by force. Lifting and transporting loads is forbidden A oo00 Striking the placing boom against obstacles is forbidden. 261We €VerRDIGm 2.13.42 Impermissible Placing booms having boom hinges which permit great angles of working range bending have a very large useful working area. Because of this high ‘mobility some placing booms can, however, also be placed in positions which are of no use for working. Under certain circumstances it is even possible to overload or cause damage to the placing boom. ‘We have indicated such unacceptable working ranged by the use of, ‘warning on the machine and appropriate notes in the Operating Instructions. Impermissible End Hose Positioning The end hose must not be moved backwards beyond the vertical the placing boom. 1 Range in which work with the end hose is not permitted 2.62 21.03.rev00Se ao 2.14 Pumping operations —_Make sure that nobody is at risk from the running machine before swsitching the machine on or setting it in motion. ‘Start machines from the driver's seat only. The driver's cab must be locked when you are operating the machine from the remote control to prevent unauthorized starting of the engine. ‘Always watch the control displays in accordance with the Operating Instructions during start-up and shut-down procedures, 2.14.1 Place of work Itis forbidden to climb onto the machine when itis in the ready mode. ‘The place of work during pumping operations is at the remote control Itis forbidden to climb onto the machine when its in operation, 263 21.03.rev00