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Filling with fluid and filter changing on

machines with suction return flow filter

Description:
Hydraulic components may be damaged by an incorrectly performed filter change, initial filling or refill. To prevent
this happening, carry out these actions on machines with an PN 534895 suction return flow filter as follows.

Contents:
1. Preparation Page 2 suction return flow filter

2. Connecting the filling pump Page 2


3. Loosening plugs on the suction return flow filter Page 3
4. Loosening the tank and suction lines Page 3
5. Refilling the hydraulic system Page 4
6. Venting the hydraulic system Page 5
7. Filter changing Page 6

Tools/auxiliary devices required:


- Suitable filling pump for filling with fluid
- Various threaded unions for connecting the filling pump
- Container for catching fluid

Authored by: G. Polizzi Date: 26.07.2012 © Putzmeister Concrete Pumps Page: 1 of 8


Filling with fluid and filter changing on
machines with suction return flow filter

1. Preparation:

Before filling, ensure that all lines in the system are properly tightened. Check the filter elements, and replace
them as required (see point 7).

from filling pump

2. Connecting the filling pump:

Machines with an suction return flow


filter are filled with fluid via the P-line on
the agitator control block.
To do this, the connection line coming
from the agitator pump
is disconnected and connected to a
suitable filling pump.

to agitator control block

Authored by: G. Polizzi Date: 26.07.2012 © Putzmeister Concrete Pumps Page: 2 of 8


Filling with fluid and filter changing on
machines with suction return flow filter

3. Loosening plugs on the suction return flow filter:

Two plugs must be loosened on the suction return flow filter to enable the air to escape when filling the hydraulic
system.
When doing this, it is important that one plug is loosened on the return side (R) and one on the suction side (S).
It is enough to loosen the plugs approx. 2 turns. It does not matter which plugs on the top of the filter are used.

See photo on the right:

Return side „R“

suction side „S“

Authored by: G. Polizzi Date: 26.07.2012 © Putzmeister Concrete Pumps Page: 3 of 8


Filling with fluid and filter changing on
machines with suction return flow filter

4. Loosening the tank and suction lines:


The following lines must be loosened to ensure that all hydraulic pumps are supplied with sufficient fluid before
commissioning. Loosen the line approx. 2 turns here as well, so that all air can escape from the system.

Feed pump
suction line

Accumulator pump
leaking fluid line

T-line on the Agitator pump


main pump suction line
To do this, loosen the following hoses:
• suction lines on the feed pump(s)
• T-lines on the main pump(s)
• suction line on the accumulator charging pump Accumulator charging
• Leaking fluid line on the accumulator charging pump pump suction line
• suction line on the agitator pump

Authored by: G. Polizzi Date: 26.07.2012 © Putzmeister Concrete Pumps Page: 4 of 8


Filling with fluid and filter changing on
machines with suction return flow filter

5. Refilling the hydraulic system


After all the necessary preparations have been made, the hydraulic fluid can be fed in using the filling pump and
via the P-line on the agitator control block. The system is filled with hydraulic fluid until air-free fluid emerges at
both plugs on the suction return flow filter (point 3) and the lines that were loosened previously (point 4). The plugs
and all lines must then be sealed tight. Then continue filling so that, by means of the counterbalance valve in the
filter, the tank is filled and the suction filter is supplied with sufficient fluid. Only then can the remaining
components (e.g. accumulator charging pump and agitator pump) be supplied with fluid via the suction filter.
Caution!
To prevent the tank from overflowing during filling, the fill level display must be constantly monitored, so that the
filling pump can be switched off promptly when the maximum fill level is reached.

6. Venting the hydraulic system


After filling, it is necessary to remove any remaining entrapped air in the
hydraulic system, since entrapped air can adversely affect functioning and
can damage components. When venting, ensure that there is no air
remaining, i.e. vent until air-free fluid emerges. To do this, the following
components MUST be vented as well.
- Drive cylinder - Accumulator charging pump
- Boom pump - Suction filter (see point 7/E)
- suction return flow filter (see point 7/F)

Authored by: G. Polizzi Date: 26.07.2012 © Putzmeister Concrete Pumps Page: 5 of 8


Filling with fluid and filter changing on
machines with suction return flow filter

7. Filter changing
Filters should be changed as required (see operating instructions 5.5.2 - Warning), but no later than after 500
operating hours or after one year, and must be carried out as follows.
Suction filter
A B
A) Loosen the bolts on the suction filter cover and
remove the filter element by turning anti-clockwise.
Catch the hydraulic fluid with a suitable container.
B) Now unscrew the dirtied filter element and replace it
with a new one. When doing this, ensure that the
magnetic bar is cleaned before fitting a new filter
element.
Caution! During fitting, screw rather than press the filter
onto the cover, because otherwise the holder could
become damaged.
suction return flow filter A B
A) Remove the drain plug from the suction return flow
filter cover and catch the hydraulic fluid with a
suitable container. Then undo the bolts and remove
the cover.
B) Now remove the filter holder, bearing in mind that
some remaining fluid may emerge from the housing.

Authored by: G. Polizzi Date: 26.07.2012 © Putzmeister Concrete Pumps Page: 6 of 8


Filling with fluid and filter changing on
machines with suction return flow filter

C) The filter element can then be removed from the C C


housing, the assembly aid (yellow ring) can be
removed by turning it and can then be cleaned
before it is fitted to the new filter element. It is also
recommended that during every filter change, the
O-rings are checked and replaced if necessary.

suction return flow filter:

D D
D) Once the new filter elements have been inserted,
the housing on the suction return flow filter still
needs to be filled with fluid. To do this, open one
plug (point 3) on the top of the filter housing,
completely fill it and reseal.

Authored by: G. Polizzi Date: 26.07.2012 © Putzmeister Concrete Pumps Page: 7 of 8


Filling with fluid and filter changing on
machines with suction return flow filter

E) Before the machine can be started up, the suction filter Suction filter:
must be vented. To do this, undo the plug shown, and
vent until air-free fluid emerges. The plug can then be
refitted. Undo the plug for
venting
F) Since some air might remain trapped in the system,
the system must be briefly started up (for approx. 5
minutes), and checked for remaining air in the suction
return flow filter. As required, do this by completely
filling up the filter housing with fluid as described in
point 3.

Authored by: G. Polizzi Date: 26.07.2012 © Putzmeister Concrete Pumps Page: 8 of 8