Dynajet 350 mg Plus, Operating Instructions Manual

Page 1: ...or machine operator and maintenance staff always keep by the machine High Pressure Cleaner Dynajet 350 mg Plus Art no 111486047 Machine no Rev 00 0404 365051013 The paper on which this document is printed is 100 chlorine free ...

Page 2: ...Putzmeister Mörtelmaschinen GmbH Max Eyth Str 10 D 72631 Aichtal Postfach 2152 D 72629 Aichtal 07127 599 0 Hotline 07127 599 699 07127 599 743 www putzmeister de e mail pmm pmw de Internet ...

Page 3: ...gh pressure gun 2 5 Safety equipment 2 5 2 5 Handling high pressure hoses 2 6 2 6 Injuries from high pressure water jets 2 7 2 7 Unauthorised use 2 7 2 8 Personal protective equipment 2 7 2 9 Selecting qualified personnel 2 9 Qualified electrician 2 9 2 10 Hydraulic operation 2 9 Inspection 2 10 Depressurising 2 10 Lines 2 11 2 11 Liability 2 11 2 12 Place of work 2 11 Operator 2 11 2 13 Working a...

Page 4: ...igh pressure circuit unloader 3 5 Personal protective equipment 3 5 3 6 Water system 3 6 3 7 Functional description 3 6 General set up of the machine 3 6 Drive motor 3 6 High pressure water pump 3 7 High pressure gun 3 7 Fan jet nozzle 3 8 Operating module 3 9 Socket 12 V 3 10 Additional equipment for emergency operation of the hydraulic system 3 10 3 8 Components on the control and monitoring uni...

Page 5: ...ncy hydraulic unit 5 1 5 2 General 5 2 5 3 Checks 5 2 Water filter 5 3 Refuelling the machine 5 3 5 4 High pressure gun 5 4 5 5 Test run 5 5 Starting the motor 5 5 Checking functions 5 6 Stopping the machine after a test run 5 7 5 6 Starting the motor using the manual starting device 5 8 6 Operation Tip for cleaning surfaces 6 1 6 1 Setting 6 1 6 2 High pressure cleaning 6 1 Pressure adjustment 6 ...

Page 6: ...nce intervals 8 2 General 8 2 Drive motor 8 2 Water pump 8 3 Water supply 8 3 Transmission 8 3 8 2 Operating materials 8 4 9 Decommissioning 9 1 Temporary decommissioning 9 1 Frost protection 9 2 Preservation 9 3 9 2 Storing the machine 9 4 9 3 Final decommissioning disposal 9 4 Material used 9 5 Parts requiring separate disposal 9 5 Index of Key Words ...

Page 7: ... information that make this handbook easier to use In the event of any queries please consult Putzmeister Aqua Pressure System Max Eyth Str 10 D 72629 Aichtal Germany Tel 49 0 7127 599 0 Fax 49 0 7127 599 743 Internet http www Dynajet de E mail pmw de or the branch or services agent responsible for you Address Telephone Fax E mail ...

Page 8: ...ons If the operating instructions or certain pages in particular the Chapter Safety Instructions are missing they must be replaced immediately The machine owner must make the location of these operating instructions known to all personnel charged with performing jobs on the machine and ensure they are accessible These operating instructions must be read and applied by any person who carries out wo...

Page 9: ...st of continual improvement these instructions are updated at defined intervals to include changes that were not added to these operating instructions at the time of going to print These operating instructions are not covered by the Amendment Service of Putzmeister Mörtelmaschinen GmbH Alterations may be made to these operating instructions without prior notification The contents of this document ...

Page 10: ...onally Environmental protection This symbol precedes tasks where special attention must be paid to environmental protection The accompanying text appears in italics and is followed by a line Note Important specifications regarding economical use of the machine appear after the word Note written in bold and the pictogram shown The accompanying text appears in italics and is followed by a line Cauti...

Page 11: ...ing instructions Note Special safety regulations may be required for some tasks These special safety regulations will only be found in the description of the particular task The following safety instructions should be regarded as supplements to the existing national accident prevention regulations and laws Existing accident prevention regulations and laws must be observed in all cases We include h...

Page 12: ...rer that are in perfect condition and suitable for cleaning tasks If you sell on the high pressure cleaner you must observe the following Pass on to the new operator all the accompanying documentation operating instructions maintenance instructions diagrams machine cards inspection certificates etc you received with your high pressure cleaner If necessary you may have to order the papers from us s...

Page 13: ... Cold clean mains water should be supplied to the machine via the low pressure hose Other materials should not be used The machine can be used for emergency operation of Putzmeister concrete pumps for boom and support operation Always consult the machine supplier before using at oil hydraulic installations Any protective covers belonging to the machine should be fitted before operation The machine...

Page 14: ...ustomisation of the machine which may compromise safety The guarantee will no longer be valid in such cases Never make any modifications additions or conversions to the machine which may affect safety without first obtaining the manufacturer s approval This also applies to the installation and adjustment of safety devices and valves as well as to welding work on load bearing elements In particular...

Page 15: ...he high pressure gun at a maximum pressure of 350 bar depending on the model This presents a high risk of injury When working with the high pressure gun wear your personal protective equipment at all times Never direct the high pressure jet at personnel The high pressure produces jet reaction forces Make sure you have a steady stance when working Never remove safety equipment or render it inoperab...

Page 16: ...ssure hoses after operation Do not crush high pressure hoses or lay them over sharp edges Avoid tensile and bending loads High pressure hoses must be stored free of kinks and tension High pressure hoses are wearing parts with a limited service life They should therefore be replaced at appropriate intervals according to the operating conditions even if there are no obvious external defects The hose...

Page 17: ...ed as an acute surgical emergency and must be treated by a qualified orthopaedic surgeon Inform the acting doctor that the accident was caused by a high pressure water jet Always secure the machine against rolling away and unauthorised use when you leave the workplace Always secure the machine against unauthorised starting before leaving the work area This means Remove the ignition key The operato...

Page 18: ...ting personnel must be informed that waterproof protective clothing only provides protection from spray water and splash particles In the case of direct contact with the high pressure water jet protective equipment does not guarantee protection against injuries caused by the high pressure water jet Never direct the high pressure jet at personnel to clean dirty protective clothing still being worn ...

Page 19: ...ervision of an experienced person Work on the electrical system and equipment of the machine must be carried out by a qualified electrician or by instructed persons under the supervision and guidance of a qualified electrician and in accordance with electrical engineering rules and regulations Work on hydraulic equipment should only be performed by personnel that has special knowledge and experien...

Page 20: ...hem Replace damaged or damp hydraulic hoses immediately Hydraulic hoses should be replaced every 6 years including a maximum storage time of 2 years even if there are no signs of external damage The duration should be calculated starting from the date indicated on the connector label manufacturing date of the hose line System sections and pressure lines hydraulic and pneumatic should be depressuri...

Page 21: ...ty insurance company or the legal authorities in your country or to inadequate 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 is taken The workplace refers to the area in which people remain in order to carry out wor...

Page 22: ... personnel comply with this regulation Have old materials such as oils filters batteries replaced parts etc disposed of in line with regulations Used cleaning cloths must also be disposed of correctly 14000700 Environmental protection Spare parts must comply with the technical requirements specified by the manufacturer Spare parts from original equipment manufacturers guarantee that this is the ca...

Page 23: ...e also described Please see the machine card to find out whether a particular option is fitted Your high pressure cleaner is a Dynajet mg from Putzmeister Mörtelmaschinen GmbH You will make it much easier for us to answer any questions or respond to orders if you can give us the details of the machine model and the machine number Dynajet XXX mg XXX bar maximum pressure Portable Gasoline 3 1 Design...

Page 24: ...s list a document folder Note The specifications relate to the series machine and may deviate if special equipment is fitted Please refer to the supplied machine card for details Below you will find an overview of the most important components which are then described on the following pages 1 7 4 6 3 5 2 1 Drive motor 2 Socket 12 V 3 Water pressure gauge 4 High pr essure water pump 5 Unloader 6 Wa...

Page 25: ...r Petrol motor 14 5 kW 3250 rpm Working pressure 350 bar Pumping rate 21 l min Note The maximum pumping rate and the maximum working pressure cannot be achieved simultaneously Operating materials Fuel Regular fuel capacity 20 l Motor oil SAE 30 W Motor oil quantity 1 6 l with filter 1 4 without filter High pressure water pump 1 04 l SAE 30 W AGIP Diesel Gamma Gear unit 180 gr SAE 85 140 W AGIP Rot...

Page 26: ...ef on the rating plate mounted on the machine 24000201 1 2 3 4 5 6 7 8 1 Model machine model 2 Machine no machine number 3 Year of manufacture 4 Max delivery pressure bar 5 Hydr pressure max bar maximum fluid pressure in the hydraulic system 6 Voltage V 7 Frequency Hz 8 Power kW Rating plate ...

Page 27: ...sure is above 150 bar for the Dynajet 150 mg 280 bar for the Dynajet 280 mg 350 bar for the Dynajet 350 mg and 350 mg Plus the unloader depressurises the water and returns it to the water inlet Personal protective equipment is not included in the scope of supply of the machine it is supplied by Putzmeister and can be purchased through Parts Sales Danger When carrying out work using the high pressu...

Page 28: ...ou can limit the field of the machine s applications to suitable areas and avoid errors in operation Putzmeister machines are easy to assemble and operate In spite of this certain precautionary measures must be taken when operating the machine to ensure that the wear parts have a maximum life limit 1 2 1 Drive motor 2 Manual starting device The Dynajet mg is driven by a petrol motor The motor powe...

Page 29: ...r hydraulic fluid up to 80 C and water up to 60 C 1 3 2 4 1 Nozzle with nozzle holder 2 High pr essure hose with insulation 3 High pr essure gun 4 High pr essure hose The purpose of the high pressure gun is to regulate the high pressure water jet It is connected to the high pressure hose Activating the lever opens the nozzle and releases the high pressure water jet The maximum operating pressure o...

Page 30: ...zle designations are composed as follows XX 0XX Spray angle Nozzle size Note Bear in mind that the nozzles have an influence on the water pressure If a nozzle is used and is too small the pressure may increase and trigger the unloader which limits the system pressure to a maximum of 350 bar If the nozzle is too large the pump may not be able to attain maximum pressure at the full delivery rate The...

Page 31: ...ting module The LEDs indicate the status of the switch before the machine is started If a switch changes status during operation the motor is stopped after 3 seconds All signals are displayed evaluated and processed as per the description If a fault is pending for approx 6 8 seconds an acoustic horn sounds and the motor is stopped Continuation next side Operating module ...

Page 32: ...ocket gives the option of connecting die Putzmeister Dynabox 350 12V for example A 10 m oil pressure hose a 10 m oil intake hose and a hose connection are included in the scope of supply for the Dynajet 350 mg Plus With these components the machine can be used for emergency operation of Putzmeister concrete pumps for boom and support operation Socket 12 V Additional equipment for emergency operati...

Page 33: ...s The functions of the machine are assigned to the following control devices Water valve fitting Water pressure gauge Operating module depending on model 1 2 1 Pressure gauge 2 Unloader valve 1 1 Water pressure gauge The water pressure is indicated on the water pressure gauge 1 3 8 Components on the control and monito ring units Water valve fitting Water pressure gauge ...

Page 34: ...ater oil deficiency 5 Oil pressure 6 Charge monitor 7 Ready The operating module monitors and displays From the motor Motor oil pressure Dynamo From the pump Oil temperature Water temperature Oil level Water level The operating module has a horn for all fault messages Faults are only detected and displayed in active operation Operating module ...

Page 35: ...the machine will not be described until the chapter Commissioning Before shipment the machine is packaged for transportation Unpack the machine and dispose of the packaging material Recyclable materials are used to pack the machine Environmental protection Dispose of the packaging material according to the applicable environment protection regulations Please separate cardboard plastic and wood and...

Page 36: ...s purpose Lifting equipment lifting tackle support trestles and other auxiliary equipment must be reliable and safe in operation Make sure that the load bearing capacity is sufficient 1 1 Jack ring Caution The machine must be properly secured on the transport vehicle to prevent it rolling away slipping or tipping over Inspect the proposed site carefully and reject the set up site if you have any d...

Page 37: ...e water supply before beginning connection work The pipe must be at least 3 4 in diameter The existing water pressure must be at least 4 bar Water pipes must be laid visibly taking local conditions into consideration and secured against damage They must not obstruct operating personnel Caution If there is a risk of freezing the pipes must be laid in such a way as to avoid the possibility of the wa...

Page 38: ... proceed as follows 1 1 WGA nipple Remove WGA nipple å A 12 L hydraulic connection remains on the pressure connection 1 1 Oil pr essure hose Fit the oil pressure hose in the scope of supply for machine AN 446834 to the pressure connection Continuation next side 4 5 Setting up the machine for emergency operation ...

Page 39: ...012_0404GB 1 1 Water intake hose Remove the water intake hose 1 1 Oil intake hose Fit the oil intake hose Note Bypass the filter when connecting the oil intake because the high pressure pump only has a low intake capacity Continuation next side ...

Page 40: ...Transport Set up and Connection 4 6 APS04_012_0404GB Ball valve for venting the oil intake hose Vent the oil intake hose via the yellow ball valve Continuation next side ...

Page 41: ... 1 3 6 6 5 4 7 7 X Dynajet mg Plus Y High pr essure filter Z Boom pump 1 Hydr hose 4SP DN10x 5000 2 Connection GS 12L 3 Connection REDSD 18 12L 4 Connection GES 18LM 5 Connection ETSD 18L 6 Connection SNV 18L 7 Screw joints BO RV 18L SA5 Oil pressure hose diagram ...

Page 42: ... first time operating personnel should be instructed on how to use the machine The entire system should be observed during the initial hours of operation to identify possible malfunctions When using the Dynajet mg Plus as an emergency unit for operating Putzmeister concrete pumps for boom and support operation commission as described without water operation The water filter high pressure hose high...

Page 43: ...during these tests must be rectified immediately A fresh inspection is necessary after every repair The machine may only be put into operation once all the inspections described below have been concluded satisfactorily Each time the machine is used at a construction site you should check the condition of your machine and carry out a test run including functional checks If you identify any faults d...

Page 44: ...anging filters observe the waste disposal regulations that apply to your region The high pressure cleaner is driven by a combustion engine The fuel tank is integrated into the frame The high pressure cleaner can be filled with fuel via the filler neck when it has been shut down Before starting up check that there is sufficient fuel in the tank and if necessary top up with fuel via the filler neck ...

Page 45: ...ed flames or ignitable sparks Ensure that no fuel spills onto hot machine parts while you are filling up There is a risk of the fuel igniting Avoid naked flames at the machine and lock the fuel tank after refuelling danger of fire 1 2 3 4 1 High pr essure pipe 2 High pr essure gun 3 Screw coupling 4 High pr essure hose When the high pressure gun is not yet ready for operation connect the high pres...

Page 46: ...the water jet at persons or animals the high operating pressure can lead to serious injuries The activated high pressure gun produces recoil and torque Ensure equipment is secure and stable Open the high pressure gun Caution The pressure side must be fully open when the drive motor is started i e press the spray gun trigger This optimises the quick fill feature on the pump and avoids dry runs Cont...

Page 47: ...ming up period Note The engine speed is controlled depending on the load There is no accelerator control the engine controls the speed depending on the load You can check the different machine functions while the motor is running Check all joints on the machine for leaks Set the working pressure on the unloader and check whether the machine reacts to changes å Changes in pressure can be viewed on ...

Page 48: ...switch it off If you want to continue using the machine proceed as described in the chapter Operation If you want to switch off the machine proceed as follows Switch off the drive motor Depressurise the machine by actuating the high pressure pistol Turn the key in the ignition lock to 0 Stopping the machine after a test run ...

Page 49: ...This optimises the quick fill feature on the pump and avoids dry runs The oil pressure that builds up during the manual starting phase will be insufficient The supply line must be disconnect from the oil pressure sensor first Remove the supply line from the oil pressure sensor Start the motor by pulling the cord on the manual starting device Caution Fuel solenoid valve remains activated in positio...

Page 50: ...eaning work proceed as follows Start the engine as described in the section Starting up Caution The pressure side must be fully open when the drive motor is started i e press the spray gun trigger This optimises the quick fill feature on the pump and avoids dry runs Depending on weather conditions run the engine for a few minutes until it reaches its working temperature Danger Observe the maximum ...

Page 51: ...ressure gun produces recoil and torque Ensure equipment is secure and stable Under no circumstances may explosive or inflammable materials be pumped Protect the high pressure hose from external intrusions and sharp corners You can adjust the working pressure by turning the unloader Note The engine speed is controlled depending on the load There is no accelerator control the engine controls the spe...

Page 52: ...g temperature Caution Always consult the relevant machine supplier before using the machine on oil hydraulic installations The high pressure pump is deactivated by a pulse controlled unloader valve and requires the initiation of a depressurised cycle otherwise the loss of performance in the bypass circuit will deactivate the motor and trigger the horn Set the unloader to maximum during emergency o...

Page 53: ...steam jet or high pressure cleaner cover or seal all openings where moisture must not enter for reasons of safety or relating to machine operation Control cabinets and electrical plug in connections are especially at risk Do not allow water to enter the electrical systems Note In the first six weeks of operation clean all painted surfaces with cold water only at a maximum water pressure of 5 bar D...

Page 54: ...em is splash proof but not waterproof Remove all the covers seals after the cleaning process Caution The machine and lines must be completely drained of residual water if there is a risk of freezing If the machine needs to be stored observe the instructions for storage in the chapter Decommissioning 6 5 Storing the machine ...

Page 55: ......

Page 56: ...f a switch changes status during operation the motor is stopped after 3 seconds The time of faults 3 seconds is added up and stored If the stored value exceeds 3 seconds the motor is also stopped If a fault does not occur again within 10 seconds the memory is deleted The fault that occurs first is stored and all other inputs are locked so that you can easily determine which fault originally caused...

Page 57: ...spray nozzle or replace spray nozzle Pump seal on the water pump worn Replace pump seal See documentation provided by the pump manufacturer Operating pressure too high Cause Remedy Spray nozzle too small Use a larger spray nozzle Spray nozzle soiled Clean spray nozzle Note Work on the electrical system and equipment of the machine must be carried out by a qualified electrician or by instructed per...

Page 58: ...cient operation of the machine We would like to emphasise here that all specified checks inspections and preventive maintenance work must be conscientiously carried out Otherwise we will refuse any liability or warranty claim Our After Sales department would be glad to provide you with advice and help at any time should you be in doubt ...

Page 59: ...ipment operating and auxiliary materials Remarks General daily Visual and function check on all safety equipment visually daily Visual inspection of electrical cabling visually annually Check threaded unions with reference to the tightening torque table Torque wrench Drive motor See the manufacturer s documentation for information on how to carry out the work after the first 8 then every 50 annual...

Page 60: ... the first 50 then every 500 Full oil change SAE 30 W Filling capacity 1 125 l 200 Checking the oil level visually at sight glass 200 Check pump valves 1000 Change pump valves Frequency every operating hours at least Action Measurement and inspection equipment operating and auxiliary materials Remarks Water supply 200 Clean water filter 400 Change water filter Transmission after the first 50 then ...

Page 61: ...30 W 1 125 l Gear unit SAE 90 W 0 2625 l Refer to the maintenance tables for oil change intervals Environmental protection You must carefully collect all operating fluids e g used oil filters and auxiliary materials and dispose of them separately from other waste Observe the national and regional regulations applicable to your area Only work with waste disposal companies that approved by the relev...

Page 62: ... Stop the water supply Release the pressure in the high pressure gun until no more water flows out 1 1 Water pressure gauge Check the pressure gauge 1 to ensure that the system is fully depressurised Remove ignition key from ignition lock Note Remove the ignition key from the ignition lock Under certain circumstances the battery may discharge if the ignition key is not removed Continuation next si...

Page 63: ...re the machine in a frost free location Frost can cause the water filter and the hoses to burst To prevent frost damage to the water filter it must be completely drained of residual water Water filter Unscrew the water filter Unscrew union nut on the water filter and remove the housing and the filter Position the machine in such a way that residual water can drain from the filter housing water pip...

Page 64: ...the pump Close the air supply Disconnect the adapter Open the bypass line to the GEKA connector and empty the high pressure pump This method is used in the factory If the high pressure cleaner is to be put out of service or into storage it has to be preserved beforehand if required Note Preservation of the high pressure cleaner prevents corrosion and premature ageing It is necessary if the machine...

Page 65: ...ained completely because they could freeze and burst Caution It is essential that frost protection measures be taken because frost may damage the pump and water filter and cause the hoses to burst The final decommissioning and disposal requires complete deinstallation of the power supply When disposing of all machine components ensure that there is no possibility of damage to health or the environ...

Page 66: ...el Water valve fitting screws Gaskets Plastic rubber PVC Hoses Plastic rubber PVC Cables Wheels Tin PCBs Polyester PCBs The following components and working materials must be separated prior to disposal Designation Applies to Electrical supply Electronic scrap PCBs with electrical components Oil Drive motor Oil High pressure water pump Material used Parts requiring separate disposal ...

Page 67: ......

Page 68: ...3 Control devices 3 11 Water pressure gauge 3 11 D Designated use 2 3 Disposal 9 4 Drive motor 3 6 E Ear defenders 2 12 Emergency operation 4 4 EMERGENCY ST OP 3 5 Environmental protection 2 12 F Fault cause and remedy High pres sure cleaner general 7 2 Final decommissioning 9 4 Foreword 1 2 Frost protection 9 2 Functional description 3 6 Drive motor 3 6 3 7 G Gas control lever 3 11 General set up...

Page 69: ...reservation 9 3 R Rating plate 3 4 Refuelling machine 5 3 S Safety devices EMERGENCY STOP 3 5 Safety equipment 2 5 3 5 Overpressure safety device 3 5 Unloader 3 5 Scope of delivery 3 2 Set up site 4 2 Setting up the high pressure cleaner 4 2 Setting values 6 1 Signs 1 4 Spare parts 2 12 Starting the motor 5 5 Using manual starting device 5 8 Storing the machine 6 5 9 4 Symbols 1 4 T Technical data...

Page 70: ...19 Putzmeister America Mortar Maschine 1733 90th Street Sturtevant WI 53177 Phone 262 886 3200 Fax 262 886 3212 Weitere Werksvertretungen mit Kundendienst in Ägypten Algerien Argentinien Australien Bahrain Belgien Bolivien Bosnien Chile China Costa Rica Dänemark Ecuador El Salvador Finnland Frankreich Griechenland Guatemala GUS Hong Kong Indien Indonesian Irak Iran Island Israel Italien Japan Jeme...

Page 71: ...Putzmeister Mörtelmaschinen GmbH Postfach 2152 D 72629 Aichtal Telefon 07127 599 0 Telefax 07127 599 743 Internet http www moertelmaschinen de E mail pmm pmw de ...