Escolar Documentos
Profissional Documentos
Cultura Documentos
and
Stabilization Training
rev.02 1
What it does
rev.02 2
rev.02 3
Folding Systems Sections number
4 5 6 7
K30L
K31L
K36-
K35L
K38L
K20L
K60H K80H
rev.02 4
Stabilization Systems
rev.02 5
Mechanical components
rev.02 6
Articulations
joint
Sections
Pipes line
Turret
Rear
Front Main Outrigger
Outrigger Frame
rev.02 7
Front outriggers Rear outriggers
Single telescopic horizontal
Fixed
Single telescopic X style
rev.02 8
Steel
components
Steel
components
Carbon
components
rev.02 9
Placing Boom Section
rev.02 10
ADVANTAGES
DIFFERENT PROPAGATION
rev.02 11
Placing Boom Articulations joint
Angular performance 90° Angular performance 180°
Triangle Angular performance 360°
First Section
Rod lever
Actuator
Cylinder
Turret
Triangle
rev.02 12
Placing Boom Pins and Bushings
First Section Boom Section
Turret
Triangle
Hollow pin Pin
Lubricating
Lubricating nipple
nipple
Bushing Blocking
pin system DU Bushing
Boom Section
Cylinder Pin
Triangle or Boom
Triangle or Pin DU Bushing
Pin Rod Level Section
Rod Level
rev.02 13
Concrete pipes DN5”
Hardened
Steel pipe
Pipes LLH
Gasket GU Gasket OR../Z
Concrete Pipes
identification plate Max pressure
rev.02 14
Concrete pipe lines Layout
IMPACT Curve
LLN-SS
Curve Pipe
LLN-SS
Curve
LLN-SS
Rubbe pipe
Pipe
LLS-SS
Pipe
LLN-SS
Curve
Pipe LLH-SS
Curve LLH-SS
LLH-PS
Reducer
LLH
rev.00 15
Concrete pipe lines Layout
Bend
*Bend LLN-SS Pipe LLN-
IMPACT
PP
Bend
LLN-PS
Bend
LLN-SS
Rubbe pipe
Pipe LLS-
SS
Pipe LLN-
SS
Bend
Pipe LLH- LLH-SS
Bend SS
LLH-PS
Riduction pipe
LLH-PR
rev.00 16
Hydraulic System
rev.02 17
Hydraulic Layout
Boom
Cylinders
Open outrigger
Cylinder Geared
motor
Outrigger sx
distributor
Boom
Outrigger dx Distributor
distributor Filter
Hydraulic Pump
A17FO…
Open outrigger
Cylinder
rev.02 18
Hydraulic Layout with Load-sensing
Boom
Cylinders
Open outrigger
Cylinder Geared
motors
Outrigger sx
distributor
Boom
Outrigger dx distributor
distributor Filter
Hydraulic Pump
A18VO…
Open outrigger
Cylinder
rev.02 19
Hydraulic pump A17FO… (ex KFA….)
rev.02 20
Boom Pressure Filter
To Boom distributor
Filter body
Indicator plug
By pass
Filter element
Filter body
rev.01 21
Boom distributor PSL…..
PSV….. HAWE
Pressure valve First section
End plates
Accumulator
LS line Pressure
adjustment
Connection block screw
Valve element
rev.02 22
Boom distributor PSVF….. HAWE
Pressure
adjustment
Pressure screw
adjustment
screw Pressure
adjustment
Valve element screw single
section
rev.02 23
Block Valve for Two geared reducer
Geared
reducer
brake
rev.02 24
Boom Cylinder DU Bushing DU Bushing
Guide ring
Piston seal
Rod seal
Guide ring
Wiper ring
Single Block Valve on Boom cylinder Double Block Valve on Boom cylinder
rev.01 25
Outrigger distributors
Distributor
without max
valve
Carry over
Distributor
with max
valve
rev.02 26
Block Valve on Double
outrigger system Sequence Valve
on Double
Block Valve on front cylinders
Hydraulic motor
Block Valve on
Triple telescopic
front cylinder
rev.02 27
Block Valve on
outrigger system
Stabilizator Cylinder
rev.02 28
Hydraulic Boom Diagram
To Outrigger
Distributor
rev.02 29
Hydraulic Stabilization Diagram
rev.02 30
Electrical System
rev.02 31
Electrical Layout Remote
control
trasmitter
Control Panel
Main Panel
Remote
control
receiver
Left Outrigger
enable box
Limit switch
Outriggers
distributor
Boom
Right Outrigger distributor
enable box
rev.02 32
Boom and Outriggers commands (Open Circuit)
rev.02 33
Boom and Outriggers commands (Closed Circuit)
rev.02 34
Boom Limit switch and Oil filter sensors
rev.02 35
BOOM MOVEMENTS
REMOTE CONTROL commands
Concrete
flow
Start/Stop
truck engine
Start/Stop
Remote Control
JOY STICK
rev.02 36
REMOTE CONTROL commands
JOY STICK
Flashing light
Radio control
status
Concrete
flow
Start Remote
Control
Start/Stop
truck engine
rev.02 37
Optional
rev.02 38
Shut off Valve
Shut-off function
Optionally the shut-off valve can be installed on the machine and managed by
software (parameter “Shut-off valve”): this device is used to avoid the spillage of
concrete from the end hose.
The shut-off management can be used when remote controls are switched on.
When the pumping unit switch (forward or reverse) is deactivated, the controller
closes the shut-off valve and stops the pumping unit simultaneously.
When the pumping unit switch is activated, the controller opens immediately the
shut-off valve and starts the pumping unit after 4 seconds.
rev.02 39
Automatic lubrication boom system
rev.02 40
Components Calibration
rev.02 41
Boom Distributor Calibration with fix hydraulic pump
rev.02 42
Boom Distributor Calibration with variable hydraulic pump
Boom manometer
rev.02 43
Pressure valve first section boom down
Pressure
adjustment
screw on
pressure valve
rev.02 44
Speed Boom Calibration
Grain
Grain
Lever
rev.02 45
Calibration of the Radio control
rev.02 46
Calibration of RONIC radio control
MODES OF OPERATION
ATTENTION
ATTENTION
1 The calibrations to be made concern the "start" and the "fast" and "slow" arrival values (both in slow and fast drives)
of currents to the solenoid valves of the proportional distributor.
a - With the "start" current adjustment, you will need to set the manipulator deviation from the central position starting
from whichever boom starts operation first.
b - With the "fast" arrival value adjustment, you will have to have the maximum excursion of the control rod of the
distributor correspond with the maximum excursion of the radio control manipulator
a -mechanical calibration of the boom distributor for the maximum speed already performed
b -radio control activated by means of the corresponding red key (a) in position "P“
rev.02 47
Calibration of RONIC radio control
Operate as follows:
1. Start up the machine.
ATTENTION
Operate on the radio control with extreme caution and,
if possible, bring the boom to a vertical position (fully extended).
4. Move near the distributor (usually on the right side of the machine
rev.02 48
Calibration of RONIC radio control
3. Start up the radio control, moving the "START" (d) lever selector to the
right. You will hear a "beep" confirming correct start-up.
rev.02 49
Calibration of RONIC radio control
Gently move the manipulator of the section you wish to adjust until you
reach the point at which the distributor permission lever ("dead man's"
lever) starts to move.
In this condition, adjust the current using the "GAS" (d) lever selector
(moving to "+" or "-") until you reach the required starting point
rev.02 50
Calibration of RONIC radio control
Gentle move the manipulator (m) forward until the horn begins to honk.
Move the manipulator of the section you wish to adjust until you arrive at
maximum stroke
Keep the manipulator in this position and adjust the current using the "GAS"
(d) lever selector (moving to "+" or "-") until you reach the maximum stroke
of the respective distributor lever
rev.02 51
Calibration of RONIC radio control
Gentle move the manipulator (m) forward until the horn begins to honk.
Move the manipulator of the section you wish to adjust until you arrive at
maximum stroke.
Keep the manipulator in this position and adjust the current using the "GAS" (d)
lever selector (moving to "+" or "-") until you reach the point corresponding to
60/70% of the stroke of the respective distributor lever.
Once you have finished using calibration mode, switch off the machine and remove the
red key (c) from the radio control, turning it counter-clockwise to set it in position "0".
Store it in a safe place.
rev.02 52
Calibration of the Radio control
rev.02 53
Calibration of radio control
MODES OF OPERATION
ATTENTION
ATTENTION
1 The calibrations to be made concern the "start" and the "fast" and "slow" arrival values (both in slow and fast drives)
of currents to the solenoid valves of the proportional distributor.
a - With the "start" current adjustment, you will need to set the manipulator deviation from the central position starting
from whichever boom starts operation first.
b - With the "fast" arrival value adjustment, you will have to have the maximum excursion of the control rod of the
distributor correspond with the maximum excursion of the radio control manipulator
a -mechanical calibration of the boom distributor for the maximum speed already performed
b - radio control activated by means of Tele-Teach- In (a) type (charged) battery insertion.
(two different types of batteries depicted)
rev.02 54
Calibration of radio control
Operate as follows:
1. Start up the machine.
ATTENTION
Operate on the radio control with extreme caution and,
if possible, bring the boom to a vertical position (fully extended).
4. Move near the distributor (usually on the right side of the machine
rev.02 55
Calibration of radio control
2. Replace the standard battery with a Tele-Teach-In (a) type, necessary for radio
control programming.
3. Activate the radio control in programming mode, keeping the two buttons “+” and
“-” on the Tele- Teach-In (a) battery pressed and pressing the “On/ Off” button.
4. Keep the two “+” and “-” buttons pressed until the green LED (b) on the radio
control (c) starts to flash quickly. Release the buttons.
rev.02 56
Calibration of radio control
Gently move the manipulator of the section you wish to adjust until you reach the
point at which the distributor permission lever ("dead man's" lever) starts to move.
In this condition, adjust the current using the "+" and "-" buttons on the Tele-Teach-In
battery until you reach the starting point required by the section involved.
rev.02 57
Calibration of radio control
Move the manipulator of the section you wish to adjust until you arrive at
maximum stroke.
Keep the manipulator in this position and adjust the current using the "+" and
"-" buttons on the Tele- Teach-In battery until you reach the maximum stroke of
the respective distributor lever.
rev.02 58
Calibration of radio control
Move the manipulator of the section you wish to adjust until you arrive at
maximum stroke.
Keep the manipulator in this position and adjust the current using the "+" and
"-" buttons on the Tele- Teach-In battery until you reach the point
corresponding to about half of the stroke of the respective distributor lever
rev.02 59
Calibration of radio control
Storage of calibration occurs in the receiver (d) when the transmitter is turned off (c). This
operation is shown to be in progress by the yellow LED (f) lights up while saving and by the
green LED (e), both present on the receiver lid (d).
After each adjustment, save data by switching off the radio control and waiting for successful
data saving before switching it back on.
rev.02 60
Single Geared motor on Turret Calibration
Pressure
Brake lock screw adjustment screw
rev.02 61
Double Geared motor on Turret Calibration
rev.02 62
Outrigger Distributor Calibration
Button
manual
stabilization
rev.02 63
CENTRE BEARING PROCEDURE -Single geared reducer-
rev.02 64
CENTRE BEARING PROCEDURE -Double geared reducer-
rev.02 65
Outrigger bearing regulation
rev.02 66
Troubleshooting
rev.02 67
THE BOOM DOES NOT OPEN OR DOES NOT MOVE WHEN IN A PARTICULAR POSITION
Probable causes
No pressure
Insufficient pressure
Load anomalies
Solenoid valve blocked or solenoid burnt out
Remedies
The Hydraulic pump that acts on the boom circuit normally feeds the pump circuit. Only when a boom command is
sent is the oil flow directed towards the relative circuit. It must thus be verified whether the distributor solenoid
is activated.
If the solenoid works it is a sign that the maximum pressure valve has its shutter blocked. Clean it carefully.
If the maximum calibration value prescribed for the functioning of the boom is not reached, check whether the
maximum pressure valve is out of tune. If this intervention does not solve the problem it is a sign that the pump
is worn and must be replaced.
Check that additional loads are not imposed on the boom. This is strictly prohibited since it will render the boom
unsafe and structurally unsound. Eliminate any loads or impediments to the manoeuvre.
If, after having checked the previous points the problem is not solved, the command solenoid for the individual boom
section must be checked (direct command solenoid valve or pilot solenoid valve of the lever distributor) to see if
it works. If not, there is a blockage of the cursor or the solenoid is burnt out.
rev.02 68
THE BOOM WOBBLES CONSIDERABLY IN A VERTICAL OR HORIZONTAL DIRECTION
Abnormal backlash:
In the joints (between the pins and their seats).
In the thrust bearing (between the fixed parts of the thrust bearing and the rotating part).
Loose thrust bearing bolts
Remedies
Replace the worn parts and respect scrupulously the lubrication frequency.
Replace the thrust bearing, tightening to the prescribed degree.
Tighten/replace the bolts.
Remedies
Clean stop and replace valve
Position the pump level after having closed the boom.
Replace the linings.
Replace the springs
rev.02 69
THE BOOM DOES NOT STAY IN POSITION UNDER LOAD
Probable causes
The blocking valve on cylinder is wrongly adjusted or dirty or damaged
Remedies
Adjust the cut-off valves or clean them or replace them
Replace the gasket pack. Check that the cylinder pipes are not damaged
Remedies
Replace the greaser
Extract the pin. Free the channels and check the causes
Remedies
Using a de-oxidising liquid, introducing it through the
greaser hole and in the coupling area.
If this has no effect, heat the external hub in which the pin
is located. The pin and the bushes must be replaced.
rev.02 70
THE PIN TURNS, BREAKING THE BLOKING PIN
Probable causes
The pin is seized due to lack of lubrication
Remedy
Extract the pin to check the state of wear and backlash of the
coupling. Consult the CIFA service department.
Remedies
Check the union between the plug and socket and connect properly
Check the connection to the plug, the socket and the cable. Replace part not working
Remedy
Look for the short circuit and repair it
Look for the short circuit and repair it
Look for the short circuit and repair it
rev.02 71
Operating Procedures
and Safety
rev.02 72
POSITIONING AND STABILIZING
Having reached the site, place warning notices and barriers around the area of action of the
machine, near the traffic or pedestrian routes so to prevent access in the area by any
person or vehicle.
With the exception of the operator (in charge of the machine or its working), nobody must
stay near the working area of the machine.
Take the machine to the workplace and ensure that the ground is solid and flat.
Ensure that there are no persons or objects in the range of action of the machine.
Insert the key and turn the selector switch enabling panel/remote controls to the panel
position to enable the same.
Remove the mechanical clamp from the removable part of the stabilizer.
Press the stabilization consent push-button on the stabilization control unit and use the
lever to: - withdraw the front and rear stabilizers.
- lower the front stabilizer.
- lower the rear stabilizer.
rev.02 73
WARNING:
During the maneuvers do not stand in the path of the stabilizer.
Repeat the operations of the previous point for the opposite side and bring the
machine visually into a horizontal position.
Use a spirit level to achieve this position of the machine
.
WARNING:
The MAX inclination must be less than or equal to 3°.
WARNING:
- check that the ground below the stabilizers does not yield.
- check that all the mechanical clamps have been returned.
-check that all the stabilization controls are set to “0”.
Should the ground not be sufficiently solid, use distribution plates or compact
wooden panels for better distribution of the stabilizers on the ground (square
15 x 15 joists).
The pump operator is obliged to stabilize the machine in accordance with the
various conditions of the ground.
This means that, according to the degree of stability of the ground (kN/m2),
the original support plates of the stabilizers must be “enlarged” by applying
larger rest surfaces in order to avoid sinking of the support feet.
rev.02 74
As accessories CIFA provides 4 support plates (60 x 60 cm or 50 x 50 cm) in plastic which, used as a simple support base, can
cover a more extensive area in relation to the vertical loads and to the permitted contact pressure.
If a larger support surface is required, the user must provide adequate square wooden joists (15 x 15 cm) - four for each
support plate.
The Table indicates to what extent the support surfaces are sufficient or whether the above joists also have to be applied.
rev.02 75
MOVEMENTS OF THE BOOM
After stabilized the concrete pump, turn selector on the control panel from local to remote and then proceed
to open boom with remote control.
The sequence for opening out the boom must follow the instructions below and the relative illustrations:
WARNING:
The distribution boom should not be extended before completely stabilizing the machine as described in the
chapter "POSITIONING AND STABILIZATION.”
WARNING:
Before extending the boom, the machine should be placed on a completely flat surface.
The maximum permissible inclination is 3°. An inclination greater than that would overload the distribution
boom’s rotation system and jeopardize the machine’s stability.
If one or more outriggers lift from the ground while the distribution boom is in operation, they should be
repositioned.
All outriggers must rest firmly on the ground.
rev.02 76
Placing Boom Diagram
DANGER
rev.02 77
ZR = OPENING SEQUENCE
rev.02 78
Z = OPENING SEQUENCE
rev.02 79
R = OPENING SEQUENCE
rev.02 80
RZ = OPENING SEQUENCE
rev.02 81
RZ = OPENING SEQUENCE (Boom above cabin)
rev.02 82
RRZ = OPENING SEQUENCE
rev.02 83
DANGERS and IMPROPER USE
Prohibition for unauthorized persons Nobody must stand under the arm,
to stand in the working area including during waiting times
Do not use the arm to lift or drag weights
The minimum distance of the arm near overhead During movements of the arm, In strong winds or gusts of winds take
electricity lines must be 7 m. avoid contact with any the necessary precautions and fold the
DANGER OF ELECTROCUTION. obstacles arm
rev.02 84
HAND SIGNALS
WARNING:
Use hand signals when:
-the movement of the arm is not in the field of vision of the operator;
-
- the operator cannot check the distances observed on account of a
false perspective.
rev.02 85
Structural controls
rev.02 86
WHY YOU MUST CHECK ONE MACHINE?
rev.02 87
CIFA SpA, as part of the strategy to ensure the reliability
and safety of the pumps fleet and in harmony with the
existing European Standards regarding the safety of
machines, has prepared an operating procedure to
identify and certify the actors involved in the activity
of Structural Controls to which our machines must be
periodically subjected.
rev.02 88
EN 12001
According to section 7.3 is fixed periodic monitoring
• The customer is informed of the need to periodically check the structure to be
given to authorized personnel.
• The test must be performed at least once a year or sooner, depending on the
number of hours worked measured by the counter supplied with the machine.
• Machines older than five years will have to perform additional inspections as
specified by the instruction manual.
Over 10 years Yearly/max 250h EN12001: Controls and update sections and structure
rev.02 90
The inspection includes:
rev.02 91
All concrete pump manufactures require inspection of certain placing boom and
pump components as a part of routine maintenance procedures.
Look the following five points:
1. The owner of a concrete pump with placing boom is responsible for its
inspection for structural integrity.
2. This inspection should cover all structural components of the boom, pedestal
and outriggers assemblies.
3. Frequency-inspections should be made:
• Annually for the first four years
• Thereafter every six months of work.
4. If cracks or other distressed parts are found, they shall be repaired according to
the producer recommendations and by qualified personnel.
5. Special events:
• In the event of road accidents
• Structural members failure
• Contact with fixed object, or boom overloads
The boom shall be inspected as above and before being returned to the work.
rev.02 92
Visual inspection is a search for the following types of problem areas which must be for
safe operation:
1. Cracks
2. Stressed or deformed areas
3. Worn pivot points
4. Worn pins or bushing
5. Pivot pins not taking grease
6. Loose or missing pin retainers
7. Damaged hydraulic cylinders
8. Loose or missing bolts or connectors
rev.02 93
The boom and outriggers areas must be thoroughly cleaned prior to
inspection. All grease, oil, concrete and rust must be removed. To accomplish
this use solvent, soap, and high pressure hot water or steam.
rev.02 94
1
2
1
3
4 4
rev.02 95
The most used non-destructive methods:
• Eddy current
• Acoustic emission
• Liquid penetrant
• Magnetic particles
rev.02 96
•The eddy current method is
extremely versatile in that it can Special small
be used for all applications probe big like a
pen point
suitable to be correlated to
variations in the chemical-
physical properties of any
conductor.
The sensing coil can detect even
the slightest lack of homogeneity
of material, whether caused by
geometric, electric or magnetic
Oscilloscope
variations. used for eddy
current method
rev.02 97
• The result of acoustic emission tests
are not conventional. This method must
in fact not be used for detecting the
type and size of defects in a structure,
but rather for recording the
development of such defects during the
application of the types of stress to
which the structure will be subjected,
provided that the loads are sufficient to
generate local strains, defected
growing, slag detachment,
delamination, friction etc.
rev.02 98
Underlined
Crack
•The test method with liquid
penetrants is suitable for
detecting defects occurring on
all types of surfaces, provided
that they are “open”.
The method is not restricted to 1 2 3
any particular material or
structure.
rev.02 99
Magnetic
field
rev.02 100
For more information on spare parts and electrical diagrams, see the
following manuals supplied with the machine
rev.02 101
Thank you
rev.02 102