On the job training on

Truck Mounted Concrete Pumps

Short description of truck mounted

concrete pump
The truck-mounted concrete pumps are hydraulically
driven twin cylinder piston pumps. Placing boom with pipes
normally installed in-between drivers cabin and pump unit.
If the placing boom is not used, a pipeline can be
connected directly to the pump unit.
Drive :
The whole concrete pump is a self-contained unit driven by
the chassis engine via a prop. shaft. The hydraulic pumps
are flanged directly to the distributor change over gear or
auxiliary drive which can be switched over to travelling or
pumping operation. Depending on the machine model, a
maximum of 2 hydraulic pumps for the concrete pump and
up to 3 hydraulic pumps for placing boom, agitator, water
pump and compressor etc. Can be installed.

Truck mounted concrete

pump / placer
The two cylinder reciprocating pumps, sucks concrete from the hopper

and pushes to the delivery line. Both the cylinders do this function
alternately. The pumping operation is achieved mainly with two of gate
valves.

Rock valve
Flat gate valve

Rock valve
In this, a conduit is pivoted inside the hopper in such away that the
cylinder is always connected with the feeding hopper and the
pushing cylinder with the delivery line.

Truck mounted concrete

pump / placer
Flat gate valve

Contd.

The concrete contained in the changing hopper is sucked into the

pumping cylinders and then pumped into the delivery pipe line by
pumping pistons. The two pumping pistons operate in opposite
directions i.e. While the returning piston sucks the concrete out of the
hopper and thus fills the cylinder with concrete , the other piston
moving forward pushes the concrete sucked in during the preceding
stroke into the pipe line . The gate valve plates are arranged in such a
manner that the suction stroke, the cylinder is connected to the
hopper and separated from the delivery line and vice versa.

Checks and maintenance

before concreting
Check oil level in hydraulic tank concrete pump. oil may fluctuate only
within the range of vision.
Check oil level in hydraulic tank placing boom with the completely
unfolded boom, extended cylinder, the oil level must still be visible in
the level glass.
Check oil tightness in hydraulic system(visual checks,tightens leaky
connections).
Check water box quantity.(water box should be full to the top edge of

Checks and maintenance

before concreting

Contd.

Check flushing agent for gate valve rods.

Check for proper changeover of cylinder at low speed.Gate valves
must reach limit stops when engaging concrete pump.If necessary ,

slowly close throttle valve on control block until gate valve hits
gently against limit switch.If impact of gate valve is too hard, slightly
open both throttle valve.

Check water tank level.

Check function of water pump.
Check function of placing boom.

OPERATING PROCEDURES
Contd.
Under all circumstance keep a safe distance from obstacles such as
masts, scaffolds, buildings, etc.
The placing boom may be operated only up to max wind force 8
(wind velocity = 77 km/hr).

The placing boom must never be used as a crane for lifting loads.
Un-authorised persons in the working areas of the concreting pump
and the placing boom is prohibited.

OPERATING PROCEDURES
Contd.
The vehicle must not travel with boom unfolded.
The rubber end hose at the placing boom must not exceed the
length as specified. It should not be linked during pumping
operations. The safety rope for the end hose must be available and
fixed.
Connections of delivery pipelines must not be opened under

working pressure. Before opening the pipelines it must be relieved

from stress by sucking back the concrete in reverse. After
assembling the pipeline secure the pipe couplings.

Never bend the end hose at the sharp angle

OPERATING PROCEDURES
Contd.
When blowing out the placing boom pipeline, the end hose must
be removed and the trap basket attached. It must also be ensured
that no persons are standing at the pipeline end in blowing out
direction.
Do not allow the hopper to be pumped completely empty. This
may cause trouble due to air locks (concrete analyzing due to
compressed air in the cylinder ) and running the pistons

dry

OPERATING PROCEDURES
Contd.
If the flushing agent is excessively contaminated, it should be changed.
Where it is absolutely necessary to change the sealing set for the gate
valve rods after Concreting operation. If stones have jammed the

agitating arms in the agitator, engage the agitator reverse for a short
time.

Check tightness in the hydraulic system(visual control,tighten leaky

unions).

OPERATING PROCEDURES
Contd.
A well cleaned delivery pipeline helps prevent blockages.
If blockages occur (concrete pump stops working, safety pressure
has been reached), switch over to trouble (reverse pumping ) for a
few strokes by means of switching lever. If blockages has not been
cured after switching back the concrete pump to operation, the
concrete pump has to switched off.Then establish where the blockage
is normally the blockage occur in the area of the reduction pipes or the

end hose.

SAFE OPERATING PROCEDURES

During operation of the concrete pump its operator is responsible for
the complete working of equipment. When leaving the concrete pump
unattended, he must secure it against unauthorized use.
Rectification of any failure, repairs and maintenance work should only
be made with drive motor disconnected.
On slopping sites the wheels be secured with blocks, release the
brake and let the machine run against the blocks, then apply the brake.
Finally support the machine.
Keep adequate distance from foundation trenches.
pressure may cause breaking off the slope.

The support

SAFE OPERATING PROCEDURES

Contd.
Jack the machine in such a manner that it stands in a horizontal
position, having achieved this, close and lock the valves of the jacking
cylinders, otherwise oil by-pass will occur and the machine could sink to
one side.
To prevent air cavitation the hopper must be filled as a minimum
with concrete approximately up to the agitator shaft. Cavitation may
cause the concrete to blow out of the hopper. Never place hand into the
concrete gate valve or the agitator hopper while the machine is running.
If the concreting with pump was doing with remote control, and after
the machine has been switched-off, always place the lever concrete
pump-forward/reverse initially into neutral position, otherwise the
concrete pump will become re-engaged.

(ROCK VALVE TYPE)

CLEANING AFTER CONCRETING

After concreting, the pipeline of the placing boom and concrete pump
must be cleaned carefully.
There are three methods of cleaning the pipe Line
1. Sucking out the pipeline :
Before sucking out the pipeline it is advisable

To produce and pump a quantity of high slump Concrete to fill the

pipeline.

CLEANING AFTER CONCRETING

Contd.
The hopper should slowly be pumped empty as far as possible.
Position placing boom so that the last boom section with its end
hose hanging vertically towards the ground and within easy
reach. Push into the end hose a soft rubber sponge ball. Engage
concrete pump to "trouble" (reversing the pumping).

The

concrete in the pipeline together with the ball will be sucked back
into the hopper.

Disconnect the siamese and bend, swing them sideways and

flush. Empty the hopper and clean.

CLEANING AFTER CONCRETING

Contd.
2. Pumping out the pipeline
The siamese and pipe bend have to be disconnected and both swing
sideways. Remove the concrete from the connecting pipe until a soaked

paper plug followed by a soft rubber sponge ball can be pushed in into
the reduction pipe. Connect cleaning head and connect the water pump
hose. Engage water pump. When discharge of paper and rubber ball

occurs at the end of the pipeline, turn-off the water pump flush the
siamese, pipe bend and hopper

CLEANING AFTER CONCRETING

Blowing out the pipeline :

Contd.

This method is similar to pumping out the pipeline method; but instead
of water line air line to be connected to the cleaning head, and connect a
trap basket at the end of pipeline.
3. Flushing of pipeline :

By flushing the pipeline remaining of concrete are removed from the pipe
walls.
For this purpose push the rubber ball about 1 m into the reduction pipe,
sprinkle water into the reduction pipe and close the pipe with another
rubber ball, so that there are a few litres of water between these two
rubber balls. Attach cleaning head. Now push the two balls with the
water cushion through the pipeline with compressed air.

CONCRETE TECHNOLOGY PREREQUISITES

The following defects give rise to non-pump ability of a freshly
mixed concrete.
Faulty concrete composition.
Insufficient content of fines per cum of fresh concrete.
Consistency too stiff.
Insufficient homogeneous mixing quality of fresh concrete.
Segregation of fresh concrete owing to inexpert transportation to
construction site.
Bleeding of fresh concrete.
Unsuitable granulometry.
Wrongly selected maximum size of aggregate in relation to nominal
diameter of the delivery pipe line.

Schwing BPL580-18/KVM28-24
concrete placing pump and boom
The concrete pump
Mounting
It is possible on various truck chassis with a minimum admissible total
weight of 14t by means of fitted sub-frame
Drive unit
Truck engine drives via flexibility suspended intermediate gearbox changeable to pumping or travelling operations - the constant axial

piston

pumps

for

concrete-pump,placing-

boom

&

auxiliary

groups.Pumps work in a reliable open hydraulic circuit,engine speed is

controlled by a rqv speed governor

Schwing BPL580-18/KVM28-24
concrete placing pump and boom
Control system

:- Full hydraulic control- Compact control block-

automatic control of constant stroke

Pumping cylinders :- 2 nos. Hardened by Special process and hard
rubber rams with Metal core
Gate valve

:- Single rod gate valve with automatic adjustment

and quickly replaceable shells

Charging hopper

:- 460 ltr capacity Hopper with rubber & grill

reversible Agitator driven by hydraulic motor, with Robust bearing and

sealing of agitator Shaft

Schwing BPL580-18/KVM28-24
concrete placing pump and boom
Optional equipment
A) air compressor
B) oil cooler
C) lateral outlet
Operating data
Theoritical output
Concrete pressure
Number of strokes
Pumping cylinder
Stroke volume
Hopper capacity
Drive power
Weight

52 cum / hr (max)
55 bar (max)
28 per min (max)
180 x 1200 mm
61 ltrs (2 cylinders)
460 ltrs
130 hp (min)
3280 kg

Schwing BPL580-18/KVM28-24
concrete placing pump and boom
The placing boom
Boom construction Boom made of high quality, fine grained steel in
box. Type construction, providing low weight and high safety in

vertical plane 3 times foldable, mounted on a slew able base column

with robust slewing drive. Folding angle of flyer of 245 deg. Resp.220
deg.
Jacking system

4 hydraulically telescopable support feet, front-

feet at laterally slewable outriggers jacking exclusively effected via

Schwing BPL580-18/KVM28-24
concrete placing pump and boom
Delivery pipeline

:- DN 125mm made of highly wear resistant

material uniform pipe lengths & bends thus equal on all boom sections
All articulated joints, also on boom end , consists of pipe bend.
Standard 90 deg bends are thick walled and wear resistant.

Drive & control

:- Drive is by hydraulic pump actuation of

placing by positive hydraulics valves operated manually or via a remote

control.
Pumping material

:-

Pumpable concrete within any consistency

range down to a water / cement ratio of 0.4 max. Aggregate size upto
63mm depending on delivery pipeline diameter

Schwing BPL580-18/KVM28-24
concrete placing pump and boom
Operating data
Pipeline dia

12 DN

Vertical reach

27.7 mtr

Horizontal reach

24 mtr

from
Slew axis center
Height of folding points (in mtr)

3.7 - 12.25 -

20.3
Articulated points three
Hoisting angle

104 deg

Schwing BPL580-18/KVM28-24
concrete placing pump and boom
The concrete pump
Mounting
Mounting is possible on various truck chassis with a minimum
admissible total weight of 22t by means of a fitted sub-frame
Drive unit
Truck engine drives via auxiliary drive or a flexible suspended
intermediate gear box - changeable to pumping or travelling operations

- the constant axial piston pumps for concrete -pump.Placing-boom &

auxiliary groups. Pumps work in a reliable open hydraulic circuit.
Engine speed is controlled by a governor.

Schwing BPL580-18/KVM28-24
concrete placing pump and boom
Control system

:- Full hydraulic control- compact control block

automatic maintenance of constant stroke

Pumping cylinders :- Two nos. Hardened by special process and
hard rubber rams with metal core

Gate valve

:-

Single

rod

gate

valve

with

automatic

adjustment and quickly replaceable shells

Charging hopper

:- 500 ltr capacity hopper with rubber & grill

reversible agitator driven by separate hydraulic Pump and motor, with

robust bearing and sealing agitator shaft.

Schwing BPL580-18/KVM28-24
concrete placing pump and boom
Optional equipment
a) air compressor

b) oil cooler

b) lateral outlet

d) vibrator

Operating data
Theoritical output
(max)

60 cum / hr

Concrete pressure

70 bar (max)

Number of strokes
(max)

31 per min

Pumping cylinder

180 x 1400mm

Stroke volume
cylinders)

72 ltrs (2

Hopper capacity

500 ltrs

Drive power

130 hp (min)

Schwing BPL580-18/KVM28-24
concrete placing pump and boom
THE PLACING BOOM
Boom construction
Boom made of high quality, fine- grained steel in Box - type construction,
providing low weight and High safety in vertical plane 3 times foldable,
Mounted on a slew able base column with robust Slewing drive.Folding
angle of flyer of 220 deg
Jacking system
4 hydraulically telescopable support feet, Front- feet at laterally slewable &

telescopable
Outriggers , rear feet at laterally extractable, Jacking exclusively effected
via support feet

Schwing BPL580-18/KVM28-24
concrete placing pump and boom
Delivery pipeline
Dn125mm dia. Made of highly wear resistant Material uniform pipe lengths
& bends. Thus Equal on all boom sections.

All articulated Joints, also on

boom ed,consist of pipe Bends.Standard 90deg.Bends are thick walled And

wear resistant

Drive & control

Drive is by hydraulic pump actuation of Placing boom by positive hydraulic
valves Operated manually or via a remote control
Pumping material
Pumpable concrete within any consistency Range down to a water / cement
ratio of 0.4 Max.Aggregate size upto 63mm depending on Delivery pipeline
diameter.

Schwing BPL580-18/KVM28-24
concrete placing pump and boom
Operating data
Pipeline dia

125 DN

Vertical reach

27.7 mtr

Horizontal reach

24mtr from slew

Axis center
Height of folding

0.7 - 12.25 - 20.3

Points (in mtr)

Articulated points

Three

Hoisting angle

104 degree

Slewing range

360 deg

Weight

5900 kg

Schwing BPL580-18/KVM28-24
concrete placing pump and boom

Capacity of oil tank

Approx.480

Approx.500

L
Capacity of water tank
L
Capacity of charching hopper :
L

Approx.500

The technical details of other models of

Schewing make boom placers
BPL
Max Hyd. pressure
(concrete pump)

units
bar

801 (r)
280

900 hdr
280

1200hdr
300

Max.Hydraulic pressure
(Agitator)

bar

100(200)

200

200

Pumping cylinder,diamm

200 * 1400

200 * 1600

230 * 2000 *stroke

Required power

74

74

74

31(33)

30 17 *

26 16 *

57 (61)

60 08 *

57 96 *

kw

Max Theoritical No of strokes

Per minute
Max concrete pr. Bar

* = piston side admission.

Putzmeister BPF 08/M24

Concrete placing pump & boom
Concrete pump

Design

:- All drives and concrete conveying parts are mounted on

an auxiliary chassis. This frame is prepared for mounting on truck chassis

having gross vehicle weight of 15tons or more & drive power of 110hp &
mounting of concrete placing boom
Drive

:- The pump is

driven via a PTO of truck engine.

Alternatively a splitter gear box can be fitted in between the propeller

shafts where all necessary hydraulic pumps are flanged on.

Putzmeister BPF 08/M24

Concrete placing pump & boom
Concrete pump
Consist of a pump chamber and hydraulically powered rotor with 2
rollers which turn around a center shaft, while pumping a special hose
embedded pumping chamber is squeezed by the action of 2 rollers,

thereby pushing forward the concrete mix inside the hose into the
conveying line vacuum within pump chamber ensures that pumping
hose regains its former cross section immediately behind rollers &
enables the concrete to be sucked in from the feeding hopper at a
high volumetric efficiency

Putzmeister BPF 08/M24

Concrete placing pump & boom
Placing boom

Design

:- M24 boom is constructed in modern

4-arm, zr

fold design trapezoifdal boom pedestal with diagonal support (trd)

provides secure support.

Construction

:- Stable steel boom pedestal takes entire support force.

The boom arms of high quality fine grained steel in box type design. All
the arms are positively & hydraulically operated. The pivot joints with
optimum angle range & slewing gar provide excellent flexibility and slip
characteristics.The extendable diagonal legs at front in conjunction with
rear pump support & axle locking provide necessary stability, support
legs are all hydraulically operated

Putzmeister BPF 08/M24

Concrete placing pump & boom
Concrete pump
Concrete mix
Pumpable concrete of all consistencies to 1slump (k1)with 32 mm
aggregate maximum

Others
A) Water pump

400lc/w 30 bar with 10mtr ho (standard) 100 bar

pump ( optional)
B) Air compressor

10 bar pressure , hydraulically operated

Putzmeister BPF 08/M24

Concrete placing pump & boom
Placing boom

Delivery line
The boom is equipped with a DN 125 ih delivery line. Pipe sections are
connected by clamp couplings. End hose is suitable for operating pressure
of upto 85bar
Boom control module
All boom movements are made by hydraulics and can be carried out
simultaneously .Safety valves mounted directly on arm cylinders serve as
protective device in case of hose rupture and over loading. Hydraulic
control block (mbc) is mounted on boom pedestal and fitted with large
hand levers for emergency operation.

Putzmeister BPF 08/M24

Concrete placing pump & boom
Placing boom
Remote control unit
Portable with 32-pin plug connection. 2 control Levers control all
directions in with the boom Moves. Four movements can be
controlled Simultaneously. Adjustment of boom arm speed from

different operating conditions can be infinitely varied with a

potential meter.

Putzmeister BPF 08/M24

Concrete placing pump & boom
Concrete pump

Max. Theoritical
hr
Concrete output

80cum /

Oil flow in ltr per min

150lpm

Delivery hose diameter

125mm

Maximum oil pressure

280 bar

Max. Theoritical
Concrete pressure

25 bar

Concrete hopper capacity

400ltrs

Putzmeister BPF 08/M24

Concrete placing pump & boom
Placing boom

Horizontalreach from middle of

Slewing unit
Maximum vertical reach
Maximum depth of reac
End hose length
Delivery line diameter
Slewing range
Slewing speed
Maximum support leg force
Working pressure (hydraulic)
Remote control

19.6 mtr
23.2 mtr
14.6mt
4.0mtr
125mm
360 0
0.61 rpm
113 kn
300 bar
24 volts

Putzmeister BPF 08/M24

Concrete placing pump & boom
Arm length

Angle

Arm 1

6.370 mtr

a 110 deg

Arm 2

4.380 mtr

b 180 deg

Arm 3

4.452 mtr

c 245 deg

range

CONCRETE BOOM PLACER

8
9
10
11
12
13
14
15

Change oil in transfer case resp. in switchable

divider gearbox.
Clean hydraulic oil cooler , more frequently in
case of excessive ratio of dust.
Drain condensation water from the hydraulic oil
tank.
Grease propler shaft of the hydraulic pump drive
Grease all placing boom articulations and the
lubricating ponts of the outriggers
Grease the step and collar bearings of the boom
column as well as the sliders of the slewing gear
Lubricate all levers , articulations, etc by means
of oil can with engine oil
Check setting of pressure limit valves respective
hydraulic oil pressures.

o
o
o
o
o
o
o
o

2000 HRS.

1000 HRS.

500 HRS.

Contd
MONTHLY

ACTIVITY

WEEKLY

ITEM

DAILY

Maintenance schedule

16

Check the fastening screws resp. anchor bolts of

the auxillary frame. The placing boom , the
differentioal and the pumping cylinders for tight fit

17

Check fastening of pumping pistons.

18

Visual check for exterior damages

19

Check oil level in agitator gear.

20

Change oil in agitator gear

21

Check the functioning of the control checking ,

safety and emergency devices.

22

Grease all lubricating points of the agitator.

23
24
25

Grease the lubricating points of the Rock Valve

and the slewing cylinder
Check the fastening screws of the Rock Valve
cover for tight fit.
Check the clamping screws of the pivoting body of
the rock valve for tight fit

o
o
o
o
o
o
o
o

2000 HRS.

1000 HRS.

500 HRS.

MONTHLY

ACTIVITY

Contd
WEEKLY

ITEM

DAILY

Maintenance schedule

Maintenance schedule

26

Check the adjusting nut of the Rock Valve pivot

shaft for play in axial direction

27

Check the cutting ring of the Rock Valve

28

Check the setting of the throttle valves.

29

Check the oil level and the contamination in the

flushing containers , change oil if necessary.

2000 HRS.

1000 HRS.

500 HRS.

MONTHLY

ACTIVITY

WEEKLY

ITEM

DAILY

Contd

o
o
o
o

REMARKS
For concrete pumps with flat gate valves the items 23,24,25,26,and 27 are not applicable
The Rock valve pumps the items 28 and 29 are not applicable.

= After first setting into operation