Header Heavy Industry Machinery Co.,Ltd
HBT80DS Dragging Type Concrete Pump Operation Manual
Qingdao Header Heavy Industry Machinery Co.,Ltd
Warning
- Pumping transfer should be forbidden when the voltage is too high ,too low as well as big fluctuate.
- Pumping transfer should be forbidden when the grease box lack of grease.
- Directly pumping transfer should be forbidden when there hasn’t the idling running.
- After finishing pumping transfer work, there must have half an hour’s idle running in order to confirm each point has normal lubricating.
- Checking the piston stroke of transfer container and adjust properly in order to make each point has normal lubricating.
- The person who hasn’t been trained is strictly forbidden to operate concrete pump.
- Please read this operation manual carefully.
HEADER PRODUCT CERTIFICATE
Name / Concrete Transfer PumpType / HBT80DS
Serial No. / 050304DFS46
Checking result / Qualified
Checker / 01
Checking Date / 1st, March, 2005
Qingdao Header Heavy Industry Machinery Co.,Ltd
Before using the equipment, please read the instructions carefully
Content
1. Product Advantages 1
2. Main Technology and Capability Parameter 3 3.The Structure of Concrete Pump 4
(1.) Whole Concrete Pump Structure 4
(2.) Pump Transfer System 5
(3.) Mixing System 6
(4.) Lubrication System 7
(5.) Brace Walking Structure 9
(6.) The Switch Instruction and
Function of Electric Control Cabinet 10
(7.) Hydraulic System 12
4. Operation Safety Notice 14
(1.) Safety Demands for Concrete Pump Operator14
(2.) Safety Notice For Equipment Using 14
(3.) Safety Notice For Equipment Maintenance 15
5. Running and Operation of Concrete Pump17
(1.) Confirm Opening Equipment Condition For Concrete Pump17
(2.) The Start Up and Running For Concrete Pump17
(3.) The Clearance of Concrete Pump18
(4.) Safety Notice For The Concrete Pump Transfer20
(5.) Safety Notice For The Pump Transfer in Winter22
(6.) The Solution For Pipe Block22
(7.) Notice For Concrete Soft Pipe Using 23
6. Equipment Adjustment24
(1.) Accumulator Adjustment24
7. Equipment Maintenance26
(1.) Daily Checking26
(2.) Big、Middle、Small Checking Periodic Table26
(3.) Checking Place and Content26
(4.) Check Record Card For Daily Construction29
8. Normal Malfunction and Solutions30
(1.) The Piston In Main Oil Cylinder
Doesn’t Move 30
(2.) Main Oil Cylinder Doesn’t Change Direction30
(3.) Main Oil Cylinder Moves Slowly30
(4.) Concrete Discharge Pipe doesn’t in good condition 29
(5.) Distribution Valve doesn’t swing 29
(6.) Distribution Valve Disable Change Direction 30
(7.) System Pressure Couldn’t Be
Rose Up or Unstable 30
(8.) Grease Supply Abnormal 30
(9.) Piston rod of Main Oil Cylinder Creeping 30
Attachment Table 1: Big、Middle、Small Checking Periodic Table
Attachment Table 2：Check and Record Card For Daily Construction
A. Product Advantages
HBT80DS Dragging Type Concrete Pump is one of the series of concrete pump transfer machinery product researched and developed by our company, according to Chinese concrete current market, development prospect, many years of machinery manufacture experience. It absorbs advance technologies from home and abroad.
Specializations
1. The product adopts advance hydraulic system, main hydraulic
pump adopts original import German Rexroth Pumps(Large
discharge amount axial plunger swash plate constant power variable
pump)，main pump adopts open oil circuit, constant power control
could realize no level timing and adjustment, according to
construction requirement, adjust discharge amount manually or
adjust discharge amount automatically according to load amount, as
a result, let the power supply be proper used.
2. Hydraulic control valve group adopts the new style valve group developed by our company, original packing Rexroth control valve: lower heat value, but higher efficiency.
3. Pump transfer system adopts S pipe valve, and it changes direction by approaching switch.
4. Hydraulic system fan cooling style, could control the oil temperature in effect.
5. Lubricate system adopts new lubrication method, compares with single lubrication system, it increases two lubricated points, which special used for lubricating the two concrete piston, as a result, the problem of single pump lubrication system could only confirm one concrete piston lubricated would be completely solved.
6. Electrical control system adopts intellectual self-control technology.
7. Protect loop could be cut off when electrical control system comes to malfunction in order to stop the malfunction spread.
8. Good operability, has a wide adaptive range for concrete material.
This product has reliable mechanical ability, good adaptive ability, high working efficiency, low noise, running steadily, convenient operation, compact structure, good irrigate quality. It could be widely used in various projects of concrete constructions, save manpower, material, short working time, release labor intensity, improve construction environment, has high economic, practical and wide market prospect.
B.Mainly Technical Parameter and Capability
Item / Item content and Type / unit / parameterConcrete
Pump / Type / Horizontal Single-acting Double List Hydraulic Piston Type
Discharge Amount(low-pressure/
High-pressure) / m³/h / 73
Theoretic discharge Pressure(low-pressure/
High-pressure) / Mpa / 13
Concrete Distribution Valve / S Valve
Transfer Distance /
150mm
/m
/ Horizontal 1200, vertical 150125mm / m / Horizontal 1000, vertical 130
100mm /
m
/ Horizontal 720, vertical 100Largest Material Size / 150mm / mm / 40
125mm / mm / 30
100mm / mm / 30
Transfer Container Semimeter X Piston Longest Strove / mm / Φ200*1600
Transfer Container Quantity / 2
Hopper Volume / m³ / 0.8
Concrete Slump range / mm / 50~230
Main Power System / Main Electrical Motor / kw / 90
Main Oil Pump German Rexroth / ml/r / 270
Others / Voltage/Frequency / V/Hz / 380/50
Appearance Size /
mm
/ 5900*1988*1750Total Weight / t / 5.6
Hydraulic Oil Box Volume / l / 570
C. The Structure of Concrete Pump
(1.) Complete Structure of Concrete Pump
All parts of concrete pump is driven and controlled by the pressure oil produced from hydraulic pump which driven by electrical motor. It composed of concrete pump transfer system, concrete mixing system, grease system, cooling system and used for installing, bracing each system’s metal structure, car bridge, support leg as well as oriented wheels.
1. Material discharge port 2. Mixing motor 3. hopper 4. Rack 5.Oil box 6. Hood 7. Hydraulic system 8. cooling system
9. tyre 10.Lubrication system 11. Power system 12. Tool box
14.Electrical motor 15. Electrical engineering system 16. Soft startup 17. Support leg 18. Pump transfer system
(2.) Pump Transfer System
(1.)(2.) Main Oil Cylinder (3.) Washing Room (4.) Direction Changing Device (5.)(6.)Concrete Container (7.)(8.) Concrete Piston (9.)Hopper (10.)Distribution Valve (11.)Swing Arm (12.)(13.)Tilt Cylinder Oil Cylinder (14.) Concrete Discharging Port.
Concrete Pump Transfer System is composed of left/right main oil cylinder(see above picture), approaching switch(see above picture), washing room(see above picture), concrete piston, transfer container, S Valve, Hopper etc.
When Pressure oil enter the non-rod chamber, pressure oil of rod end chamber enter left oil cylinder by close oil circuit, meanwhile, bring concrete piston drawing back and produce self-sucking effect. At that time, under the help of hopper mixing vane, concrete in hopper which pass S valve suction port is sucked into transfer container until the stroke of right main oil cylinder piston arrive at terminal. After realizing automatic direction changing by approaching switch, the concrete sucked in left container enter into pump transfer pipe by output port of S valve, finish a suck and transfer process. Because left and right main oil cylinder is continually finishing their own suck and transfer process across, concrete in hopper could be transferred to S pipe output port continuously, and pass the pipe arriving the working point to finish continous pump transfer work.
(3.) Mixing System
Concrete mixing system is composed of mixing direction changing valve group(see below picture), mixing oil motor and mixing vanes installed in the hopper. Its function is: equably mix the concrete in hopper and increase the sucking effect of concrete pump.
During working, if mixing vanes is jammed by material, turn the valve group handle for direction changing, make mixing vanes turn around, when it become normal, recover vanes at positive rotation.
Mixing direction changing valve group(see below picture)is composed of one San Wei Si Tong valve and a stacked discharge valve, operate San Wei Si Tong valve handle could stop all activity of vane of hopper manually.
1. Cut-off valve 2.Pressure reducing valve 3. Manual direction changing valve 4.Stacked discharge valve
(4.) Lubrication System
Lubrication system is compose of power system and manual lubrication.
Manual lubrication is composed of six lubrication points: Material output lubrication point, mixing motor bearing block lubrication point, tilt cylinder spherical surface axletree lubrication point. All of them are lubricated by manual butter.
It is composed of grease box, grease pump, filter, grease distribution valve and the one-way valve of every lubrication, and its main function is lubricate S valve, concrete piston and mix bearing block, reduce the resistance and friction when it moves to avoid leaking material produced by moving parts abrasion
Grease pump suck in grease from grease box, after pressurization, it enter grease distribution valve. Its power comes from pressure oil, and its oil circuit derive from tilt cylinder oil circuit, so the movement of grease pump and tilt cylinder has the same step.
Grease distribution valve(see below picture) takes charge of putting the lubrication oil of grease pump distribute to every lubrication point reasonable.
In order to confirm the lubrication of concrete piston isn’t affected by piston stroke, add water to assist lubrication (the water level couldn’t higher than half of the washing room) in the washing room, the lubrication effect could be improved obviously. Meanwhile, if piston abrasion and there has material leakage phenomenon, it’s easy to observe from the water of washing room.
The effect of lubrication would decide the life of some parts of concrete pump. Idle running before and after pump transfer every time is very important, so we require you do according to below instructions:
Before and after pump transfer every time, the concrete pump must run idle for half an hour in order to keep every lubrication point normal. Remember it is every time!
Check whether the grease box lack of grease frequently!
Especially the idle running after pump transfer, if we don’t carry out this operation, it would lead to early damage for each airproof, S valve, concrete piston, mixing axle early damage, finally leads to leak concrete at every place, lower the working efficiency, and produce malfunction. What’s more, once the concrete bespatter with the piston stick on the main oil cylinder curdled and solidify, it would damage oil cylinder airproof, as a result, there would be oil leakage.
Grease box lack of grease would lead to more serious aftermath.
All of the spare parts damage which produced by disobey operation demands doesn’t belong to warranty range.
(5.)Bearing Walking Mechanism
This structure include underframe, axle(include walking wheel), guide wheel and supporting leg. When truck drags the concrete pump in close distance, should put away guide wheel, supporting leg, the driving speed on secondary road couldn’t more than 15km/h.
When the concrete pump working, the supporting leg would brace the complete equipment, the way put down the supporting leg is just as follows:
1) Operate the lift handle of the guide wheel, make the guide wheel draw back to the upper side, front dragging frame falls, the complete vehicle keeps forward.
2) Put down behind supporting leg, insert supporting leg lock pin well, and fasten the check mechanism of lack pin.
3) Make jockey wheel ejection to downward, front dragging frame, put down front support leg, insert and lock the lock pin well.
4)After finishing all the operation, we must confirm the complete vehicle level almost plate, and confirm the wheels don’t load, finally, draw back the guide wheel.
5)Using opposite operation control guide wheel could draw back the supporting leg.
6)If the earth isn’t plate, set wooden board or hard substance under the supporting leg in order to keep complete vehicle steadily.
(6.)The switch indication electrical parts and function of electrical control cabinet
1. Electrical Motor Startup 2. Electrical Motor Stop 3. Pump Transfer Startup 4. Pump Transfer Stop 5. Distribution Valve Inching 6. Main Cylinder Inching 7.Negative Pump 8. Cooling 9. Power Indication Light 10. Remote Switch 11. Voltmeter.
(1) Main Pump Electrical Motor Button(1,2)
(2) Startup Main Pump Transfer Button(3,4)
After main electrical motor startup, press pump transfer button3 (Green), concrete pump turns to automatic pump transfer status. Press pump transfer stop button4(blue), pump transfer would be stopped.
(3) Distribution Valve Swing Button5
Turn left/right distribution valve inching button5, realize the distribution valve left/right inching by range estimation
(4) Main Cylinder Inching Button6
Turn left/right main cylinder inching button6 could realize main cylinder left/right inching.
(5) Positive/Negative Pump Switch7
When concrete is under positive pump working, turn positive/negative switch7, the pump would turn to negative pump status. Under the positive pump transfer process, once there is blocking up omen, should negative pump 2-3 stroke at once, then turn to positive pump in order to remove the block up phenomenon.
(6) Cooling Electrical Motor Switch8.
Turn right the cooling electrical motor switch8, the cooling electrical motor startup, on the contrary, it stops.
(7) Power Indication Light9
Close the air switch, the power indication light9 on, on the contrary, the light off.
(8) Control Remote Switch10
Set the switch at ”control” position, pump transfer work come to electrical control box operation status, remote control wouldn’t have effect; on the contrary, the control switch on the remote control box has the effect.
(9) Voltmeter
Connect Power supply, close the air switch, the voltmeter indicate the power supply range should be 380±5%.
(10) The switch on the remote control box and its function: insert the cable plug into the electrical remote electrical socket, and tighten the screw cap, set “remote control” select switch at the “control” position, the power indication light on the remote control box turn light, remote control box enter working status. All operation button see below picture.
1. Pump Transfer Indication Light1
Turn “Pump transfer Startup”, indication light on; when the pump transfer stop, the light off
2. Positive and Negative Pump Switch2
When the concrete pump at the positive pump, turn this switch to the negative pump place, it would realize negative pump.
3.Power Supply Indication Light3
After inserting the remote control cable plug into the electrical control box remote control socket, set the “remote control” select switch at “remote control” position, the power supply indication light on.
4. Pump Transfer Stop Switch4
When turn to “pump transfer startup” position, it realizes automatic pump transfer; Turn to “pump transfer stop” position, the pump transfer stop; Release the switch, it could reset automatically.
5. Distribution Valve Inching Switch5
Turn left or right the switch, could realize distribution valve inching, release the switch could reset automatically.
11) Approaching Switch
Approaching switch installed on the the orientation groove of water tank cover, one at left side, the other at right side. When the sensor on the main oil cylinder of sucking stroke running to the effective working area of approaching switch, the approaching switch works, the electronic hydraulic direction changing valve get power supply, and realize automatic direction changing.
Distance between undersurface and sensor should keep at 3-5mm, if the distance is too far, there would have no induction, too near, the sensor may crash the approaching switch .
If the approaching switch is installed at wrong position, and the induction distance is too far, , oil stain pasted the switch bottom or too high water temperature may lead to wrong activity.
(7.)Hydraulic System
1. Hydraulic Pump(See below picture)
2. Collecting Valve Group(See below picture)
3. Voltmeter(See below picture)
Hydraulic Pump Combination Valve lump
1 Main Oil Pump 1. Main Overflow Valve
2.Constant Power Adjustment 2.Main Electronic Hydraulic Direction Changing Valve
3.Hydraulic Stroke Adjustment 3.Stacking Style Pressure Reduce Valve
4.Pressure Cut Off Adjustment 4.Hypo-ElectronicHydraulic Direction Changing Valve 5. Hypo-Overflow Valve
5. Horizontal Pressure Pump
6.Constant Pressure Adjustment
7. Gear Pump
Voltmeter
Reduce Pressure- Mixing Valve Group 1. Pump Transfer Voltmeter
1.Cut-off Overflow Valve 2. Control Voltmeter
2.Pressure Reduce Valve 3. Distribution Voltmeter
3..Manual Direction Changing Valve 4. Mixing Voltmeter
４. Stacking Overflow
1）Main Oil Pump is Axial Piston Pump, this pump installs constant power control device. In constant power district, when the pressure in the concrete pipe get higher, the oblique plate angle of main pump will decrease, confirm the power keep constant value, therefore, the electrical motor wouldn’t out of load, and the power using rate could be improved. This pump also has the additional hydraulic stroke limited and pressure cut off device. By adjust the handle of pressure reduce valve on pressure reduce-mixing valve group to control the pressure between 0.5-3.0Mpa. Pay attention: When adjust the output pressure of pressure reducing valve, make the pressure not more than 4Mpa, otherwise, the main oil pump would be damage. Normally, don’t touch the pressure reducing valve!
2) Constant Pressure Pump