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HG33



HG33
CONCRETE PLACING BOOM
OPERATION MANUAL
PREFACE
HG33 CONCRETE PLACING BOOM OPERATION MANUAL

Preface
This Operation Manual, attached with hydraulic and electrical basic diagrams, introduces
in detail the technical features of HG33 concrete placing boom, operation illustration of the
complete machine and major parts, and safety precautions during operation.
Before equipment operation, please read this Operation Manual carefully and familiarize
yourself with all the content. Only after completely understanding the Operation Manual,
can you operate the machine skillfully and safely. This will help you:
- To get a better understanding of the structure and performance of the concrete
placing boom;
- To avoid the danger and machine malfunction due to improper operation;
- To increase the reliability in operation of the concrete placing boom;
- To prolong the service life of the concrete placing boom;
- To reduce the maintenance cost and stoppage time.
The operation and safety are inseparable, and the safety precautions in this Operation
Manual are only a part of safe operation. For more details about safety precautions, please
carefully read the Safety Manual matching with this Operation Manual.
Failure to follow the Operation Manual and Safety Manual for operation or carelessness of
operators and on-site operating personnel will cause casualties and serious damage of
concrete placing boom and property. Therefore, the operators and owners should attach
great importance to the safety issue.
For the modification due to the improvement and updating of products, some details or
instructions shown in the Operation Manual may differ from your machine. For any
question on the machine or the Operation Manual, contact SANY Heavy Industry Co., Ltd.
through 24-hour service hotline (0086-21-60303131) for service support.
Please put it within your reach for reference at any time.

SANY Heavy Industry Co., Ltd.

Please carefully read this Manual,


and operate the concrete placing boom based on
full understanding of all the content.

I
READING GUIDANCE
HG33 CONCRETE PLACING BOOM OPERATION MANUAL

Reading Guidance

The Operation Manual is provided as a guide to operate the machine properly, covering the technical
instructions of complete machine, equipment start, parts operation and safety precautions, as well as
equipment cleaning and moving, etc.
1. Technical Instructions
This part introduces the composition of complete machine, technical features, technical parameters,
etc., and then introduces the structures and working principles in terms of the mechanical, hydraulic and
electrical systems.
2. Equipment Start
This part introduces the operation method for starting the concrete placing boom.
3. Boom Operation
This part introduces the safety precautions related to boom and the operation methods for boom
unfolding and folding.
4. Other Operations
This part introduces the pumping operation, cleaning of concrete placing boom and jacking operation.
5. Annex
The annex includes the hydraulic and electrical basic diagrams.

Explanation of Signs:

This is a sign of “Caution”.


When you see this sign on the machine or in this Operation Manual, it indicates the possible injury of
personnel or property damage. It is a prohibition.
Please obey the precautions and methods suggested for the safe operation.

On the sign boards, the is used together with such words that mean hazard as “Danger”,
“Warning” and “Caution”.

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READING GUIDANCE
HG33 CONCRETE PLACING BOOM OPERATION MANUAL

Danger

Be vigilant on serious danger! It means an immediate danger, which may cause death or serious injury if
no preventive measure is taken.

Warning

Be vigilant on medium danger! It means a potential danger, which may cause serious injury if no preventive
measure is taken.

Caution

Pay close attention to slight danger! It means a potential danger, which may cause slight or moderate
injury if no preventive measure is taken.
The sign of “Danger” or “Warning” should be established nearby the place where the special hazard is
easy to occur, while the general precautions should be listed on the sign of “Caution” for calling attention to
the safety indication.

PROMPT

It is used to give additional instructions to some specific information.

It indicates the current operation fails to comply with the safety regulations and it is easy to cause casualty
accident, so it should be forbidden.

It indicates the current operation complies with the safety regulations.

III
CONTENTS
HG33 CONCRETE PLACING BOOM OPERATION MANUAL

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CONTENTS
HG33 CONCRETE PLACING BOOM OPERATION MANUAL

Contents

Instructionss …………………………………………………………………………………… 1
1 Technical Instruction
1.1 Basic Structure …………………………………………………………………………………………………1
1.2 Main Features ……………………………………………………………………………………………… 3
1.3 Technical Parameters …………………………………………………………………………………………5
1.4 Mechanical Parts ………………………………………………………………………………………………7
1.5 Hydraulic Control Equipment ………………………………………………………………………………10
1.6 Electrical Control Device………………………………………………………………………………………11

2. Equipment Start……………………………………………………………………………………… 17
2.1 Preparation for Start……………………………………………………………………………………………17
2.2 Motor Start………………………………………………………………………………………………………19

3. Boom Operation……………………………………………………………………………………………21
3.1 Safety Precautions……………………………………………………………………………………………21
3.2 Boom Operation……………………………………………………………………………………………… 26
3.3 Remote Control of Boom Electromagnetic Valve……………………………………………………………27

4. Other Operations……………………………………………………………………………………………35
4.1 Pumping Operation……………………………………………………………………………………………35
4.2 Cleaning of Concrete Placing Boom…………………………………………………………………………37
4.3 Jacking Operation of Concrete Placing Boom………………………………………………………………38

5. Appendix ………………………………………………………………………………………………………41
5.1 Hydraulic Basic Diagram ………………………………………………………………………………………41
5.2 Electrical Basic Diagram ………………………………………………………………………………………42

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HG33 CONCRETE PLACING BOOM OPERATION MANUAL

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TECHNICAL INSTRUCTIONS
HG33 CONCRETE PLACING BOOM OPERATION MANUAL

1 Technical Instructions

This chapter introduces the structure and main


technical parameters of the placing boom and the
hydraulic and control devices.

1.1 Basic Structure


There are many types of concrete placing booms,
and the installation modes include floor type,
elevator shaft type, wall type, tower type and ship-
mounted type.
HG33 concrete placing boom is a floor type placing
boom, and mainly consists of boom, assembling
parts of turntable, slewing mechanism, fixed
revolving tower, pillar, delivery pipeline, hydraulic
system, electrical system and climbing system, etc.
(see Fig. 1-1).

5 4 2
6

3
1

1. Boom 2. Assembling parts of turntable 3. Slewing mechanism 4. Fixed revolving tower


5. Electrical system 6. Hydraulic system 7. Climbing system 8. Pillar 9. Delivery pipeline
Fig. 1-1 General Drawing of HG33 Concrete Placing Boom

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TECHNICAL INSTRUCTIONS
HG33 CONCRETE PLACING BOOM OPERATION MANUAL

(1) Boom
The boom is made up of multi-section
boom,linkage, cylinder, etc. It is foldable and
dividable.

(2) Assembling parts of turntable


The assembling parts of turntable is made up
of turntable, boom shaft, cylinder connecting
shaft, rubber hose plinth, etc.

(3) Slewing mechanism


The slewing mechanism is made up of slewing
bearing, gear, reducer assembly, etc.

(4) Fixed revolving tower


The fixed revolving tower is formed by welding
the stiffening plate, backup plate, supporting
plate, short tube, web-plate, side plate and
flange ring together.

(5) Electrical system


The electrical system is mainly made up of
control cabinet, remote controller and other
electrical elements.

(6) Hydraulic system


The hydraulic system is divided into climbing
hydraulic system and boom operation hydraulic
system, and mainly made up of hydraulic
pump, multi-way valve, cylinder and other
hydraulic elements.

(7) Climbing system


The climbing system is made up of climbing
frame and jacking cylinder. The climbing frame
is of a 4-removable-block structure to improve
its installability and removability.

(8) Pillar
The pillar includes three parts: upper pillar,
middle pillar and lower pillar. Each pillar is
about 6 m long, with a square column
structure.

(9) Delivery pipeline


The delivery pipeline includes standard straight
pipe, adapter pipe and elbow, and is easy to be
replaced.

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TECHNICAL INSTRUCTIONS
HG33 CONCRETE PLACING BOOM OPERATION MANUAL

1.2 Main Features

SANY placing boom has such advantages as


reasonable placing radius, durable pipeline, quick
installation, cost effectiveness and safe & reliable
quality by full hydraulic control technology, wear
resistance technology, PLC control and other
advanced technologies.

(1) Design and manufacturing technology of boom


SANY placing boom shares the mature design
technology of SANY truck-mounted concrete pump
boom. The adoption of such advanced design
philosophies as finite elements analysis, dynamic
simulation analysis, model analysis and dynamic
response analysis and fatigue test effectively
lowers the peak stress of boom, so as to extend its
service life and improve its reliability. According to
the installation conditions, two types of boom,
namely, integral type and separate type, are
available.

(2) More varieties and installation modes


The complete range of SANY placing booms
can meet the requirements for small, medium
and large placing radius ranging from 15m,
18m, 20m, 24m, 28m, 33m, 39m to 41m. By
installation mode, the placing booms are
classified as floor type, elevator shaft type,
wall type, tower type, ship-mounted type,
integral type, high-speed-railway type, etc.

(3) Full hydraulic control technology


With the adoption of full hydraulic control
technology, the boom operation can be adjusted
steplessly; with adoption of proportional control
system with pressure compensation and load
sensing, the operating speed of boom can be
changed at will by adjusting the angle of control
lever, with outstanding operating performance.

(4) Intelligent electrical control system


With famous German Siemens PLC programmable
controller which is provided with manual control,
cable control, 100-m remote control and four
optional frequency ranges, simple, convenient and
reliable operation can be achieved.

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TECHNICAL INSTRUCTIONS
HG33 CONCRETE PLACING BOOM OPERATION MANUAL

(5) Telescopic support technology


The adoption of different telescopic supports
makes the floor type placing boom be installed in
the elevator shaft as well.

(6) Portability of climbing equipment


The climbing frame is of a split structure, which
improves efficiency and reduces labor intensity,
and is safe and reliable.

(7) Boom cylinder controlled by balance valve


The balance valve control can provide precise
placing and self-locking of boom to effectively
prevent the boom from accidental drop, ensuring
safety and reliability.

(8) Wear resistance technology of durable delivery


pipe
Through careful selection and tests, with adoption
of special materials with substantially increased
hardness and strength and patented heat
treatment technology, the service life of the
delivery pipe is increased by more than 2 times of
that of ordinary delivery pipe in case of same wall
thickness and similar concrete properties.

(9) Quick installation technology


The wide adoption of modularization design
technology and quick connection device quickens
and facilitates the installation and lifting of the
concrete placing boom.

(10) Lighter weight of the total machine


The total weight of the machine will be more
lighter, without no matched weight, and the lifting
weight will be lighter which is no more than 4.2t.

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TECHNICAL INSTRUCTIONS
HG33 CONCRETE PLACING BOOM OPERATION MANUAL

1.3 Technical Parameters

1.3.1 Parameters Table of Concrete Placing Boom(see Table 1-1).

Table 1-1 Parameters of Floor Type Concrete Placing Boom

Technical Data of SANY HG33 Concrete Placing Boom


Model H G 3 3
Maximum placing radius m 33
o
Boom rotation 365
Tower height m 20
Performance Installation mode - Floor
Climbing speed m/min 0.5~0.8
Climbing mode - Cylinder jack-up type
Working ambient temperature ℃ -10~45
Motor model - Y160L-4,IMB35,IP55
Electrical system Power kW 15
Rotation speed r/min 1460
System pressure MPa 32
Hydraulic system Flow I/min 23.5
Oil tank capacity L 180
Control mode - Manual/Cable/Remote control
Delivery pipe cleaning mode - Wet cleaning/Dry cleaning
Gross weight kg 17300
Type - Four-section Z type arm
Pipeline size mm DN125
End hose length m 3
Length Mm 9050
Arm 1 o
Articulation 92
Boom Length Mm 7900
Arm 2 o
Articulation 180
Length Mm 7950
Arm 3 o
Articulation 241
Length Mm 7960
Arm 4 o
Articulation 235

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TECHNICAL INSTRUCTIONS
HG33 CONCRETE PLACING BOOM OPERATION MANUAL

1.3.2 Placing Range of Concrete Placing Boom


(see Fig. 1-2)

180

3m
92

365

241

235

Fig. 1-2 Placing Range of HG33 Concrete Placing Boom

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TECHNICAL INSTRUCTIONS
HG33 CONCRETE PLACING BOOM OPERATION MANUAL

1.4 Mechanical Parts


1.4.1 Boom System
The boom system is used for concrete delivery and
placing.
The boom system is mainly composed of a plane
four-linkage mechanism hinged by multi-section
boom, linkage, cylinder and connecting pieces,
which can be folded and unfolded, and delivers
concrete to the specified position at the end of
boom, pouring point (see Fig.1-3), by the extension
or retraction of boom cylinder and rotation of
turntable and through the delivery pipe on the
boom.

11 14
2 3
4
13
6 12
5
8
10

9 15
1

1. Cylinder of arm 1 2. Arm 1 3. Articulation shaft 4. Linkage I 5. Cylinder of arm 2


6. Linkage II 7. Arm 2 8. Cylinder of arm 3 9. Linkage III 10. Linkage IV
11. Arm 3 12. Cylinder of arm 4 13. Linkage V 14. Linkage VI 15. Arm 4
Fig. 1-3 Diagram of Boom of 28-meter Concrete Placing Boom

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TECHNICAL INSTRUCTIONS
HG33 CONCRETE PLACING BOOM OPERATION MANUAL

1.4.2 Revolving Tower

The revolving tower of floor type concrete placing


boom is composed of assembling part of turntable,
slewing mechanism and fixed revolving tower (see
Fig.1-4).
The turntable is connected with counterweight
assembly and boom respectively, with its lower
part linked with slewing bearing by high-intensity
bolts. The slewing bearing supporting the tilting 1
moment generated by the boom is the key part that
affects the safety of the complete machine. The
slewing bearing is of an internationally well-known
brand. The hydraulic motor drives the turntable and 2
boom to rotate for 365° through the reducer.

1. Turntable 2. Slewing mechanism


3. Fixed revolving tower
Fig. 1-4 Revolving Tower

1.4.3 Climbing System

The climbing system is composed of climbing


frame, pillar and jacking cylinder. The climbing
frame is fixed on the floor with floor-through bolts.
The jacking cylinder is placed in the climbing 1
frame, with the upper part supporting the cross pin
crossing the steel tube of pillar. Every time the
cylinder stretches out, it can jack up the placing
boom by 750 mm. Keep jacking up until the height 2
is desirable (see Fig.1-5).

1. Pillar 2. Jacking cylinder 3. Climbing frame


Fig. 1-5 Climbing System

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TECHNICAL INSTRUCTIONS
HG33 CONCRETE PLACING BOOM OPERATION MANUAL

1.4.4 Piping of Concrete Placing Boom


The piping of concrete placing boom is composed of
a series of elbows, straight pipes, pipe clamps and
delivery pipe supports (see Fig. 1-6).
(1) The delivery pipe is at the side of boom, with its Clamp Seal body
length matched with that of the boom. For each arm,
several sections of straight pipes are set in the
middle and a 90° elbow is set at each of the two
ends. The two elbows can rotate separately. The 90° Delivery pipe Delivery pipe
elbow connecting two adjacent arms can rotate
around the axis of the articulating shaft of the two
arms so that the delivery pipe may rotate with the 3
boom rotation. Since the boom bears the weight of
delivery pipe, impact and eccentric moment, it is not
allowed to increase the thickness and outer diameter
of the delivery pipe, otherwise the service life of the
boom would be reduced and the stability of the
concrete placing boom would be also affected.
(2) Since the straight pipes and elbows are fixed in
different places, the impact and wear that different
Fig.1-6 Connection of Delivery Pipe
delivery pipes suffer are not same. Normally, the
wear of elbows is larger than that of straight pipes.
The closer to the boom end the delivery pipe is, the
less the wear it suffers will be. As an exception, the
penultimate elbow suffers the greatest wear,
because apart from normal wear, it suffers the
gravitational impact of falling concrete as well.
Therefore, the delivery pipe wall thickness and wear
resistant measures should be selected according to
the degree of wear. Try to ensure all delivery pipes
in one complete set are of a same service life.
(3) In case of ordinary concrete delivery, after
pumping 4000 to 5000 cubic meters of concrete.
Release the U-bolts fixing the delivery pipe and pipe
clamps by a half respectively, and then use rotary
tools to rotate the delivery pipe by 120° to 150°. In
case of special concrete delivery, the concrete
volume pumped during rotation should be adjusted
according to requirements so as to ensure even
wear of the delivery pipes and prolong the service
life.
(4) The delivery pipe should be fixed while the
boom is not under tension, e.g. all arms are placed
flatly freely and well supported; or all arms are are
supported but not folded; or the boom is folded and
placed on the support. Otherwise the delivery pipe
may be stressed, which would damage the pipe
support and boom. In the process of pumping, the
end hose may vibrate seriously and even escape
out.

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TECHNICAL INSTRUCTIONS
HG33 CONCRETE PLACING BOOM OPERATION MANUAL

1.5 Hydraulic Control Equipment

The boom electromagnetic valve is on the oil tank


(see Fig.1-7).

1 2 3 4 5 6 7 8

1. Bypass valve 2. Climbing electromagnetic valve 3. Rotation electromagnetic valve


4. Electromagnetic valve of arm 1 5. Electromagnetic valve of arm 2
6. Electromagnetic valve of arm 3 7. Electromagnetic valve of arm 4 8. Pressure gauge
Fig.1-7

Caution

The boom electromagnetic valve is a kind of


electro proportional control valve, and is
normally operated by remote control, while
the handle operation is only for emergency.
The electromagnetic valve's current
determines the control speed and the
stability of start.

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TECHNICAL INSTRUCTIONS
HG33 CONCRETE PLACING BOOM OPERATION MANUAL

1.6 Electrical Control Device


The electric control device is configured with
operation panel of electric control cabinet,
elements of electric control cabinet and remote
control system.
1.6.1 Operation panel of electric control cabinet
(see Fig. 1-8)

5 6
2

1. Voltmeter (displaying the supply voltage of power grid) 2. Emergency stop


3. Motor start 4. Motor stop
5. Amperemeter (displaying the operating current of motor) 6. Remote control/local control

Fig.1-8 Operation Panel of Electric Control Cabinet of Concrete Placing Boom

Caution

The switches on the operation panel are


mainly responsible for motor start, motor
stop as well as remote/local control
switchover and emergency stop, the
voltmeter is for showing voltage and the
amperemeter is for showing current.

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TECHNICAL INSTRUCTIONS
HG33 CONCRETE PLACING BOOM OPERATION MANUAL

1.6.2 Elements of Electric Control Cabinet


The elements of electric control cabinet are inside
the cabinet as follows (see Fig.1-9):

12 1 7

10

4
6

8
2

11 9 3

1. Rectification bridge 2. Voltage Meter 3. Circuit breaker 4. Transformer 5. CPU


6. Transformer 7. Reed relay 8. Thermal relay 9. Print board 10. Reed relay 11. contactor 12. Fuse
Fig.1-9

Caution

The cabinet is mainly used for installing the


electric appliance elements required by the
concrete placing boom in order to facilitate
the centralized wiring and maintenance and
provide high protection level. When
checking and replacing the elements, it is
necessary to cut off the main power supply
and reset various functional switches.

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TECHNICAL INSTRUCTIONS
HG33 CONCRETE PLACING BOOM OPERATION MANUAL

1.6.3 Remote Control System


The remote control receiver is installed in the side
of electric control cabinet. The descriptions on the
symbols on the operation panel are as follows (see
Fig.1-10).

12

13
15

11

14
1 2 3 4 5 6 7 8 9 10

16 17

1. Boom rotation (outwards: left rotation; inwards: right rotation) 2. Motor stop
3. Arm 1 (outwards: unfold; inwards: fold) 4. Heater preheating
5. Arm 2 (outwards: unfold; inwards: fold) 6. Motor start 7. Button for electric horn
8. Arm 3 (outwards: unfold; inwards: fold) 9. Frequency band selection
10. Fast / slow action of boom (outwards: fast; inwards: slow) 11. Arm 4 (outwards: unfold; inwards: fold)
12. Arm 5 (outwards: unfold; inwards: fold) 13. Operating indicator lamp for remote controller
14. Remote control receiver 15. Transmitting antenna
16. Remote controller power supply 17. Emergency stop
Fig.1-10

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TECHNICAL INSTRUCTIONS
HG33 CONCRETE PLACING BOOM OPERATION MANUAL

Caution

When the local control/remote control switch


on the operation panel is set at the position
for remote control, the remote controller can
achieve various functional operations.
Switch off the remote control power supply
when replacing the battery.

PROMPT

It is prohibited to flush the electric control


cabinet body and electric appliance elements
with water or expose them to water.

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HG33 CONCRETE PLACING BOOM OPERATION MANUAL

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HG33 CONCRETE PLACING BOOM OPERATION MANUAL

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EQUIPMENT START
HG33 CONCRETE PLACING BOOM OPERATION MANUAL

2 Equipment Start

2.1 Preparation for Start

(1) Before startup, check whether the hydraulic oil


level is proper, and then turn on the cut-off valve
switch at the oil inlet of oil tank (see Fig. 2-1).

2
3

1. Upper oil level in oil tank 2. Lower oil level in oil tank after boom is fully unfolded
3. Turn on the cut-off valve switch at the oil inlet of oil tank.
Fig. 2-1

(2) Open the main air switch, and confirm the


value displayed by the voltmeter on electric control
cabinet is within 380 V ± 20 V (see Fig. 2-2).

1. Turn on the main air switch before commissioning. 2. The normal value displayed by the voltmeter is
within 380V±20V.
Fig. 2-2

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EQUIPMENT START
HG33 CONCRETE PLACING BOOM OPERATION MANUAL

3) Shift the remote control/local control switch to


the position for local control for the first
commissioning.

Remote control/local control switch, which should


be shifted to the position for local control for
commissioning (left rotation) (see Fig. 2-3).

Knob switch

Fig. 2-3

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EQUIPMENT START
HG33 CONCRETE PLACING BOOM OPERATION MANUAL

2.2 Motor Start


Start the motor by pressing the start button, and
check the rotation direction of the motor (the same
as that indicated by the arrow). If the direction is
incorrect, change any two phases in the three-
phase line of the motor to alter the direction.
During the start of the motor, a Y-△ switchover
lasting for 6 s is performed. In case of any
abnormal sound or phenomenon, press the
emergency stopping button at once. The motor
should be started again only after troubleshooting.

(1) Emergency stopping button (red);


(2) Motor start button (green);
(3) Motor stop button (red);
(4) Amperemeter displays properly: the starting
current is below 260A and the operating current
below 80A.

2 4 1 3

Fig. 2-4

(1) Viewed from the shaft extension end, the


rotation direction of the motor is clockwise.

Fig. 2-5

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HG33 CONCRETE PLACING BOOM OPERATION MANUAL

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BOOM OPERATION
HG33 CONCRETE PLACING BOOM OPERATION MANUAL

3 Boom Operation

3.1 Safety Precautions

(1) Only after affirming the concrete placing boom


has been assembled properly, can the boom be
operated. The boom must be operated in the order
described in the operation instructions.

(2) Don’t unfold the boom in thunder storm or bad


weather;

(3) Don’t use the boom when the wind velocity


exceeds Grade 6 (13.8 m/s).

(4) The concrete placing boom is an equipment for


pumping the concrete of a density less than 2400
kg/m3 and can't be used for other purposes such
as transportation and lifting (see Fig. 3-1).

Fig. 3-1
(5) When operating the concrete placing boom
nearby electric wires, be careful and keep a proper
distance from the electric wires (see Fig. 3-2 and
Table 3-1); otherwise, it will be fatal for all
personnel working on or nearby the concrete
placing boom and the devices connected with it
(remote control device, end hose, etc.). In case of
high-tension sparks, a “ high-tension funneled
area” will be formed under and around the
equipment

It is prohibited to work near high-tension wires.

Fig. 3-2

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BOOM OPERATION
HG33 CONCRETE PLACING BOOM OPERATION MANUAL

Table 3-1

Voltage (kV) Minimum Distance (m)

0~1 1.5
1~100 3.5
100~200 4.5
200~300 5.5
>300 0.01(U-50)+3

(6) If you span different voltage belts (step


voltage), the current resulting from potential
difference may flow through your body (see Fig. 3-
3).

Fig. 3-3

(7) Before operating the boom, check whether


there is any obstacle around to prevent the boom
from colliding with buildings or other obstacles.
When the operator can't see the whole working
area or correctly identify the distance between the
extended part of the concrete placing boom and
the adjacent object due to his position, a signaler
should be assigned to command. All the
movements of the boom must be within the visual
field of the signaler (see Fig. 3-4).

Fig. 3-4

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BOOM OPERATION
HG33 CONCRETE PLACING BOOM OPERATION MANUAL

(8) When the boom is being unfolded, no person


should stand under the boom (see Fig. 3-5).

Fig. 3-5

(9) For any abnormity of boom, the operator must


press the emergency stopping button at once for
diagnosis and troubleshooting by professional
maintenance personnel.

(10) In case of bad wether such as gale, storm and


lightning, stop pumping and fold the boom (see
Fig. 3-6).

Fig. 3-6

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BOOM OPERATION
HG33 CONCRETE PLACING BOOM OPERATION MANUAL

(11) Don't rotate the boom over or behind the


concrete placing boom for concrete placing (see
Fig. 3-7).

Prohibited area
for placing

Fig. 3-7

(12) It is prohibited to climb by taking the boom as


a platform or auxiliary device (see Fig. 3-8).

Fig. 3-8

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BOOM OPERATION
HG33 CONCRETE PLACING BOOM OPERATION MANUAL

(13) Take care to avoid overlap of working areas of


the concrete placing boom and other large
equipment such as crane and other placing
booms (see Fig. 3-9 and Fig. 3 -10).

Fig. 3-9

Fig. 3-10

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BOOM OPERATION
HG33 CONCRETE PLACING BOOM OPERATION MANUAL

3-2 Local Control Operation of Boom


Electromagnetic Valve
Operate the handle of boom electromagnetic valve
to fold, unfold or rotate the boom and pay attention
to the pressure. If the pressure is not enough,
adjust the pressures of multi-way valve and
balance valve as required.
Multi-way valve arm 1-way, arm 2-way, arm 3-way
and arm 4-way pressure gauges' readings: below
34±1 MPa;
Rotation-way pressure gauge's reading: below 15
MPa;
Climbing-way pressure gauge’s reading: below 25
MPa.

Unfold

Fold

1 2 3 4 5 6

1.Climbing 2.Rotation 3.Arm 1 4.Arm 2 5.Arm 3 6.Arm 4


Fig. 3-11

1.Boom-way, outrigger-way and rotation-way pressure gauges


Fig. 3-12

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BOOM OPERATION
HG33 CONCRETE PLACING BOOM OPERATION MANUAL

3-3 Remote Control of Boom


Electromagnetic Valve

3.3.1 After the commissioning under local control


mode, shift the remote control/local control switch
to the position for remote control and then start the
remote controller to control the concrete placing
boom.
(1) Remote control/local control switch, which
should be shifted to the position for remote control
for commissioning (right rotation).

(2) Remote receiver

1
2

Fig. 3-13

Under the remote control mode, when the remote


receiver is energized normally (the key switch of
transmitting system is off), seen from the display
window at the top of the receiving system, only a
yellow indicator lamp and a red indicator lamp are
on.

1 2 3 4

1. Red indicator lamp 2. Yellow indicator lamp


3. Green indicator lamp 4. Green indicator lamp
Fig. 3-14 Remote receiver
Caution

The hydraulic valve group should be


adjusted by professional personnel but not
ordinary people.

27
BOOM OPERATION
HG33 CONCRETE PLACING BOOM OPERATION MANUAL

(1) Turn the key switch to position “1”.

Fig. 3-15

(2) Turn the emergency stopping button to release


it. 2

Fig. 3-16

(3) When this button for electric horn is pressed


down, the horn sound from the concrete placing 3
boom means that the receiving system is under
control.

Fig. 3-17 Remote Transmitter


After turning on the key switch of transmitting
system (and pulling up the red emergency
stopping button of transmitting system), the
indicator lamps on the transmitting system will
flash quickly (frequency sweeping). After several
seconds, the indicator lamps will flash regularly,
and the yellow and red indicator lamps on the
receiving system will go out and the green
indicator lamp will go on, (at this time, if you are at
the side of the receiving system, you will hear the
sound of relay being closed in the receiving
system) and the remote control system is started.

28
BOOM OPERATION
HG33 CONCRETE PLACING BOOM OPERATION MANUAL

1 2 3 4 5

6 7 8 9 10 11

1. Rotation 2. Arm 1 3. Arm 2 4. Arm 3 5. Arm 4 6. Motor stop


7. Preheating 8. Motor start 9. Button for horn 10. Frequency band selection 11. Fast/slow
action
Fig. 3-18

PROMPT

=When the remote controller is in operation,


push the rocker outwards, and the
corresponding arm will be unfolded; while
push the rocker inwards, and the
corresponding arm will be folded.
=The remote controller can be locked
automatically in case of same frequency
interference. At this time, the action of
boom will stop. Only after the operator
turns on the key switch, presses the start
button and reselects the frequency band,
can the remote controller operates again.
=When the red indicator lamp of the remote
transmitter flashes, it means insufficient
power supply. The battery should be
replaced.

29
BOOM OPERATION
HG33 CONCRETE PLACING BOOM OPERATION MANUAL

3.3.2 Unfolding of Boom


Unfolding of Arm 1 (see the figures)
1

(1) The boom incline upwards about 85° when arm


1 is unfolded;

85
Fig. 3-19

(2) Remote control: pull the second button


upwards;
2

Fig. 3-20

(3) Local control: pull the third handle upwards.


3

Fig. 3-21

Do not pull all the buttons to the limit position


directly. Pull the handle slowly to the maximum
position.

30
BOOM OPERATION
HG33 CONCRETE PLACING BOOM OPERATION MANUAL

Do not pull all the buttons to the limit position


directly. Pull the handle slowly to the maximum
position.

Unfolding of Arm 2 (see the figures)


(1) Unfold the arm 2 to be horizontal before the
1
unfolding of arm 3.

Fig. 3-22

(2) Remote control: pull the third button upwards;


2

Fig. 3-23

(3) Local control: pull the fourth handle upwards.

Fig. 3-24

31
BOOM OPERATION
HG33 CONCRETE PLACING BOOM OPERATION MANUAL

Unfolding of Arm 3 (see the figures)


(1) Unfold the arm 3 to be horizontal before the 1
unfolding of arm 4.

Fig. 3-25

Unfold arm 4, and then put down the root hose

(1) Pull this handle downwards to put down the


root hose.

Fig. 3-26

32
BOOM OPERATION
HG33 CONCRETE PLACING BOOM OPERATION MANUAL

Rotation of Boom (see the figures)

Fig. 3-27

(1) Remote control: pull the first button upwards; 1

Fig. 3-28

(2) Local control: pull the second handle upwards.


2

Fig. 3-29

33
HG33 CONCRETE PLACING BOOM OPERATION MANUAL

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OTHER OPERATIONS
HG33 CONCRETE PLACING BOOM OPERATION MANUAL

4. Other Operations

4.1 Pumping Operation

The delivery pipe of the concrete placing boom


should be lubricated prior to putting the concrete
placing boom into service, with the process as
follows:
(1) Before pumping concrete, fill the hopper in the
stationary concrete pump or line pump with water
and carry out forward pumping to lubricate the
pipeline until there is water coming out from the
root hose of the concrete placing boom, and then
open the discharging door of the hopper and carry
out reverse pumping to draw the water in pipeline
back to the hopper;

(2) Add an appropriate amount of mortar


(proportion: cement: sand=1:2; quantity and
requirement: 500 kg of cement, 1000 kg of sand,
and the mortar is required to be dense) to carry out
forward pumping. The quantity of cement mortar
can be determined by experience. Normally,
3
pipeline of 10m requires cement mortar of 0.05 m .
Caution: Do not pump the mortar before the
concrete is in place.

(3) After pumping mortar, pump concrete


immediately. And then the concrete placing boom
can start working.

PROMPT

For the first use of concrete placing boom,


pumping with water is needed. However, for
the later use, only pumping with mortar is
needed.

35
OTHER OPERATIONS
HG33 CONCRETE PLACING BOOM OPERATION MANUAL

PROMPT

Causes of concrete segregation:


- Too small concrete viscosity
- Insufficient slurry mixing
- Gap between S-valve and glasses plate
due to wear
- Pipeline leakage
- Concrete hardening in S-valve and
pipeline
- Improper mix proportion
- Improper specifications of slurry, less sand
or slight concrete hardening during mixing

4.4.1 After Pumping

After pumping, mount and fix the root hose, retract


and fold the boom with an upward angle about 85°
(see the following figure).

85

Fig. 4-1

36
OTHER OPERATIONS
HG33 CONCRETE PLACING BOOM OPERATION MANUAL

4.2 Cleaning of Concrete Placing Boom

After pumping, it is necessary to clean out the


concrete inside the pipeline as the remaining
concrete would coagulate and block the pipe.

(1) After pumping, fully unfold the boom of the


concrete placing boom, with an upward angle of
45°. Open the discharge outlet of hopper in the
stationary concrete pump or line pump to
discharge the remains completely!

(2) Start reverse pumping for pressure relief and


then open the variable diameter pipe to clean the
hopper with a water gun.

(3) Insert one or more sponge(s) into the variable


diameter pipe.

(4) Close the discharging door of stationary


concrete pump or line pump and mount the
Fig. 4-2
variable diameter pipe well.

(5) Add water into the hopper of stationary


concrete pump or line pump and ensure the water
supply is enough.

(6) Adjust the concrete output to the maximum


and start forward pumping.

(7) To avoid air pumping, connect the water


supply to the hopper until the sponge(s) is(are)
pumped out from the end hose of the concrete
placing boom.

37
OTHER OPERATIONS
HG33 CONCRETE PLACING BOOM OPERATION MANUAL

4.3 Jacking Operation of Concrete


Placing Boom

Once the effective height (extended height) of the


concrete placing boom cannot meet the
requirements of concrete placing, it is time to jack
up the concrete placing boom.

(1) Preparation for Jacking


To jack up the concrete placing boom, the boom
should be folded and horizontal, and the slewing
mechanism should be braked. Before jacking,
check and confirm the verticalities of the pillar and
the climbing frame are not more than 0.5°.
During jacking, a person should be assigned
specially for the operation with careful observation.
After every step, careful examination should be
done before the next step of operation.
When the placing boom is jacked up, the wind
velocity should not be more than Grade 4.
For every time of jacking, take care to avoid
damaging cables and hydrualic rubber hoses and
causing accident. Check each connector for
looseness and leakage.

(2) Jacking of Pillar


Step 1: Install the jacking cylinder, protection
devices and cross pins, and then guide the
operation box from the electric control cabinet to
the floor where the jacking cylinder is;
Step 2: Jack up the pillar until the cylinder is under
stress, and loosen the wedge with a hammer, and
then continue to jack up the pillar until the cylinder
completes one stroke;
Step 3: Insert a cross pin at the lower part of the
jacking cylinder;
Step 4: Compress the jacking cylinder to the
minimum length;
Step 5: Move the cross pin from the previous pin
hole to the next hole;
Step 6: Jack up the pillar for 30 mm, draw out the
cross pin at the lower part of the jacking cylinder,
and then continue to jack up the pillar until the
cylinder completes one stroke. Repeat the above
process until the concrete placing boom reaches
the required height. Finally, tighten the wedge of
the climbing frame.

38
OTHER OPERATIONS
HG33 CONCRETE PLACING BOOM OPERATION MANUAL

Cross pin

Jacking cylinder

Protection device

Step 1 Step 2 Step3

Step 4 Step 5 Step6

Fig. 4-3

39
OTHER OPERATIONS
HG33 CONCRETE PLACING BOOM OPERATION MANUAL

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5 APPENDIX
5.1 Hydraulic Basic Diagram

Fig.5-1 Basic diagram of hydraulic system


Jack-up Jack-up
oil cylinder oil cylinder

1.Ball valve 2.Boom pump 3.Oil filter 4.Pressure meter


5.Multiway valve 6.Solenoid 7.Ballance valve 8.Rolling motor
9.Hydraulic lock 10.Ballance valve 11.Thermometer
12.Air filter 13.Liquid level meter 14.Oil cy

PB_HDC_EN_01
HG33 CONCRETE PLACING BOOM OPERATION MANUAL

41
Appendix
Appendix
HG33 CONCRETE PLACING BOOM OPERATION MANUAL

5.2 Electrical Basic Diagram

EL
FU4(2A) 17
15
13 19
(50WA)
FU5/4A 23
24V AC220V
14
QF1 TC2(BK-150)
L1 U1 AC380V FU1/6A
21 22

L2 V1
I
L3 W1 W1
N

29

PA A LH V PV QF2/10A
31

I >

W4 V4

FR
KM3
U3 V3 W3

W5 V5
KM2

M1

U2 V2 W2

KM1

Fig.5-2 Basic diagram of electrical system PB_EDC_EN_ 01

42
108 108
7824
1 2 100V 160V 100V 160V
C1 C2 C3 C4
12 11
V4 DT4 KA7 KA8 DT5
V5
40
SB15
109 115 111 113

Fig.5-3 Basic diagram of electrical system


V6 V7

117
100
SB1 KA7 KA8
123
left rotating limit position
right rotating limit position

SQ15 SQ16
SB2
125

KA1

40 40

108

PB_EDC_EN_ 01
HG33 CONCRETE PLACING BOOM OPERATION MANUAL

43
Appendix
44
Appendix

42
17
23

FU2/6A KA2 KA3 HL B1 B2 KA4 KA5 KA6 KA9

45 47 49 51 53 55 57 59 60

Fig.5-4 Basic diagram of electrical system


N L 1L 0.0 0.1 0.2 0.3 2L 0.4 0.5 0.6 3L 0.7 1.0 1.1

40
CPU 224 Mainframe
HG33 CONCRETE PLACING BOOM OPERATION MANUAL

FU3/4A M L+ 1M 0.0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 2M 1.0 1.1 1.2 1.3 1.4 1.5

61 63 79
81 83 85

SB6 SB5 71 73 75 77 KA1 FR 100 88 90


SB7 SB8 SB1

PB_EDC_EN_ 01
Remote receiver B02

Fig.5-5 Basic diagram of electrical system


A4 C1 A8 C5 A7 C4 A6 C3 A5 C2 A9 B5 B4 B6 A3 A2 C9 A1

1 2 3 4 5 6 7 8 9 10 88 90 71 73 77
I1.1 I1.5 I0.2 I0.3 I0.5 11 12

40 DT10 DT11 DT12 DT13 DT14 DT15 DT16 DT17 DT18 DT19

PB_EDC_EN_ 01
HG33 CONCRETE PLACING BOOM OPERATION MANUAL

45
Appendix
46
Remot emitter B01
Appendix

boom rotating boom4 motion boom3 motion boom2 motion boom1 motion

Fig.5-6 Basic diagram of electrical system


1234
HG33 CONCRETE PLACING BOOM OPERATION MANUAL

power supply motor start motor stop electric hooter channel choice start speed choice status indicator

1 2
A4
3 4 5 1
C1 A8 81
6 7 8 9 2 3
C5 A7 C4 83 85
10 11 12 13 14 4 5
A6 C3 A5
15 16 17 18 19 6
C2 B5 B4 108
20 21 22 23
B6 A3 A2
24 25 26
A1 A9 40

PB_EDC_EN_ 01
Appendix
HG33 CONCRETE PLACING BOOM OPERATION MANUAL

FU2/6A
25
22
TC1(600WA) VC

41
AC380V AC24V

27
40

29 KA1

33
AC220V(300WA)

31 KA9 KA2 KA3

FU6/2A 32 34 FU3/4A

KM2 KM1

36 35 38
KM3 KM1 KM2

37

43 FU7/6A

KA4 KA5 KA6

91 93 95

DT1 V1 DT2 V2 DT3 V3

40

Fig.5-7 Basic diagram of electrical system PB_EDC_EN_ 01

47
Appendix
HG33 CONCRETE PLACING BOOM OPERATION MANUAL

5.3 Attached Accessories List

Table 5-1 Attached Accessories List of Placing Boom

Code Designation Number Unit Remark

A260403010015 Rubber Hammer(1.5pounds) 1 PCS

A260403010006 Ball face hammer 0.91QB1290.2-91 1 PCS

A260401040003 Monkey Wrench 250GB4440-98 1 PCS

A260401040005 Monkey Wrench 450GB4400-98 1 PCS

A260401030106 Single open end spanner10GB4388-95 1 PCS

A260401030005 Double-ended spanner 17×19GB4388-95 1 PCS

A260401030007 Double-ended spanner22×24GB4388-9 2 PCS

A260401030008 Double-ended spanner27×30GB4388-95 2 PCS

A260401030031 Double-ended spanner 34×36GB4388 1 PCS

A260401030040 Double-ended spanner 41×46GB4388-95 1 PCS

A260401090065 Convertible spanner 16GB4388-95 1 PCS

A260401090061 Convertible spanner 13GB4388-95 1 PCS

A260401020001 Inner hexagon spanner 3-19 GB5356-98 1 PCS

A260401090012 Ratchet wheel spanner 20×500GB3390.3-04 1 PCS

A260401010035 Socket spanner 24 pieces set GB3390.1 ~ 4-04 1 PCS

A260401010068 Socket 34×20GB3390.1 1 PCS

Socket 36×25GB3390.1-04(lengthened type


A260401010044 1 PCS
about 40mm)
A260401010056 Socket34×25GB3390.1 1 PCS

A260401010045 Socket 41×25GB3390.1-04 1 PCS

A260401010033 Socket46×20GB3390.1 1 PCS

A260401010046 Socket 46×25GB3390.1 1 PCS

A260401010047 Socket 50×25GB3390.1-04 2 PCS

A260401010037 Socket 55×20GB3390.1 1 PCS

A260401010090 Socket 60×25GB3390.1-04 1 PCS

A260404000010 Nipper pliers 160QB2440.1-99 1 PCS

48
Appendix
HG33 CONCRETE PLACING BOOM OPERATION MANUAL

Table 5-1 Attached Accessories List of Placing Boom

Code Designation Number Unit Remark

Phillips blade driver 75×3-2CQB3864-99 (plastic


A260402020007 1 PCS
handle)

Screwdriver bits for slotted head screw


A260402010013 1 PCS
75×0.6×4-2CQB3863-99 (rubber)
A260401090129 Manual reinforcing spanner XVR15 1 PCS

A810504000842 Placing boom random tool box BLG19″ 1 PCS

A420205000036 Kesaixin Detergent 755 400 g

A420300000032 Kesaixin adhesive 277# (50ml) 1 ml

A550300000216 Red Safety helmet 888-A 4 PCS

A559900000011 Gauze glove (for production) 8 PCS

A550300000068 Blue Work Clothes 170# 5 PCS

B429900000016 Cere cleaning agentAP742 3 PCS

/ User's guider 1 PC

/ Drawing volum 1 PC

/ Manufacturer Certificate 1 PC

49
Appendix
HG33 CONCRETE PLACING BOOM OPERATION MANUAL

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www.sanygroup.com.cn

SANY Industry Town, National Economic & Technical Development Zone,


Changsha, Hunan, China 410010
E-mail: sanyservice@sany.com.cn
Service hotline: 0086-21-60303131

Materials and specifications are subject to change without notice in accordance with our continuous technical innovations.
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