HGP32 CONCRETE PLACING BOOM

MAINTENANCE MANUAL

XUZHOU CONSTRUCTION MACHINERY GROUP CO., LTD.

XUZHOU XCMG SCHWING MACHINERY CO., LTD.
The First Edition in June, 2016
 HGP32 CONCRETE PLACING BOOM

MAINTENANCE MANUAL

Total pages: 21

PIN

Delivery Date

The maintenance manual is a part of the crane!

Always keep it at hand for reference!

The design and manufacture of the machine comply with the standard of

JB/T 10704-2007 Concrete Placing Equipment

 Preface

Thank you for selecting the products made by Xuzhou XCMG SCHWING
Machinery Co., Ltd.
This manual describes the maintenance and troubleshooting for HGP32 concrete
placing boom. It can serve as a reference for the operators, maintenance persons
and technical personnel.
In order to ensure an excellent working condition of the machine, the
maintenance manual should be carefully studied before operation, which may help
the operator know about various maintenance conditions, meaning of signs,
especially cautions about human body and the machine.
Only the trained and qualified personnel can operate this machine!
The untrained personnel can never operate the machine!
The operation of the machine should strictly obey the instruction manual!
Only in this condition could the machine work in a safe and high performance
condition.
We decline any liability in case of machine faults and accidents caused by
incorrect operation.
This manual is an indispensable part of the equipment, so it should be kept with
the equipment.
We reserve the right to modify the design without further notice.
We will appreciate your valuable comments and suggestions on our product.

June, 2016
 Content
I. Safety ........................................................................................................................................1-1

1. Symbol & icon ..................................................................................................................1-1

2. Safety protection equipment..............................................................................................1-1
3. Safety regulations on maintenance ....................................................................................1-2
II. Maintenance ............................................................................................................................2-1

1. Maintenance intervals .......................................................................................................2-1

2. Delivery pipelines .............................................................................................................2-2
2.1 Minimum wall thickness and operating pressure of delivery pipelines ...................2-2
2.2 Measuring wall thickness .........................................................................................2-3
3. Lubrication ........................................................................................................................2-4
3.1 Lubricant ..................................................................................................................2-4
3.2 Lubricating modes ....................................................................................................2-5
4. Replace hydraulic oil .........................................................................................................2-5
4.1 Preparation ...............................................................................................................2-5
4.2 Replacing oil ............................................................................................................2-5
5. Replacement and adjustment of wear parts .......................................................................2-6
5.1 Disassembly and assembly of filter element ............................................................2-6
5.2 Replacement of other parts .......................................................................................2-7
6. Swivel parts .......................................................................................................................2-7
6.1 Swivel device ...........................................................................................................2-7
6.2 Slewing bearing ........................................................................................................2-7
7. Related technical data in maintenance ..............................................................................2-8
7.1 Capacity ....................................................................................................................2-8
7.2 Oil brand and capacity..............................................................................................2-8
7.3 Tightening torque of bolts ........................................................................................2-8
III. Malfunction and Troubleshooting ..........................................................................................3-1

1. Remote controller doesn’t work or partial function is faulty ............................................3-1

2. A section of boom drops automatically .............................................................................3-1
3. Placing boom can’t rise up ................................................................................................3-2
4. Climbing cylinder fail to maintain positions under loading ..............................................3-2
5. Remote controller can’t be used ........................................................................................3-2
IV Appendix ................................................................................................................................4-1

Hydraulic System Diagram ...................................................................................................4-1

Electrical system principle diagram－A ...............................................................................4-2
Electrical system principle diagram－B ...............................................................................4-3
Electrical system principle diagram－C ...............................................................................4-4
Electrical system principle diagram－D ...............................................................................4-5
Electrical system principle diagram－E ................................................................................4-6
HB56K Easy-wear Parts List ................................................................................................4-7
HB56K Main Parts List .........................................................................................................4-7
HGP32 Concrete Placing Boom Maintenance Manual Safety

I. Safety
1. Symbol & icon

Warning

Common dangers

High voltage power lines

Death hazard

Daily checks

Check every 60 hours

2. Safety protection equipment

Helmet:

Helmet is used to protect head against the falling concrete or components of

delivery pipes if the hose explodes.

Glasses:

Glasses can keep eyes from the concrete splash or other granule attack.

Ear shields:

For protecting ears against noises when you are close to the machine.

1-1
HGP32 Concrete Placing Boom Maintenance Manual Safety

Gloves:

Keep your hands from corrosive chemicals and machine’s corrosion and avoid

cut.

Safety shoes:

Protect your feet from being injured by falling objects and pierced by a scrapped

nail.

3. Safety regulations on maintenance

Periodic check and maintenance of the machine is necessary. The maintenance should be
implemented by the qualified repairman.
If it’s necessary to readjust the safety valves and throttle valves that have been adjusted by our
engineers, it must be done by the persons trained by our
company. It is forbidden to remove seals from the safety
valves.
1) The work of welding and repairing the placing
boom and its components, turret, base structure,
standard section, foundation base and every wearable
part must be implemented by qualified persons. Refer to
the right figure.
i NOTE Fig. 1-1
Before starting welding, batteries must be dismounted; all the switches on the control box and
the power lines of the remote receiver must be pulled out.
2) The drive engine must always be shut down and pressure let off from the hydraulic units
and pipelines before carrying out repair work.
3) Before carry out the maintenance on the placing boom, folding the boom at first, then
dismantle and fix it. Support the boom sections whenever performing maintenance and repair
work on the pressure valves, cylinders or hydraulic pipelines.
i NOTE
Rigid delivery pipelines can be easily replaced with the placing boom folded in travelling
configuration. If rigid delivery pipelines are replaced with the placing boom unfolded,
tensions could ensue when reassembling.
4) Before cleaning the machine with high-pressure water, remove the end hose and install a
collector.
1-2
HGP32 Concrete Placing Boom Maintenance Manual Safety

5) If components in the electric, pneumatic and hydraulic circuits (valves, pumps etc.) need to
be changed, they are to be checked and adjusted in accordance with the data (pressure, voltage,
etc.) of the machine record sheet and circuit diagram.
6) To increase the service life of the delivery pipeline, all delivery pipes must be clockwise
turned 120°and elbows 180°after delivering approx. 6000m3. Observe the minimum wall
thickness and operating pressure.

Fig. 1-2
7) If pumping does not work and fault can’t be removed within an hour, clear the concrete in
delivery pipeline, otherwise the concrete will solidify.
8) When dismounting parts, take note of their fitting positions and refer to parts catalogue.
Make use of the spare parts list and service information to ensure correct assembly.
9) Before cleaning the machine with water or steam jet (high-pressure) or other cleaning
material, close off or glue up all openings into which no water/steam/cleaning material is
allowed to enter due to safety and functional reasons. Especially dangerous are electric motors
and switch boxes. After cleaning, water and glue should be completely removed.
DANGER
Never aim a water or steam jet at electric components of the machine!
Danger to life due to the conductivity of the
machine! Moreover, the electrical unit can be damaged!

Fig. 1-3

1-3
 HGP32 Concrete Placing Boom Maintenance Manual Maintenance

II. Maintenance
1. Maintenance intervals

1) Routine maintenance: before and after every day’s work.

2) 50 hours maintenance: after every 50 hours of operation.
3) 100 hours maintenance: after every 100 operating hours
4) 500 hours maintenance: after every 500 operating hours
5) 1000 hours maintenance: after every 1000 operating hours
General information:
Concrete pump and placing boom have to be inspected after every 250 hours of operation, at
least once a year by a qualified person trained by our company. Inspected items are control
pressure of pump, high pressure, welding conditions of the placing boom and all articulated
joints conditions.
Table 2--1
○Check !Cleanse ●Replace
Check items Maintenance interval/h
Description
Daily 50 100 250 500 1000
Check if the hydraulic
Top up if not ○
oil is full
Condensation formed at
Drain off the condensation
the bottom of hydraulic ○
until hydraulic oil flows out
oil tank
All the parts that have
Replace the parts that are worn
come into contact with ○
the concrete
Hydraulic pipeline Ensure no hydraulic oil leaks ○
Electric wiring harness Check for water (open
○
drainage plug)
After every day’s work, clean
all the machine carefully to
Overall machine prevent the delivery pipelines ◎
from being blocked by the
leftover concrete
Lubricate all the lubrication
points, and fill the lubrication
Lubrication points ●
center according to
specification
Check all the bolts for
looseness and tighten them by
Connecting bolts ○
torque wrench according to the
given torque.
2-1
 HGP32 Concrete Placing Boom Maintenance Manual Maintenance

Change the filter element (after

100 hours’ operation for the
Filter element ●
first time) and clean the
magnetic bar and filter drum
Hydraulic oil tank Clean the hydraulic oil tank ◎
The hydraulic oil in the
Change these oil ●
hydraulic oil tank.
All the mechanical and Inspect them by specialists
hydraulic devices ○
and the user

Safety devices Check if all the safety devices

○
are in proper working order
Slewing bearing and Inspect the wear condition of
○
pinions slewing bearing and pinions
Finished by specialists. Items
Oil pump to be checked: pump control ○
pressure, high pressure.
All the weld seam condition of
Placing boom placing boom, conditions of ○
every pivot point.
Pump and elevating
Check for oil leak ○
cylinder
Check if there has emergency
Emergency stop ○
stop function
Change it ( after 30 hours’
operation for the first time),
Gear oil ●
then change it according to the
requirement in the table

2. Delivery pipelines

2.1 Minimum wall thickness and operating pressure of delivery pipelines

Example for the min. wall thickness:

Given: operating pressure =12MPa, pipe diameter = 125mm
Solution: trace a horizontal line a from axis Y at height 120 towards the right until intersecting
diagonal line DN125. Then trace a vertical line until reaching axis X at the position of 5.1mm.
The minimum wall thickness is 5.1mm.
ND= low pressure HD= high pressure
BD= operating pressure DN=nominal diameter

2-2
HGP32 Concrete Placing Boom Maintenance Manual Maintenance

120 High pressure

80 Low pressure

DN= Inner diameter of

pipe

Min. wall thickness (mm)

Fig.2-1 Chart of the relation between min. wall thickness and pressure

2.2 Measuring wall thickness

The delivery pipes are subject to wear, so it’s very important to measure the wall thickness of
2-3
HGP32 Concrete Placing Boom Maintenance Manual Maintenance

the delivery pipe before starting large-scale work. Otherwise, the unexpected burst of the pipe
will affect the work and even endanger human life.
DANGER
When the delivery pressure reaches the given value, and the wall thickness is less
than the permissible min. wall thickness, the pipe may burst especially if it is blocked.
WARNING
Hammer the delivery pipeline with wood hammer shaft slightly. Otherwise the
delivery pipeline may be damaged.

木锤

Fig.2-2
Measure the wall thickness according to instructions on the measuring equipments. Measure
the wall thickness by knocking at many points along the outside of the pipe, not only at one
point. The wear outside the elbow is larger than that inside the elbow or straight pipe, so pay
more attention to the outside of the elbow while measuring.
To ensure uniform wear of the concrete delivery pipeline, all delivery pipes should be turned
120°clockwise and elbows 180°after delivering approx 6000m3 concrete every time.

Fig. 2-3

3. Lubrication

Lubricate all lubrication points on reciprocal moving parts periodically to ensure the
machine’s service life.

3.1 Lubricant

WARNING
2-4
 HGP32 Concrete Placing Boom Maintenance Manual Maintenance

Molybdenum bisulfide grease is forbidden. In order to ensure the effective lubrication and
guarantee the service life of the machine, please use L-XBCHB1 or L-XBCHB 2 EP
lithium-base grease for manual lubrication.

3.2 Lubricating modes

1) Manual lubrication
a. Grease the rotating joints of concrete delivery pipe.
b. Infuse lubricant to the lubrication points of the placing boom every 50h (refer to fig.2-4).

Fig. 2-4
c. After 100 operating hours, the bearings and seals must be checked and replaced if necessary.

4. Replace hydraulic oil

This part explains how to replace hydraulic oil completely. The maintenance interval can be
found in “Maintenance”.
Cleaning is the most important operation for hydraulic system maintenance. You have to do
everything possible to keep dust, dirt and other impurities out of the system. Even little particle
can cause blockages to the valves, pumps and other systems. A special filter should be used for
filling oil, never directly fill new oil into hydraulic system.

4.1 Preparation

Before replacing oil, carefully perform the following operations:

Switch off the remote controller
Stop engine
WARNING:
Ensure against any unauthorized start-up by moving the ignition key from the control
panel. Remove the key from switch and turn off power.

4.2 Replacing oil

a. Remove all hoses from oil tank.

i NOTE
Make marks on all hoses and joints so as to reassemble them correctly.
2-5
 HGP32 Concrete Placing Boom Maintenance Manual Maintenance

Wipe all openings with clean cloth as deep as possible. Don’t forget the concealed holes.
b. Drain off the hydraulic oil by opening the draw-off valve under the oil tank.
c. Remove all filters and re-install the filter elements.
d. Replace all defective hoses.
e. Fill up the oil tank with new oil.
i NOTE
Dispose of used filter liners in conformity with regulations in force as regards waster
products.
You must fill the tank through filters. After trial run, refill the tank to the maximum permissible
capacity.
f. Check all joints including screwed joints.
g. Check connection of electric devices.
h. Carry out functional check.
i. Implement trial run for several times.
j. Re-install all safety devices, signs and indication plates removed.

5. Replacement and adjustment of wear parts

5.1 Disassembly and assembly of filter element

i NOTE
The filter elements must not be cleaned and then used again. They must be replaced.
Before replacing them, inspect O-rings and other seals of filtering components, which should
be replaced if damage is found.
1) Clean the filter casing with diesel oil or other cleaning agent to avoid contaminating oil tank
during displacement.
2) Place a receptacle beneath filter to collect oil from the filter.
3) Remove the oil return pipeline, screw the end cap to pull out the filter element.
2-6
HGP32 Concrete Placing Boom Maintenance Manual Maintenance

4) Replace the filter element, and then screw in the filter casing.

5.2 Replacement of other parts

The hose which is exposed to sunlight or under high pressure should be put through
mechanical test. If a hose line becomes brittle or cracked, replace it at once.

6. Swivel parts

6.1 Swivel device

1) Maintenance
After the first 30h operating hours of reducer (including the intermittent operating time),
clean the inside of the reducer and the brake with cleansing agent and replace gear oil. Then
replace oil every 100 operating hours.
Check the inside of the reducer and brake for metal particles.
It’s better to replace oil before the oil becomes cool. That’s helpful to drain the oil in the tank
completely.
Don’t use mixed oil.
2) Replacing oil
Make sure that all oil ports of reducer and brake are in proper positions.

Remove the plugs and drain the oil in the reducer and brake completely.
i NOTE
Clean the inside of the reducer and the brake with cleansing agent before filling new oil.
Fill cleansing agent into the reducer and brake and install the plugs. Let them run at high
speed for several minutes and then drain off cleansing agent.
WARNING
The application of erosive cleansing agent and improper lube will change oil
character, consequently damage the slewing track and relevant parts.

6.2 Slewing bearing

(1) Lubrication
Proper lubrication is necessary for durability of the slewing track and the gear.
The frequency of lubrication depends on the working conditions and circumstance. Normally
it has to be done every 100 operating hours.
WARNING:
When the machine has been at a standstill for a long period, the slewing bearing
should be lubricated. Lubrication should be carried out more frequently in tropical
climates, dusty or damp environments or areas that are subject to notable changes in
2-7
HGP32 Concrete Placing Boom Maintenance Manual Maintenance

temperature.
(a) Lubricate the slewing bearing of the placing boom. Grease it to reduce wear. Maintain the
seals to avoid corrosion. Grease it until the grease seeps from grease nipple.
(b) Lubricate the pinions. Whether greasing by spraying or brushing, the lube should cover the
pinions and the toothed surfaces fully.
(c) Check the tightness of the bolts on the boom rotation bearing. During this operation, the
tensile stress caused by the boom must be released from the bolted connection. The placing
boom should be placed in the transport position. Tightening should be carried out on the
diametrically facing bolts, two by two.
(d) Inspect the bearing ring teeth and pinions in order to reduce wear. The requirements below
should be followed:
1) Position the placing boom with sections closed in horizontal position;
2) Measure the gap between the bearing ring tooth and pinion tooth with feeler gauge, and
if it exceeds the given value, return to procedure C;
3) Re-assemble all the parts and re-tighten them with bolts. Inspect the tightness of all
bolts and consistence of every bolt and nut periodically.
(e) Overall inspection: inspect the tightness of bolts. Inspect consistence of every bolt and nut
periodically.

7. Related technical data in maintenance

7.1 Capacity

1) Hydraulic oil tank capacity: about 120L;

2) Hydraulic system capacity: about 120L（excluding oil tank）;
3) Concrete delivery pipeline: about 12L/m forф125mm pipe;

7.2 Oil brand and capacity

1) Hydraulic oil: it is recommended to use L-HM32 high quality anti-friction hydraulic oil in
temperatures of -15℃～5℃, L-HM46 hydraulic oil in temperatures of 5℃～40℃ and L-HM68
hydraulic oil with good high temperature properties in temperatures above 40℃.
NOTE:
Different brands of hydraulic oil should not be mixed. Before filling another
brand of oil, drain the old oil in the oil tank completely.

7.3 Tightening torque of bolts

The given friction coefficient is 0.14, tightening torque in N·m

Refer to the following table for tightening torques of bolts
2-8
HGP32 Concrete Placing Boom Maintenance Manual Maintenance

Table 2-2

Tread pitch Spanner size Quality grade

Size
h sw1 sw2 8.8 10.9 12.9
M4 0.7 7 3 2.9 4.1 4.9
M5 0.8 8 4 5.3 7.8 9
M6 1 10 5 8 14 17
M8 1.25 13 6 22 32 38
M10 1.5 17 8 44 64 75
M12 1.75 19 10 76 112 130
M14 2 24 14 120 180 210
M16 2 24 14 185 275 325
M18 2.5 27 14 270 385 450
M20 2.5 30 17 380 550 640
M24 3 36 19 650 940 1095
M27 3 41 19 990 1390 1620
M30 3.5 46 22 1300 1890 2200
M36 4 55 27 — 2000 —
Tightening torque N·m

2-9
HGP32 Concrete Placing Boom Maintenance Manual Malfunction and Troubleshooting

III. Malfunction and Troubleshooting

NOTE:
Only experts can perform the repair on the electric control box and the hydraulic system. If
it runs into special trouble and no remedy found in this manual, please contact the local after
service department of our company for repair.

1. Remote controller doesn’t work or partial function is faulty

Cause Solution
The plug of remote controller is not Inspect the plug for correct connection.
in socket or not in place
Plug gets short circuited or no Check the connection of plug, socket and cable,
electricity and replace the components damaged.
Turn button or press button is Check and replace them if damaged.
damaged
Controller port or program is Check controller port or program
damaged

2. A section of boom drops automatically

Cause
Balance valve becomes dirty
There is dust in the relief valve
Internal or external leakage. The
seals of hydraulic cylinder piston or
piston rod are damaged.
Solution
A. Telescope the hydraulic cylinder of the
descended boom repeatedly to get rid of the dirt
B. Disassemble and clean the balance valve
A. Telescope the hydraulic cylinder of the
descended boom repeatedly to get rid of the dust
B. Inspect and clean the relief valve
Replace the seals

3-1
HGP32 Concrete Placing Boom Maintenance Manual Malfunction and Troubleshooting

3. Placing boom can’t rise up

Cause Solution
Insufficient pressure in hydraulic Inspect the system pressure and adjust it to the
system value specified.
Relief valve is dirty or damaged Inspect and clean the valve.
Hydraulic pump is faulty Inspect the pump.

4. Climbing cylinder fail to maintain positions under loading

Cause Solution
Leakage in hydraulic valve Inspect and clean it, replace it if necessary.
Leakage in hydraulic oil cylinder Replace oil cylinder gaskets.

5. Remote controller can’t be used

Cause Solution
The CAN wire of the remote Inspect CAN wire of remote controller
controller is different

NOTE:
1. The maintenance of all hydraulic pipelines must be carried out after the pipeline pressure is
discharged.
2. All servicemen for electric devices should possess electric knowledge. Alteration of electric
components and circuits and addition of electric function are not permitted.

3-2
HGP32 Concrete Placing Boom Maintenance Manual Appendix

IV Appendix
Hydraulic System Diagram

4-1
HGP32 Concrete Placing Boom Maintenance Manual Appendix

Electrical system principle diagram"A

4-2
HGP32 Concrete Placing Boom Maintenance Manual Appendix

Electrical system principle diagram"B

4-3
HGP32 Concrete Placing Boom Maintenance Manual Appendix

Electrical system principle diagram"C

4-4
HGP32 Concrete Placing Boom Maintenance Manual Appendix

Electrical system principle diagram"D

4-5
HGP32 Concrete Placing Boom Maintenance Manual Appendix

Electrical system principle diagram"E

4-6
HGP32 Concrete Placing Boom Maintenance Manual Appendix

HB56K Easy-wear Parts List

No. SAP code Name Material Qty. Position

φ125 Delivery pipe Delivery pipeline
1 -- 1set
(including elbow) of lower structure
φ125 Delivery pipe Delivery pipeline
2 -- 1set
(including elbow) of superstructure
3 152601232 End hose -- 1 Boom assembly

HB56K Main Parts List

No. SAP code Name Qty. Position Remark

Slewing speed reducer
1 150200942 1 Swivel device
(incl. motor)
Between turret and
2 152400217 Slewing bearing 1 base structure
Multiple-way valve for Hydraulic system of
3 803408739 1
superstructure superstructure
4 803100126 High pressure filter 1 Hydraulic system
5 803588490 Remote controller 1 Electrical system
6 803409123 Gerotor motor 1 Hydraulic oil tank
803001614 1
803002067 1
7 Balance valve Hydraulic system
803001613 5
803001900 1
Balance valve of
8 803408738 2 Hydraulic system
climbing cylinder
9 803410102 Coupling 1 Dynamic unit
10 803001796 Boom pump 1 Hydraulic oil tank
11 803544908 Pressure gauge 1 Hydraulic system

NOTE: The products of our company are always in improvement, so take this table only as
reference.

4-7
XUZHOU CONSTRUCTION MACHINERY GROUP CO., LTD. CHINA
XUZHOU XCMG SCHWING MACHINERY CO., LTD.
Add：No. 29 Taoshan Road, Xuzhou Economic Development Zone, Jiangsu Province, China
Post code: 221004
Network address: www.xcmgjsjx.com
E-mail: xgjjbckf@163.com
Sales telephone: +86-516-87892066
Sales fax: +86-516-87892529
Service telephone: +86-400-110-9999
Service fax: +86-516-87892055
Spare parts telephone: +86-516-87892511
Spare parts fax: +86-516-87892510
Service and quality complaint telephone: +86-516-87892555