1.8 Manual de Maquina Zoomlion

Maintenance Manual of
Trailer Concrete Pump
ZOOMLION HEAVY INDUSTRY SCIENCE AND TECHNOLOGY CO.,LTD.

Maintenance Manual of
Trailer Concrete Pump
Version 02 in January 2014

E + m C ´ Í v Maintenance
\ B ò B \ ´ Manual
To customer
Honorable customer, thanks for choosing ZOOMLION Trailer Concrete Pump, please read this manual
carefully and strictly abide by relevant regulations before the maintenance.
Regular check and maintenance of the machine are indispensable means to make full use of the machine
performance, ensure safe and reliable operation and longer service life. For the convenience of your mainte-
nance, we specially present to you this maintenance manual.
This manual introduces to you the regulations and explanations in maintenance of Trailer Concrete Pump,
common machine failures and corresponding solutions are also provided in the manual for your reference.
For the normal operation of the machine and your personal safety, please be sure to read this manual
carefully and other attached documents. If you have any questions or doubts, please contact the local service
engineers, you are guaranteed to get timely and efficient technical support. It should be declared that our com-
pany will not be liable for any bad consequences due to disobedience to this manual.
For the continual upgrading of product design and difference of product models, some images and contents
in this manual may be different from your actual product. It is declared that our company reserves the rights to
make revisions to this manual for technical improvement. If there are any amendments, you will no longer be
specially informed. Thanks for your kind understanding.
We sincerely appreciate you trust and support for ZOOMLION products. Wish you all the best.
I
Safety information
Explanations to the safety sign in the manual are as follows:
Be cautious of extreme dangers,

Danger
otherwise it may cause death or severe injuries.
Be cautious of medium dangers,

Warning
otherwise it may cause severe injuries.
Be cautious of light dangers, otherwise,

Notice
it may cause light or medium injuries.
Be cautious when there is no safety signs,

Caution
otherwise, it may cause property damage.
II
Content
To customer ........................................................................................................................................................ I
Safety information ............................................................................................................................................II
Chapter I Maintenance...................................................................................................................................1-1
1.1 Daily maintenance ..............................................................................................................................1-1
1.1.1 Daily maintenance ...................................................................................................................1-1
1.1.2 Maintenance after 50 hours operation (1500-2500m3) ............................................................1-5
1.1.3 Maintenance after 100 hours operation(3500-5000m3) ...........................................................1-6
1.1.4 Maintenance after 500 hours operation(15000-25000m3) .......................................................1-8
1.1.5 Maintenance after 750 hours operation....................................................................................1-8
1.2 Maintenance of pumping unit .............................................................................................................1-9
1.3 Maintenance of hydraulic system .....................................................................................................1-10
1.3.1 Hydraulic oil and grease ........................................................................................................1-10
1.3.2 Shift check and precautions ...................................................................................................1-10
1.3.3 Maintenance of hydraulic threaded pipe joints......................................................................1-12
1.3.4 Cleaning and replacement of filter element ...........................................................................1-12
1.4 Maintenance of lubrication system ...................................................................................................1-14
1.4.1 The use of lubricant ...............................................................................................................1-14
1.4.2 Refill lubricant / grease .........................................................................................................1-14
1.5 S tube adjusting and wear parts replacing ........................................................................................1-17
1.5.1 Clearance adjustment of the cutting ring and spectacle wear plate .......................................1-17
1.5.2 Replace spectacle wear plate and cutting ring .......................................................................1-17
1.6 Maintenance of electrical system......................................................................................................1-20
1.6.1 Electrical circuit maintenance................................................................................................1-20
1.6.2 Welding precautions...............................................................................................................1-20
1.6.3 Maintenance of display ..........................................................................................................1-21
1.6.4 Annexe ...................................................................................................................................1-21
Chapter II Troubleshooting ...........................................................................................................................2-1

2.1 Pumping system usual failure .............................................................................................................2-1
2.2 Mixing system usual failure................................................................................................................2-3
2.3 Distributing system usual failure ........................................................................................................2-4
III
2.4 Lubrication system usual failure.........................................................................................................2-7

2.5 Starting system usual failure...............................................................................................................2-7
2.6 Main electrical and hydraulic failure ..................................................................................................2-8
Chapter III Description of pumpable concrete ............................................................................................3-1

3.1 Concrete ..............................................................................................................................................3-1
3.2 Concrete preparation...........................................................................................................................3-1
3.3 Transport .............................................................................................................................................3-1
3.4 Concrete placing .................................................................................................................................3-1
3.5 Notes on the concrete pumpability .....................................................................................................3-2
3.6 Appendix: check and maintenance schedule ......................................................................................3-5
IV
Maintenance Manual of Trailer
Concrete Pump
Chapter I Maintenance
!!!!!!!!!!!!!!
Chapter I Maintenance
Maintenance
1.1 Daily maintenance
1. The operator must make maintenance accord-
ing to this manual, refer to Fig. 1-1.
2. The engine is closed and total switch of power
supply is shut off before maintenance, refer
to,(used for trailer concrete pump driven by diesel
engine.)
3. The engine is closed and air switch of power
supply is shut off before maintenance, refer
to(used for trailer concrete pump driven electric Fig. 1-1
machinery)
1.1.1 Daily maintenance
1. Check the hydraulic oil level, keep it above 3/4

of the oil level indicator, or else clean hydraulic
oil of the same brand needs being added. We rec-
Oil level indicator
ommend cleaning the oil via filtering unit whose
filter rating is 20μ, refer to Fig. 1-2.
2. Check the oil quality. Stop the machine, after
30 minutes, let 0.5L oil flow into a clean measur-
ing cup, the oil should be primrose and translu-
cent, if the oil is polluted to a high degree or emul-
sified or muddy, or there are sediments at the bot- Fig. 1-2
tom after several hours deposition, the oil must be
changed.
3. Pour grease into the grease box and fill the water tank with water, refer to Fig. 1-3.
1-1
Filling grease Filling grease

Filling the water tank with water
Maintenance
Fig. 1-3
4. Take off the cover of the water tank; check
In the water tank
whether the concrete piston seal is well, no sand
is penetrated into the water tank, refer to Fig. 1-4.
Fig. 1-4
5. Check the gap between cutting ring and spec-
tacles wear plate.
Gap
Due to cutting stone and friction, cutting ring
and spectacles wear plate will wear out, to en-
sure the uniform wear and thus longer service life,
we recommend: per time after stop pumping and
thorough cleaning, check the condition of both
parts, if the gap between the cutting ring and spec-
tacles wear plate exceeds 2mm, you should adjust
it, refer to Fig. 1-5. Fig. 1-5
6. Check the working status of the lubrication system, grease would overflow every lubrication points including
on the swinging lever and bearing of the mixing shaft. The manual lubrication points should be lubricated every
working shift. Lubrication points are shown on the lubrication label, refer to Fig. 1-6, Fig. 1-7, Fig. 1-8.
1-2
Where lubricant overflows
Maintenance
Fig. 1-6
Fig. 1-7
Fig. 1-8
1-3
7. Check whether the S valve swings and mixing

system rotate forward and reversedly normally.
(Check it when the engine is started, stop en- Distribution
Maintenance
gine after check to proceed to other maintenance valve
items), refer to Fig. 1-9. Mixing

shaft
Fig. 1-9
8. Check whether the radiator surface is clean,
clean the dirt at once or the oil temperature will
overheat, refer to Fig. 1-10.
Fig. 1-10
9. Check the indicator of vacuum gauge that
Vacuum gauge
should be within green area (don’t exceed
0.04MPa). Generally, the vacuum degree for
suction oil should be below 0.02MPa. The vac-
uum degree for returning oil should be below
0.35MPa, refer to Fig. 1-11.
10. Check the wear of delivery pipes by tapping.
Check whether the seals of pipe joints are well.
11. Check oil leakage, exudation of oil and wa-
ter leakage of hydraulic system and diesel en- Fig. 1-11
gine.(Only used for trailer concrete pump driven
by diesel engine.)
12. Check whether electrical components are nor-
mal. Check whether all the electrical joints are dry
and free of oxidation and that there are no loose
connections. If necessary, spray these joints with
a water-repellent spray. , refer to Fig. 1-12.
Fig. 1-12
1-4
13. Check accumulator and keep accumulator dry

and clean. Oxidation or dirt on the accumulator
and accumulator terminals can cause short cir-
Maintenance
cuits, voltage drop and discharge especially in
damp surroundings. Clean the accumulator termi-
nals and cable terminals in order to remove oxi-
dation by using a brass brush. Tighten the cable
terminals well and grease them with protective
Fig. 1-13
grease or Vaseline. (used for trailer concrete pump
driven by diesel engine) , refer to Fig. 1-13.
1.1.2 Maintenance after 50 hours operation (1500-2500m3)
1. Carry on above maintenance.

2. Check whether the bolts of the pumping cylin-
Tighten the nuts
ders and drag rods are loose; tighten them with
a torque wrench, refer to Fig. 1-14. Tightening
torque according to the table below, as Table 1-1:
Fig. 1-14
Table 1-1 Tightening torque (N.m)
Wrench opening Nut grade

Spec
(mm) 8.8 grade 10.9 grade 12.9 grade
M6 10 11 16 18
M8 13 25 37 44
M10 17 50 73 86
M12 19 86 125 145
M14 22 135 200 235
M16 24 210 310 360
M18 27 300 430 500
M20 30 430 610 710
M22 32 580 830 970
M24 36 730 1040 1220
M27 41 1080 1550 1800
M30 46 1450 2100 2450
1-5
Table 1-1 (continued) Tightening torque (N.m)
Wrench opening Nut grade

Spec
Maintenance
(mm) 8.8 grade 10.9 grade 12.9 grade

M33 50 2000 2800 3300
M36 55 2500 3600 4200
3. Check the bolts of the intermediate connecting

rod and others to ensure the connection firm.
1.1.3 Maintenance after 100 hours operation(3500-5000m3)

2. Check the condition of the cutting ring and the
spectacles wear plate. If necessary, replace them,
refer to Fig. 1-15.
Cutting ring
Fig. 1-15
3. Check the wear condition of the piston. If nec-
essary, replace them, refer to Fig. 1-16.
Fig. 1-16
1-6
4. Check whether hydraulic oil mixes with over-

much water, every twenty days unscrew the base
plug screw at the bottom of the oil tank and drain
Maintenance
the water about 2-3L, then fasten the bottom plug
screw, refer to Fig. 1-17.
Bottom plug
screw
Fig. 1-17
5. Check the sealing of grease pump and clean it.
If the piston is worn out, if necessary, replace it,
refer to Fig. 1-18. Plunger
Fig. 1-18
6. Check the filter element at the outlet of grease
pump and clean it, if necessary, replace it, refer to
Fig. 1-19.
7. Check whether hydraulic oil is degenerative
and emulsified, or else the hydraulic oil should
be replaced, the oil tank should be cleaned com-
pletely.
Fig. 1-19
1-7
8. Check accumulator, the electrolyte should be

5-10mm over the electrode plate of the accumu-
lator. Distilled water is added if necessary. Charge
Maintenance
the accumulator after the liquid is filled up by run-

ning the engine at fast idle for at least 30 minutes,
refer to Fig. 1-20.
Notice Fig. 1-20
Certain free maintenance accumulator

has special instructions, which must be fol-
lowed. (used for trailer concrete pump driven
by diesel engine.)
1.1.4 Maintenance after 500 hours operation(15000-25000m3)

2. Check the worn condition of S tube and S tube bearing.
3. Check the worn condition of mixing shaft, mixing blade and mixing bearing, refer to Fig. 1-21.
Mixing bearing
Mixing shaft
S tube bearing
S tube bearing
Mixing blade
Fig. 1-21
4. Check oil quality. If necessary, change it. Only the oil recommended by our company is permitted being
filled. Generally after pumping 10000m3 concrete, change the hydraulic oil completely.
5. Check the pressure of the accumulator. The charged pressure of the accumulator is about 10-11MPa.
1.1.5 Maintenance after 750 hours operation

2. Check the wear of the concrete cylinder. Replace it if the chrome plating is worn seriously.
3. Test the whole machine, every parameter should accord with requirement.
1-8
1.2 Maintenance of pumping unit

Frequent pumping will cause fast wear of moving parts of pumping unit. Proper maintenance will increase
Maintenance
efficiency and prolong life. Please do inspections of the following items before pumping and after pumping.
1. Every shift lubrication tank and lubrication points are filled with grease; the water tank is full of clear water.
2. Check whether all electric components are normal every shift.
3. Check whether the pumping changing direction, S valve swings and mixing system rotate forward and re-
versedly normally.
4. After pumping is carried on about 2000m3, check the gap between spectacles wear plate and cutting ring, if
the gap between the cutting ring and spectacles wear plate exceeds 2mm and wears equably, you should adjust
it.
5. Replace the cutting ring.
6. Replace the spectacles wear plate.
7. Check the worn condition of S tube, S tube bearing, mixing device, mixing blade and mixing bearing every
shift. If the wear is overmuach, they need being replaced. (The replacing method is referred to this manual.)
8. Check whether the sealing of the concrete piston is well, no sand is penetrated into the water tank. If there is
much concrete in the water tank, the concrete piston should be checked whether it needs being replaced. ( The
replacing method is referred to operation manual.)
1-9
1.3 Maintenance of hydraulic system
1.3.1 Hydraulic oil and grease

Maintenance
1. Hydraulic oil
Hydraulic oil recommendations: DTE24 or
HZ32 is used in winter; DTE25 or HZ46 is usu-
ally used in summer; if the ambient temperature
exceeds 48℃, DTE26 or HZ68 is recommended
to use.
1) Use the hydraulic oil recommended by our
company. Don’t use other oil or mix oils of dif-
ferent brands.
2) The temperature of the hydraulic oil should be
controlled between 35-60℃, refer to Fig. 1-22.
3) The level of the hydraulic oil is above 3/4 of
oil level indicator.
4) The oil quality should be primrose and trans-
parent, if the oil is contaminated or emulsified or
muddy, the oil must be changed.
5) Hydraulic oil has great effect on the machine,
it’s necessary to change oil thoroughly generally
after pumping 15000 m3 or 6 month at the first
time and later every pumping 50000 m3 or 12 Fig. 1-22
month and to clean oil tank and filters at the same
time.
2. Grease
Grease: use non extreme-pressure type “00”
semi liquid lithium base grease in summer and
non extreme-pressure type “000” semi liquid
lithium base grease in winter. This machine
should use the grease which brand is recom-
mended.
1.3.2 Shift check and precautions
1. Before the maching is started, release the de-

posited water at the bottom of the oil tank. Open
the drain valve at the bottom of the oil tank to re-
1-10
lease water every 50 hours at the same time. Pay

attention not to let the hydraulic oil outflow.
2. Check the radiator exterior. If there is dirt, it
Maintenance
must be cleaned at once, or else, the oil tempera-
ture will be much hotter, refer to Fig. 1-23.
Fig. 1-23
3. Check the indicator of vacuum gauge should be
within green area every shift, refer to Fig. 1-24.
Fig. 1-24
4. Every shift check whether there is oil leakage
of hydraulic system, the cover sealing of the oil
tank is loose and it makes the water and air come
into.
5. Every shift, check whether the pressure of the
accumulator attains manufacturer request. If not
enough, it is possible that the rubber bladder of
the accumulator is not enough or the rubber blad-
der is damaged (the method of the accumulator
being charged nitrogen and skin bag of the rubber
bladder being replaced is referred to the operation
manual).
1-11
1.3.3 Maintenance of hydraulic threaded pipe joints
1. If the oil leakage occurs when the joints are

Maintenance
used, the thread is permitted being tightened most

1/2 to 3/4 circles, refer to Fig. 1-25.
2. If the oil leakage still occurs, the joint and
the hydraulic pipe connected with the joint are
needed being replaced. Hydraulic hose can be
used to replace the hydraulic pipe. Hydraulic
pipeline and joint must be installed and connected
properly.The vibration must be avoided, which
is not controlled. It can't be contacted with the
machine and also connected compulsively. Fig. 1-25
3. Lock washer is used for pipe joint to prevent it
being distorted.
4. If hydraulic hose is used for connection, the
sealing joint and O-ring between them need be-
ing checked. If the sealing joint and O-ring are
damaged, the hydraulic hose must be replaced.
1.3.4 Cleaning and replacement of filter element
1. Clean the shell of the filter with diesel fuel or

other oil.
2. Place a container under the oil filter to collect
the oil in the oil filter.
3. Loosen the bolt 4; the check valve of filter will
automatically shut the inlet of the filter, refer to
Fig. 1-26.
Notice
Only the filter element appointed by our

company can be used.
No. Name
4. Loose the big hexagon nut on the lid 3; disman-
1 Shell of the filter
tle the lid of the filter.
2 Vacuum gauge
5. Take out the magnetic bar, clean it with silk and
3 Lid of the filter
gasoline.
4 Bolt
6. Check the filter element and the O ring in the
lid,replace them if damaged. Dip the filter element Fig. 1-26
1-12
into gasoline for a while before cleans it. Blow

compressed air into the filter from outer to inner.
After it is cleaned for 2~3 times, it can be assem-
Maintenance
bled. It’s not allowable to use paper filter element
repeatedly.
7. Clean the shell of the filter with silk.
8. Assemble the filter element according to the
opposite procedure. First, install the filter element
then the magnetic bar, bolt, assemble the lid of the
filter and fasten it, push the bolt towards the inner
of the filter and screw down it.
1-13
1.4 Maintenance of lubrication system

In the pumping unit, mixing unit and so on there are many moving parts that need to be lubricated regularly
Maintenance
to ensure efficient and long working life.
1.4.1 The use of lubricant
The quality of lubricant directly affects efficiency and service life of moving parts. For different lubricate
point, the use and replacement of the lubricant/grease is different. According to the below lubrication Table
1-2, to the corresponding lubrication part, operater should periodically check the level and the oiliness of the
lubricant and grease.
Table 1-2
Lubrication interval/hr. Re-

No. Parts Lubricant/grease
50 200 1000 marks
Semi-fluid lithium
1 Pumping system Refill
grease
Cleaning water 30# engine oil
2 Replace
pump 40# engine oil
Notice
You must always use lubricant appointed by Zoomlion, bad lubricant will cause permanent damage
to lubrication system. Our company accepts no liability for system failure caused by using bad lubricant.
1.4.2 Refill lubricant / grease
Before startup, please check whether each

lubrication point is thoroughly lubricated. Refill
if necessary. If it is necessary to replace lubri-
cant, please empty the old lubricant completely
and use new lubrication completely to ensure the
optimum lubrication effects, refer to Fig. 1-27.
Fig. 1-27
Lubrication frequency depends on working environment.Normal lubrication should be performed as the
form above. If the working environment has high humidity, dusty and high temperature changes, higher lubri-
cation frequency will be needed. After the machine stops for a long time, a thorough lubrication to all parts will
be necessary.
1-14
It is important to keep the lubricant clean. Before refilling, please clean the nozzle of the grease gun to
avoid the joints and bushes being damaged.
The lubrication of the concrete piston is devided into automatic lubrication and manual lubrication. The
Maintenance
manual lubrication of the concrete piston can be lubricated as follows:
1. Bring one of the pistons to the end of stroke (near the pumping water tank).
2. Add lubricate to the concrete piston by using grease gun.
3. Perform the reverse operation for the other piston. It is recommended to carry out this lubrication every 50
hours.
Check the working status of the lubrication system, grease would overflow every lubrication points includ-
ing on the swinging lever and bearing of the mixing shaft. The manual lubrication points should be lubricated
every working shift, refer to Fig. 1-28, Fig. 1-29.
Distributor Lubricant overflows here
Fig. 1-28
Manual lubrication points Lubrication points
Fig. 1-29
1-15
Notice
Maintenance
Notes on adding grease for boosting lubrication pump

If the boosting lubrication pump is initially used or suffers a constant pumping failure due to grease
use-up or other causes, please turn anticlockwise both of the bleed valves for half a circle until the air
is fully removed and the grease can be pumped continuously without bubbles, then turn the two valves
tightly, refer to Fig. 1-30.
Cmffe!wbmwf
Fig. 1-30
1-16
1.5 S tube adjusting and wear parts replacing
1.5.1 Clearance adjustment of the cutting ring and spectacle wear plate
Maintenance
After pumping 5000m3 concrete, check the
S tube
clearance between the spectacles wear plate and
cutting ring. If the clearance is more than 2mm
and the wear is uniform, adjust the clearance as This gap
the following procedures: Fig. 1-31.
1. Close motive source, shut off the total power
supply and set free the accumulator pressure.
Fig. 1-31
2. Clean the hopper and S tube, refer to Fig. 1-32.
Clean hopper
Fig. 1-32
3. Remove the bolt 3 and baffle 4; screw the nut
5; pull the S tube towards the back wall board of
the hopper. In this way, the gap between specta- Bolt 3
cles wear plate and cutting ring could be reduced.
Fasten bolts 3 and baffle 4, refer to Fig. 1-33.
Baffle 4
Nut 5
Fig. 1-33
1.5.2 Replace spectacle wear plate and cutting ring
When concrete is pumped, if serious slurry

leakage results in, this affects the normal opera-
tion, then change the cutting ring.
1-17
1. Replace cutting ring.

1) Shut down motive source, and turn off power
supply, release accumulator pressure and take out Hopper grid
Maintenance
the hopper grid, refer to Fig. 1-34.
Fig. 1-34
2) Remove the bolt and baffle, unscrew nut
20mm, do not loose the bolt too much, otherwise,
when move S tube backward, the sleeve (outlet Bolt
side) of S tube will retreat from wiper. That will
damage the sealing, thus slurry will enter, so the
Baffle
life of the S tube is reduced, refer to Fig. 1-35. Nut
Fig. 1-35
3) Unscrew the nuts; dismantle the connection
flange of outlet, refer to Fig. 1-36。
Nut Outlet
Fig. 1-36
1-18
4) Move the S tube toward the outlet, when the

gap between cutting ring and spectacles wear
Force
plate reaches 20mm, then take out the cutting direction
Maintenance
ring, refer to Fig. 1-37.
Cutting ring
Fig. 1-37
5) Check the wear of the rubber spring. If neces-
sary, replace it at the same time, refer to Fig. 1-38.
6) Install the new cutting ring.
2. Replace spectacles wear plate
1) Repeat above-mentioned steps.
Rubber spring
Fig. 1-38
2) Unscrew all fixing bolts of the spectacles wear
plate, refer to Fig. 1-39.
Fixing bolts
Fig. 1-39
3) Take out the spectacles wear plate after a little
shake, refer to Fig. 1-40.
4) Install the new one, and fasten the fixing bolts
of the spectacles wear plate.
Spectacles
wear plate
Fig. 1-40
1-19
1.6 Maintenance of electrical system
Notice
Maintenance
1. The personnel who be engaged in to maintain and maintain, must through the profession training
qualified.
2. In the process of maintain and maintain, the machine should park the ground in flatness, the engine
should stop the operate.
3. Maintain ally must while cut off the premise of the power.
4. All fittings for to replace, must purchase toward Zoomlion. The anti suggestion customer by oneself
purchases; my company by oneself purchases the question that fittings cause to the customer all irre-
sponsible.
1.6.1 Electrical circuit maintenance
The electricity circuit is after machine circulate with long hours, connecting the place or the weld spots
probably loose shed off, insulate the lamella weathering and protect the lamella fretting etc. circumstance, so
should the periodical progress maintenance maintain, the normal without a break running that to guarantee the
machine. The electricity circuit maintains to include a little bit following contents:
1. Each cable connects whether the setting bolt of the place is loose or not, whether welding shed off or not,
whether the corrosion scaling, if have and should make to fix and sweep the disposal, conduct electricity the
function with the to build up.
2. The insulation lamella of the cable whether is already aging or copper is bare, if have and should replace in
time, in order to prevent the circuit short circuit causes a fire.
3. The protection tube of the cable, such as the snake type tube, the ripple tube in machine over a long period
of time circulate whether have the fretting, particularly electric cable near the engine and other heat division,
even should intensify to protect the function.
4. Check whether GND wiring is firmly connected, prevent it from be shaken and ensure it to be connected
well.
5. The teat walk whether line have or not is fixedly, avoiding the excessive rock.
Notice
Please use and install cable correctly, wrong installation may cause overload, short circuit and fire.
1.6.2 Welding precautions
Go forward to go the electric welding working hours in the machinery, should dismantle the conjunction
circuit equip as follows to unload:
1. The anode of the electricity control division and connect a ground of line.
1-20
2. A little bit other easily be electron by the interference the vitality piece, if coder etc.
Notice
Maintenance
1. While welding, connect a ground of line and should near to the quilt welding piece possibly, cause the
arc in the bearing absolutely not to.
2. After welding, connect with the reverse order up the above-mentioned apparatus.
3. Carry on to welding the operate while launching running absolutely not to.
1.6.3 Maintenance of display
1. Display screen is a precision electronic product and its working environment temperature is not proper to
lead high.
2. To avoid irreparable damage, never hit the screen with hard or heavy objects, or press the screen using harsh
movements.
3. If PLC breaks off, a word “ERR” or “Communicating” appears on the right-down corner of the touch screen.
Please check the PLC whether it correspondence line connect to screen line.
1.6.4 Annexe
1.6.4.1 Vulnerable parts list
Following Table 1-3are vulnerable parts. If substance things different from these ones, take the real state
account.
Table 1-3
Name Trademark Habitat

IFM GERMANY
PLC
EMERSON USA
TE FRANCE
RELAY
PANASONIC JAPAN
TE FRANCE
RELAY FRAME
PANASONIC JAPAN
PANASONIC JAPAN
DISPLAY
ZOOMLION CHINA
REMOTE CONTROL ZOOMLION CHINA
1-21
Maintenance
1-22
Concrete Pump
Chapter II Troubleshooting
!!!!!!!!!!!!!!
Chapter II Troubleshooting
2.1 Pumping system usual failure

Table 2-1 Pumping system usual failure' reason and eliminating methed
Pumping system
Faults Reasons Resolvents
Troubleshooting
1. Pumping start-up button failure, loose 1. Tighten cable terminal, dry electrical
connection, open-circuit, electrical system system components and replace pumping
components is moist. start-up button.
2. Fault of solenoid directional valve, 2. Remove and clean the valve spool, or
Pumping usually because valve spool is jammed or replace the solenoid.
cylinder solenoid burns out.
pistons do 3. Turn the knob of reducing valve too 3. Adjust the knob of reducing valve.
not move much, so the control pressure is too low.
4. Hydraulic oil inside the oil tank is too 4. Refill hydraulic oil and keep the oil level
little. above 3/4 of oil level indicator.
5. Suction filter element is seriously 5. Replace filter element.
jammed.
The gap between the proximity switch 1. Adjust the gap between 2~3mm.
and piston flange is too big or they don’t
contact.
2. The bottom of the proximity switch is 2. Clean the bottom of the proximity switch.
adhibitted by grease or other eyewinkerand,
Pumping which makes induction not sensitive.
cylinders 3. Proximity switch is failure or the 3. Replace the proximity switch or
don’t change switches position is wrong (especially interchange the switches position.
direction when the machine is switched from
high pressure state to the low pressure
state, operator forgets to interchange the
proximity switches position.)
4. The solenoid coil of the solenoid 4. Replace the solenoid.
directional valve burns out.
2-1
Table 2-1 Pumping system usual failure' reason and eliminating methed(continued)
Pumping system
1. The wear of the feed pump elements 1. Replace the feed pump elements which
causes the oil much little. are worn.
2. Turn the knob of reducing valve too 2. Adjust the knob of reducing valve.
much, so the control pressure is too low.
Pumping 3. The pressure of the control oil is not 3. Adjust the control system again: the
cylinder enough. pressure of the relief valve on the feed pump
pistons move is adjusted 2.5 MPa and the pressure of the
Troubleshooting
slowly and flush valve is adjusted 2 MPa.

weakly. 4. When pumping concrete to higher storey, 4. Inch the hydraulic cylinder for several
due to no oil compensation , hydraulic oil times to refill oil.
in the close chamber of pumping cylinder
decreases, and the stroke of pumping
cylinder becomes shorter and shorter.
1. The concrete pistons are worn out. 1. Replace the concrete pistons.
2. The gap between the spectacles wear 2. Adjust gap.
plate and cutting ring is too large.
Bad situa-
3. Concrete is so bad that the suction of 3. Adopt pumpable concrete.
tion for con-
concrete is too bad.
crete output:
4. S tube has been blocked partly. If the 4. Reverse pumping must be done for
pumping dis-
pumping pressure rises to 32MPa suddenly. 2~3 strokes at once by turning REVERSE
continuously
PUMPING, then normal pumping will be
or small con-
done. If the pumping pressure is still too
veying vol-
high after reverse pumping has been done
ume
for several times, it shows that the concrete
pipeline may be blocked, we must stop
pumping and clean the pipeline.
The center of 1. The mechanism position of the servo 1. Adjust the mechanism position of the servo
the hydraulic valve of the main oil pump is not centered. valve of the main oil pump to zero.
cylinder is 2. The hydraulic position of the servo valve 2. Adjust the hydraulic position of the servo
deflective. of the main oil pump is not centered. valve of the main oil pump to zero.
Pumping stop button failure, loose Tighten cable terminal, dry electrical system
Can not stop
connection, open-circuit, electrical system components and replace pumping stop button.
pumping
components are moist.
2-2
2.2 Mixing system usual failure

Table 2-2 Mixing system usual failure' reason and eliminating methed
Mixing system
Faults Resolvents
When they are blocked, rotate the blades reversely.
Due to poor pumpable characteristic, mixing
Use wood to block blades and readjust the pressure
resistance is very big or mixing blades are blocked
to 14MPa
The setting pressure of relief valve is not enough Check and replace it if necessary
Mixing motor has been damaged Check and replace it
Troubleshooting
The gear for mixing system is damaged Tighten cable terminal, dry electrical system
Mixing turning button failure, loose connection,
Components and replace mixing turning button
electrical system components are moist
Mixing shaft or shaft bushing has been damaged Check and repair it
The setting value of pressure switch is changed Readjust it
2-3
2.3 Distributing system usual failure

Table 2-3 Distributing system usual failure' reason and eliminating methed
Distributing system
1. Fault of hydraulically operated direction
control valve, usually because valve spool is 1. Remove and clean the valve spool
jammed
2. S tube is blocked by objects 2. Clean the objects
3. The failure of relief valve causes the swing 3. Readjust the relief valve pressure or
Troubleshooting
pressure not enough replace relief valve

4. Check and repair the constant pressure
4. The failure of constant pressure pump cause
S tube does pump, replace the wear parts and readjust
swing pressure not enough
not swing the pressure of the constant pressure pump
5. Poor concrete pumped and stop machine for
a long time , that increase swing resistance, so 5. Clear the poor concrete in hopper
S tube can’t swing
6. Bearing of S tube worn out, that increases
6. Stop engine and replace bearing
swing resistance
7. The horizontal concrete pipes is too short 7. Lengthen horizontal concrete pipes or
when concrete is pumped to higher storey add an bend pipe at the outlet of hopper
1. Recharge nitrogen gas to 8～10.5MPa,
1. Pressure of accumulator is not enough or or replace the bladder of accumulator and
bladder is damaged recharge nitrogen gas to setting value 8～
10.5MPa
2. Switch off the shut-off valve. (Clockwise
2. Don’t switch off the shut-off valve
direction is off)
S tube
3. Replace the sealing of the swing
swings 3. Swing cylinders leak oil seriously
cylinders
slowly and
4. The pilot valve spool of the pressure relief
weakly
valve worn out would result in swing pressure 4. Replace the pressure relief valve
lower than 15MPa
5. The valve spool spring of the reversal valve
breaks up, which can’t make the valve spool
5. Replace the reversal valve
arrive the appointed position. The wear of
valve spool will result in inner leakage
2-4
Table 2-3 Distributing system usual failure' reason and eliminating methed (continued)
Distributing system
S tube
doesn’t
The nylon bearing of the swing cylinder is Put an adjusting gasket under it or replacing
swing
worn, deformed or has different thickness it
to right
position
Mortar
comes into Dustproof ring at the small shaft side of S tube
Troubleshooting
the side of is deformed, bearing is worn out or the gap is Check and replace them
swing lever too large
of S tube
Table 2-4
Distributing system
1. Inching button for gate valve failure 1. Replace the gate valve inching
or cable disconnect. button, or tighten cable terminal.
2. Pilot valve spool of E&H directional valve 2. Remove and clean the valve
jammed or solenoid coil damaged. spool, or replace the solenoid.
3. The outlet is clogged due to check
3. Replace the check valve.
valve failure.
4. The spool of hydraulic operated
4. Remove and clean the
directional valve for switching over
valve spool.
automatically is jammed。
Gate valve does
5. Orifice in the pilot oil line of hydraulic
not move. 5. Clean orifice.
operated directional valve is blocked up.
6. Gate valve got stuck. 6. Clean the objects.
7. The failure of sequencing valve maybe 7. Readjust the pressure or replace
cause shifting pressure is not enough. the sequencing valve.
8. Tighten the shut-off valve
8. Don’t fasten the shut-off valve or itself failure.
or replace it.
9. Poor concrete pumped and stop machine for
a long time , that increase shifting resistance, 9. Clear the poor concrete in hopper.
so gate valve can’t move.
2-5
Table 2-4 (continued)
Distributing system
1. Recharge nitrogen gas to
1. Pressure of accumulator is not enough 10.5MPa, or replace the bladder of
or bladder is damaged. accumulator and recharge nitrogen
gas to setting value 10.5Mpa.
2. Switch off the shut-off valve.
2. Don’t switch off the shut-off valve.
(Clockwise direction is off.)
Gate valve 3. Replace the sealing of the
Troubleshooting
3. Gate valve cylinders leak oil seriously.

changes direction cylinders.
slowly and 4. he pilot valve spool of pressure relief valve
4. Replace the pressure relief valve.
weakly worn out would result in low shifting pressure.
5. Due to solenoid failure or spring of main spool
breakage in the E&H directional valve, the main
5. Replace the reversal valve.
spool can’t move to right position. Worn-out
main spool would result in inner leakage.
6. Readjust the pressure or replace
6. Pressure of sequencing valve is set too low.
the sequencing valve.
Gate valve
Gate valve kits are stuck or blocked
doesn’t shift to Clean them.
by other things.
the right position
2-6
2.4 Lubrication system usual failure

Table 2-5 Lubrication system usual failure' reason and eliminating methed
Lubrication system
Faults Resolvents
The valve spool of the progressive distributor is
Clean the progressive distributor
blocked
The valve at the outlet of lubrication pump is failure Check and replace it
The lubrication system can’t feed the grease. The
filter in the suction port or outlet of the pump is Clean and replace it
Troubleshooting
blocked
Grease can’t meet requirement, its viscosity is large, Use the right grease according to standards along
which makes the grease can’t pass the filter with different seasons
One of lubricating lines is blocked, usually
lubrication points on distribution valve bearings is Clean the stem in the bearing and lubricating lines
blocked
Adjust the overflow valve: clean the overflow valve,
The outlet pressure of boosting lubrication pump outlet check valve or bleed the air (loosen the bleed
is low valve at the underside for 3-5 minutes and then
tighten it.)
The pressure gauge reading of boosting lubrication
pump is high, and won’t drop to Zero after the Check for pipe blockage.
transfer tube switching.
2.5 Starting system usual failure

Table 2-6 Starting system usual failure' reason and eliminating methed
Starting system
Faults Resolvents
Loose connection and open-circuit. Tighten cable terminal.
Electrical system components are moist. Dry electrical system components.
Pumping start up button failure. Replace pumping startup button.
2-7
2.6 Main electrical and hydraulic failure

Table 2-7 Main electrical and hydraulic failure
Main electrical and hydraulic failure

Components Faults Resolvents
Coil or contactor is damaged, so contactor
Auxiliary relay Replace it
can not close and disconnect normally
Solenoid Solenoid is burnt out Replace the solenoid which is burnt out
1. The bottom of the proximity switch is
1. Clean the bottom of the proximity
adhibitted by oil which makes induction
switch
Troubleshooting
not sensitive
2. The gap between the proximity switch
and piston flange is too big , which makes 2. Adjust the gap between 2～3mm
Proximity switch induction not sensitive
3. The temperature of the water tank is
very high, which makes wrong action 3. Adjust the temperature of the water tank
occur and S tube swing disorderly
4. It is damaged completely, which can’t
4. Replace the proximity switch
induce, or it is always in connection
1. The accumulator pressure is not enough 1. Add the air pressure
Accumulator
2. Bladder is damaged 2. Change the bladder
2-8
Concrete Pump
Chapter III Description of pumpable concrete
!!!!!!!!!!!!!!
Chapter III Description of pumpable concrete
3.1 Concrete
Concrete is a mixture of cement, water, fine aggregate (sand) and coarse aggregate (stone) and so on in
right proportion.
3.2 Concrete preparation

The most common concrete mixing means is: mixing in a forced mixer with vertical shaft or horizontal
shaft after loading of material from batching unit. High-quality concrete can be achieved by mixing in a forced
mixer.
3.3 Transport
Description of pumpable concrete

Concrete is only transported by road in the truck mixer, as the batching, mixing equipments and truck-
mounted concrete pumps are rarely located in the same place.
3.4 Concrete placing

After the concrete is unload from the mixer to the hopper, the pump forces the material from the hopper to
the end of the boom pipe where a nozzle is fitted. Concrete is conveyed to this point at given speed and sprayed
to the appointed position.
3-1
3.5 Notes on the concrete pumpability

Pumpable concrete is a material that will run through a pipe. It must have lubrication characteristics given
by the cement, fine sand less than 0.2 mm and water.
Factors determining the pumpability of concrete
Four factors that determine and define the pumpability: fine sand, aggregate gradation, water/cement ratio,
concrete uniformity.
1. The content of fine aggregate must be at least 350~400kg/m3. (Fine sand and cement whose diameter is below
0.2mm). Table 3-1below shows the content of fine sand corresponding to the maximum size of aggregate. For
crushed aggregate, the content of fine sand should be 10% higher, as it has greater difficulties in running through
pipes due to larger surface.
Table 3-1
Weight of fine sand for one cubic meter

Max. aggregate size (mm)
of concrete (Kg)
8 525
15 450
20 430
30 400
50 350
2. Aggregate size
A good concrete is almost a pumpable concrete. The ideal concrete for pumping has different sizes of
aggregate, which is composed of so many kinds of sizes that the smallest can penetrate the spaces between the
large ones. Table below shows the proportion of pumpable concrete and all kinds of size aggregate. Variation
in composition is normally possible within pumpable range, but it is also beyond the range. Obviously sand
and fine aggregete play a predominant part in the composition. We recommend fine sand percentage as follows:
Recommended fine sand percentage (%), refer to Table 3-2.
Table 3-2
Sand percentage （ % ）
Max. aggregate
With additive Without additive
）
size (mm)）
Pebble Gravel Pebble Gravel
15 48 53 52 54
20 45 50 49 54
30 42 45 45 49
40 40 42 42 45
Notice
The min. percentage of fine sand should exceed 40%, or else pumping concrete is very difficult.
3-2
The Table 3-3below shows max.aggregate size permitted.

Table 3-3
Min.diameter of delivery （ mm）

Max.aggregate size（）
pipe (mm) Pebble Gravel
125 40 30
150 50 40
Recommend aggregate gradation is shown in the following Table 3-4(weight percentage of different sizes
of aggregate through each standard screen).
Table 3-4
Aggregate
Nominal size of screen mesh(mm)
size(mm)
50 40 30 25 20 15 10 5 2.5
40-5 100 100-90 70-35
30-5 100 100-95 75-40
25-5 100 100-90 90-60

20-5 100-90 100-90
Wear of the pipe and pump increases due to the following reasons:
1) The geometrical shape of the aggregate: crushed aggregate with sharp angles tends to break the lubricating
film formed by the fine particles and cement, behaving inside the pipe like sand paper if concrete moves in the
pipe. The friction between the individual pieces of aggregate increases and the possibility of some chips being
wedged and producing a blockage in the pipe increases.
2) Hardness: hardness has no influence on pumpability while it has influence on the wear. An experiential rule
considers that the concrete can be pumped if the maximum size of the aggregate is less than 1/3 the diameter of
the pipe. If the percentage of the largest size aggregate does not exceed 10%, then the maximum dimension of
the aggregate can be increased slightly.
3-3
3. Concrete consistency
It is the important factor for pumpablity,
which defines the use and deformability of fresh
concrete. The consistency is measured mainly by
the slump (see Fig. 3-1). It depends on:
1) the quantity of cement
2) the aggregate composition
3) the percentage of fine material
4) the amount of water
Fig. 3-1
Dry concrete is difficult to be pumped, it

may result in suction difficulty, lower production,
discontinuous pumping and obvious wear. To
improve pumpability, reduce or eliminate these
problems, additives which increase fluidity are
recommended.
Fluid concrete (slump is over 15cm) has no
difficulty in being sucked but tends to go sepa-
rated, causing blockage of the pump and pipe. In
order to improve the concrete pumpability, use
plasticizing additives or increase the percentage
of 0.2mm fine material, sand and cement in the
concrete.
4. Uniformity of the concrete
A measuring system with high quality can
ensure perfect precision in the individual ingredi-
ent, and high quality mixing machinery is simi-
larly important in obtaining a homogeneous con-
crete which can’t cause blockage.
5. Additives
There are various types of additives on the
market for improving the fluidity, plasticity and
permeability of concrete. Pumpability of the con-
crete can be increased when additives are used
properly. We suggest that the additives are used
according to the specification provided by manu-
facturer.
3-4
3.6 Appendix: check and maintenance schedule
3-5
etercnoc elbapmup fo noitpircseD
3-6
Table 3-5
Interval time of maintenance may be shortend under different situation Time of first operation:
Check (symbol ●)
First per
Adjustment and clean (symbol ◎)
op- shift per per per per per
Replace (symbol ) Notes
era- or 8 50h 100h 500h 750h 1000h
Maintenance items and
tion h Measures
parts
Distributing system
● ● ● Spectacles wear plate Check the gap
● ● ● Cutting ring Check the gap
● ● The port of S tube Check it for wear
● ● The interior of S tube Check it for wear
Sealing of small shaft
● ● Check it for damage
side of S tube
Bearing of small shaft
● ● Check it for wear
side of S tube
Chromeplate bushing at large
shaft side of S tube
Bearing of large shaft
\ B ò B \ ´
● ● Check it for damage
side of S tube
Sealing of distributing Check it for inner or
● ●
cylinder external leakage
Manual
Pumping unit
Check wether there is
● ● Water tank
sand in it
Check (symbol ●)
First per
era- or 8 50h 100h 500h 750h 1000h
tion h Measures
parts
Connection of clamp
● ◎ ● ◎ Check it for loose
and piston
Clean it after pumping
● ◎ ● ◎ Concrete piston Check it for wear
is completed
Clean it after pumping
●/◎ ● ◎ Interior of concrete cylinder Check it for wear
is completed
Sealing at the rod side
● ◎ ● ◎ Check it for damage
of cylinder
● ● Rod of pumping cylinder Check it for damage
Sealing at the piston side
● ● Check it for inner leakage
of cylinder
\ B ò B \ ´
Mixing system
● ● Sealing of mixing shaft Check it for damage
● ● Bearing of the mixing system Check it for wear
Mixing shaft and mixing
Manual
blades
Power system
3-7

3-8
Check (symbol ●)
First per
era- or 8 50h 100h 500h 750h 1000h
tion h Measures
parts
● ● Check the oil level
Oil quality must meet the
Fuel tank
● ● Top up oil requirement of engine
supplier
Hydraulic system
● ● Check the oil level
Oil quality must meet the
Replace the oil requirement of maintenance
manual
◎ ◎ Hydraulic oil tank Replace the filter
● ● Check the vacuum gauge
\ B ò B \ ´
Drain the condensation
● ●
water off the tank
◎ ● ◎ Clean the oil tank
Manual
Check (symbol ●)
First per
era- or 8 50h 100h 500h 750h 1000h
tion h Measures
parts
● ● Check whether it's jammed
Replace the pressure filter
Replace the filter of
main pump
Filter
Replace the suction filter
◎ ◎ Clean return filter
Replace the return filter Filter can not be washed
◎ ◎ Clean the air filter
● ● Accumulator Check the pressure of it
● ● Check the surface
Radiator
◎ ◎ Clean the surface of it
\ B ò B \ ´
Lubrication system
Points at both sides of
● ● ● Lubricate it before operation
mixing shaft seat
● ● ● Each point Lubricate with grease
Manual
● ◎ ● ◎ Filter of lubrication
● ◎ ● ◎ Progressive oil distributor
3-9

3-10
Check (symbol ●)
First per
era- or 8 50h 100h 500h 750h 1000h
tion h Measures
parts
Mechanic parts
Check outlet and delivery
● ●
pipes for wear
Check joints of pipes ,
● ●
pin for loosing
Electrical system
Check the electrodes
● ● Battery
for oxidation
Clean the electrical outlet
● ● Electrical connection
and connection
● ● Electrical componets Check the function
\ B ò B \ ´
Check whether there is other
● ● heating object resulting in
high temperature of machine
Check whether dust comes
● ●
Manual
into electric control box
Check (symbol ●)
First per
era- or 8 50h 100h 500h 750h 1000h
tion h Measures
parts
Cable terminal is well
● ●
connected
Check the PLC works
● ● ●
normally
Check the proximity switch
● ● ●
is normal
● ● ● Output voltage is normal
Check the power of
● ● ● photoelectric coupler
is normal
Check the operation of
\ B ò B \ ´
● ● ● electrical componets are
normal
Manual
3-11

ZOOMLION HEAVY INDUSTRY SCIENCE AND TECHNOLOGY CO.,LTD.
Address: No.677 Lugu Avenue,Yuelu District,Changsha,Hunan Province,China

Postcode: 410205
Website: http://www.zoomlion.com

1.8 Manual de Maquina Zoomlion

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Maintenance Manual of

Trailer Concrete Pump

ZOOMLION HEAVY INDUSTRY SCIENCE AND TECHNOLOGY CO.,LTD.

Version 02 in January 2014

Explanations to the safety sign in the manual are as follows:

Be cautious of extreme dangers,

Be cautious of medium dangers,

Be cautious of light dangers, otherwise,

Be cautious when there is no safety signs,

Chapter II Troubleshooting ...........................................................................................................................2-1

2.4 Lubrication system usual failure.........................................................................................................2-7

Chapter III Description of pumpable concrete ............................................................................................3-1

1.1.1 Daily maintenance

1. Check the hydraulic oil level, keep it above 3/4

Filling grease Filling grease

Where lubricant overflows

7. Check whether the S valve swings and mixing

gine after check to proceed to other maintenance valve

items), refer to Fig. 1-9. Mixing

13. Check accumulator and keep accumulator dry

1.1.2 Maintenance after 50 hours operation (1500-2500m3)

1. Carry on above maintenance.

Wrench opening Nut grade

Table 1-1 (continued) Tightening torque (N.m)

Wrench opening Nut grade

(mm) 8.8 grade 10.9 grade 12.9 grade

3. Check the bolts of the intermediate connecting

1.1.3 Maintenance after 100 hours operation(3500-5000m3)

1. Carry on above maintenance.

4. Check whether hydraulic oil mixes with over-

8. Check accumulator, the electrolyte should be

the accumulator after the liquid is filled up by run-

Notice Fig. 1-20

Certain free maintenance accumulator

1.1.4 Maintenance after 500 hours operation(15000-25000m3)

1. Carry on above maintenance.

1.1.5 Maintenance after 750 hours operation

1. Carry on above maintenance.

1.2 Maintenance of pumping unit

1.3 Maintenance of hydraulic system

1.3.1 Hydraulic oil and grease

1.3.2 Shift check and precautions

1. Before the maching is started, release the de-

lease water every 50 hours at the same time. Pay

1.3.3 Maintenance of hydraulic threaded pipe joints

1. If the oil leakage occurs when the joints are

used, the thread is permitted being tightened most

1.3.4 Cleaning and replacement of filter element

1. Clean the shell of the filter with diesel fuel or

Only the filter element appointed by our

into gasoline for a while before cleans it. Blow

1.4 Maintenance of lubrication system

to ensure efficient and long working life.

1.4.1 The use of lubricant

Lubrication interval/hr. Re-

1.4.2 Refill lubricant / grease

Before startup, please check whether each

Distributor Lubricant overflows here

Manual lubrication points Lubrication points

Notes on adding grease for boosting lubrication pump

1.5 S tube adjusting and wear parts replacing

1.5.2 Replace spectacle wear plate and cutting ring