Truemax PB28A3R Operation Manual

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Foreword ...........................................................................................................................................................2

Ⅰ Safety Instructions ....................................................................................................................................3

Ⅱ Construction of the PB28A3R Concrete Placing Boom ........................................................................6

Ⅲ Main Technical Specifications .................................................................................................................8

1. Technical specifications of the concrete placing boom ..............................................................................8

2. Working range ............................................................................................................................................9

Ⅳ Erection and Dismantling ...................................................................................................................... 10

1. Cruciform base template, Concrete foundation ........................................................................................ 10

2. Erecting and Dismantling ......................................................................................................................... 11

Ⅴ Electrical system ..................................................................................................................................... 17

1. Cable remote control apparatus ................................................................................................................ 18

2. The radio remote control .......................................................................................................................... 19

3. Adjustment of the slewing limiter ............................................................................................................ 20

4. Notice ....................................................................................................................................................... 21

5. Diagram of electrical principle ................................................................................................................. 22

Ⅵ Hydraulic system .................................................................................................................................... 23

1. The principle of the hydraulic system ...................................................................................................... 23

2. Manifold valve block ................................................................................................................................ 25

3. Adjustment of the hydraulic system ......................................................................................................... 26

4. Notice ....................................................................................................................................................... 27

Ⅶ Operation & maintenance ..................................................................................................................... 29

1. Safety regulations ..................................................................................................................................... 29

2. Operating step ........................................................................................................................................... 31

3. Maintenance ............................................................................................................................................. 32

4. Analysis of the common failure ............................................................................................................... 35

Ⅷ Climbing .................................................................................................................................................. 36

1. Construction of climbing device .............................................................................................................. 36

2. Fitting the floor frame .............................................................................................................................. 40

3. Climbing ................................................................................................................................................... 42

4. After climbing .......................................................................................................................................... 44

5. The sustained load of the supporting part ................................................................................................. 46

Ⅸ Complementary instructions ................................................................................................................. 47

1. Rest position ............................................................................................................................................. 47

2. Satellite use ............................................................................................................................................... 47

Ⅹ Transport ................................................................................................................................................ 50

XI Documents .............................................................................................................................................. 51

AppendixⅠ: List of the easily-worn parts ................................................................................................... 52

Appendix Ⅱ: Operation essentials of concrete jam prevention ................................................................ 53

Appendix Ⅲ : Abrasion of pipeline of the concrete placing boom ........................................................... 54

Contents

Operation Manual（PB28A3R）

Table of Contents

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Summary of Contents for Truemax PB28A3R

Page 1: Table Of Contents
Operation Manual（PB28A3R） Contents Foreword ................................2 Ⅰ Safety Instructions ............................3 Ⅱ Construction of the PB28A3R Concrete Placing Boom ................6 Ⅲ Main Technical Specifications .........................8 1. Technical specifications of the concrete placing boom ................8 2. Working range ............................9 Ⅳ Erection and Dismantling ........................10 1.
Page 2: Foreword
"note" word in this publication, which involves safety of persons and equipment. Truemax has been devoting every effort to the perfect of her products. Therefore they are submitted to change without notice. If you have any questions, please don’t hesitate to contact Truemax for more consultation.
Page 3: Ⅰ Safety Instructions
Operation Manual（PB28A3R） Ⅰ Safety Instructions 1、 Do not stand under the boom 2、 Do not use it as a crane 3、 Do not touch 4、 Mind your head 5、Hoist from here 6、Danger...
Page 4 Operation Manual（PB28A3R） 7、Do not open the pipe clamp 8、Do not open the pipe before releasing the pressure 9、Do not insert the hose into concrete 10、Do not work under the boom 11、Maximum length of the Jib: 3m 12、Mind the wear and tear on the...
Page 5 Operation Manual（PB28A3R） 13、Do not weld when the power is on 14、Be careful with hose connection 15、Demonstrative diagram for boom operation 16、Do not open an engaged globe valve; The hydraulic oil must be up to the standard and pure; In normal...
Page 6: Ⅱ Construction Of The Pb28A3R Concrete Placing Boom
Operation Manual（PB28A3R） Ⅱ Construction of the PB28A3R Concrete Placing Boom Below you will find an overview of the main important components:...
Page 7 Operation Manual（PB28A3R） Component Remark Includes 3 arms, hydraulic cylinder and four-bar linkage. The big arm is divided into two segments. The root of the big arm is connected with Boom assembly the swivel table Platform of boom Specially designed working platform where hydraulic pump and Swivel table electrical control cabinet are set on.
Page 8: Ⅲ Main Technical Specifications
Operation Manual（PB28A3R） Ⅲ Main Technical Specifications 1. Technical Specifications of the concrete placing boom Model PB28A3R Delivery pipe dimension (outside diameter×thickness) JJ83（mm×mm） Φ133×4.5 Delivery hose dimension (inside diameter×length) （″×mm） 5″×3000 Radius of placing boom(m) 27.7 Stationary height(to the join between the end of the boom and Swivel table (m) 22.6...
Page 9: Working Range
Operation Manual（PB28A3R） 2. Working range...
Page 10: Ⅳ Erection And Dismantling
Operation Manual（PB28A3R） Ⅳ Erection and Dismantling There are two methods to erect the equipment: freestanding stationary and inside climbing. 1. Cruciform base template, Concrete foundation Cruciform base template...
Page 11: Erecting And Dismantling
30 meters. 2.1.3 According to the maximum weight of the subassemblies of the equipment, choose proper hoisting equipments and mounting tools(auxiliary hoisting tools, sleeper, rigging and rope clamps). Note: The maximum weight of the subassemblies of PB28A3R is 4.3 tons.
Page 12 Operation Manual（PB28A3R） 2.1.4 The court should be large enough for transporting and storing the equipment. 2.1.5 Users make concrete foundation according to our requirements. 2.1.6 Prepare plenty of wedges with thickness about 1—4mm to adjust the plainness tolerance of the joint surface between the foundation and the tower section.
Page 13 Operation Manual（PB28A3R） 2.3.1.2 Erecting the upper-tubular column (weight: 3800kg) Notice: Make sure the mid platform, ladder, delivery pipe, guard ring are installed on the upper column. Lift the upper-tubular column on the lower-tubular column and screw each other with 16 high-tensile bolts (M30 )which must be tightened with a torque 1400N.m.
Page 14 Operation Manual（PB28A3R） 2、Locate the working platform on the beams which are fixed on the upper-tubular column, fasten the working platform to the end of the beams with the retaining pins and secure these with cotter pins. 2.3.2 Erecting the rear section of big arm, swivel table, lower-support and slewing ring support (weight: 3500kg) Lift this assembly on the upper-tubular column，and connect the lower-support to the quick mounting...
Page 15 Operation Manual（PB28A3R） In the fig： (1) Pull the locating bolt out of the tab on the upper tubular column. (2) Fold the tab upwards. (3) Join the lower-support to the quick mounting adapter using the locating bolt. (4) Secure the locating bolt with the securing bolt and a cotter pin.
Page 16 2.3. 2.5 The dismantling of the concrete placing boom The dismantling of the equipment is according to the opposite sequence of the erection. The dismantling of the climbing frames please go to chapter 7. PB28A3R Freestanding stationary placing boom...
Page 17: Ⅴ Electrical System
Operation Manual（PB28A3R） Ⅴ Electrical system The electrical system of PB28A3R concrete placing boom consists of electromotor of pump, electrical control cabinet, and magnetic valve junction box, cable and radio remote control apparatus. The electromotor provides power for hydraulic pump. In electrical control cabinet, there are phase-sequence protection circuit, power protection circuit, direct current power supply circuit, control circuit driven by pump electromotor, and control circuit of magnetic valve.
Page 18: Cable Remote Control Apparatus
Operation Manual（PB28A3R） 1. Cable remote control apparatus The diagram of cable remote control apparatus 1.1 "Emergency" button The button is used to control the DC on/off. The electromotor will stop and all switches on the panel are disabled when the button is pushed down, even if the electromotor is running. The "emergency" button should be pushed down to prevent error action after work.
Page 19: The Radio Remote Control
Operation Manual（PB28A3R） when the switch is up, and retract when the switch is down. 1.8 "Power" indicator The indicator displays power of control circuit on/off. When the "emergency" button is released, the DC supply powers on and then the indicator is light. Push the "emergency" button, and then the indicator is unlighted.
Page 20: Adjustment Of The Slewing Limiter
Operation Manual（PB28A3R） 2.8 "Unfolding mid arm" button The mid arm of the concrete placing boom unfolds when it is pushed down. 2.9 "Folding mid arm" button The mid arm of the concrete placing boom folds when it is pushed down.
Page 21: Notice
Operation Manual（PB28A3R） 3.2.3 Moving the placing boom to the right position without load, the micros-witch for the said mechanism shall actuate instantaneously, adjust the corresponding shaft Z to make the memory-cam T contact the micro-switch WK. 3.2.4 Fasten the nut M5, otherwise the memory will be confused.
Page 22: Diagram Of Electrical Principle
Operation Manual（PB28A3R） 5. Diagram of electrical principle...
Page 23: Ⅵ Hydraulic System
Operation Manual（PB28A3R） Ⅵ Hydraulic system 1. The principle of the hydraulic system The diagram of the hydraulic system...
Page 24 Operation Manual（PB28A3R） Name Oil tank Filter installed on pump inlet 3/4＂ Globe valve Motor Oil pump Shock-proof manometer Twin pressure relief valve Oil lever indicator with thermometer Air cleaner Filter installed on return line Solenoid directional valve Solenoid directional valve...
Page 25: Manifold Valve Block
Operation Manual（PB28A3R） 1.2 Logic relation table of the solenoid directional valves Valve 12(1) Valve 12(2) Valve 12(3) Valve 12(4) Valve 12(5) Valve (slewing) （small arm）（mid arm）（big arm）（climbing） Pump starting × × × × × × ⊙ Unfolding small arm ×...
Page 26: Adjustment Of The Hydraulic System
Operation Manual（PB28A3R） Manifold valve block 3. Adjustment of the hydraulic system 3.1 Adjusting the maximum hydraulic working pressure The maximum hydraulic working pressure of the equipment is decided by the pressure relief valve (7) setting. The setting method as follow: After pump running normally, switch the corresponding switch to the "folding big arm"...
Page 27: Notice
Operation Manual（PB28A3R） speed. Screw the valve cores counterclockwise to increase the speed. 3.3 Adjusting the pressure relief valve of the slewing motor Adjust the stacked pressure relief valve 23 on the manifold block to adjust open pressure of the relief valve.
Page 28 Operation Manual（PB28A3R） Slewing reductor 回转减速机构 Structure of rotary motor...
Page 29: Ⅶ Operation & Maintenance
Operation Manual（PB28A3R） Ⅶ Operation & maintenance 1. Safety regulations In order to ensure the concrete placing boom safe in working, and avoid the risk of workmen and equipment being hurt, we must comply with under-mentioned regulations and relate safety regulations of tower crane.
Page 30 Operation Manual（PB28A3R） · It is forbidden that persons come into the zone beneath the placing boom during the equipment working. · It is forbidden to unfold the mid arm and small arm when the safety hooks do not released. ·Unfold the placing boom only in the sequence, firstly unfold big arm, then mid arm and last small arm.
Page 31: Operating Step
Operation Manual（PB28A3R） · Do not deliver concrete in these positions as fig. 2. Operating step Note: Open the gate valve of oil tank before operating the equipment. （1）Switch on the sword switch to turn the external electric power on. （2）Push on the main switch on the electrical control cabinet to switch power supply on.
Page 32: Maintenance
Operation Manual（PB28A3R）（6）Unfold the mid arm and small arm in turn. （7）Push on the "left slewing" or "right slewing" to slew the placing boom left or right. （8）The sequence of folding arms as follows: firstly fold the small arm, lift the big arm approximately 45o angle of elevation, then fold the mid arm until secure the safety hook on the lower cover plate of the big arm to the pin on the root of small arm, set the big arm horizontally finally.
Page 33 Operation Manual（PB28A3R） · Check whether the cotter pins of the railing drop off or not. 3.1.3 Monthly inspection · Check whether the slewing limit switch work normally or not. · Check if the slewing reductor works abnormally. · Tighten the connecting bolts of the tower section.
Page 34 Operation Manual（PB28A3R） The choke at the linkage pin of the hydraulic cylinder of the mid arm and the big straight link The choke at the linkage pin of the big crooked link and the big straight link The choke at the linkage pin of the big crooked link and the fore big arm...
Page 35: Analysis Of The Common Failure
Operation Manual（PB28A3R） 4. Analysis of the common failure Failure Reasons Solutions The direction of the oil pump's rotation is Check the direction of the oil incorrect. pump' rotation The value of the manometer is Check the circuit and overflow zero...
Page 36: Ⅷ Climbing
Operation Manual（PB28A3R） Ⅷ Climbing 1. Construction of climbing device Climbing device, which is consist of climbing pins, climbing frames, and climbing cylinders, is separated with cruciform base after climbing. 1.1 Floor frame There are 3 climbing frames arranged in a sequence, namely up-frame, mid-frame and lower-frame. Interval of climbing frame shown as the following table.
Page 37 Operation Manual（PB28A3R） Hole in floor 1.1.2 Wall frame This device can be only used in 2.0～2.7m elevator shaft well. For any other dimensions it needs special design. When working, the extension legs can reach out to the holes prepared in the wall which must be smooth and...
Page 38 Operation Manual（PB28A3R） The holes prepared in wall...
Page 39 Operation Manual（PB28A3R） Fix the climbing frame together with iron plate. The fixation climbing frame Note: In order to avoid damage and accidents, every extension leg of the climbing frames must be fastness to prevent the frames move to one-side. 1.2 Hydraulic climbing cylinder Two hydraulic climbing cylinders whose rated pressure is 16Mpa should be installed on the seat of the two main support bar of the mid-frame, which must be ensured work synchronously.
Page 40: Fitting The Floor Frame
Operation Manual（PB28A3R） 1.3 Locating bolt Locating bolt is mainly used to transfer vertical loads. For easy inserting and pulling out, there is a clasp at one side. 2. Fitting the floor frame The floor frame with its climbing bolt carries the boom once this is no longer standing on the cruciform base.
Page 41 Operation Manual（PB28A3R） 2.2 Bolt the two floor frame components together. Insert the 8 wedges in the cut-outs provided for them. Caution： The tubular column must only be secured to the climbing frames using wedges at the upper and lower climbing frames during concrete placement and in the boom’s rest position.
Page 42: Climbing
Operation Manual（PB28A3R） 3. Climbing Once the placing site has reached height at which the placing boom can no longer easily be used, it is necessary to shift the tubular column upwards. 3.1 Preparing before climbing Mount the climbing system on the middle climbing frame, Open the fast coupling of climbing and start ①...
Page 43 Operation Manual（PB28A3R） ② Fold the arms to level position and shift it to almost vertically upwards position. Tubular column must be vertical. ③ ④ At least 2 climbing frames. ⑤ Disconnect delivery line depend on the building site condition. ⑥ Remove the wedges between the climbing frame and the tubular column.
Page 44: After Climbing
Operation Manual（PB28A3R） ⑧ Retract the piston to the end ,then pull out the locating bolt in the piston groove then insert it to the next hole. ⑨ Repeat , then the machine can raise step by step . ④ ⑥ ⑦ ⑧...
Page 45 Operation Manual（PB28A3R） Caution：The tubular column must only be secured to the climbing frames using wedges at the upper and lower climbing frames during concrete placement and in the boom’s rest position. No wedges should be used on the central climbing frame of the three, as otherwise the horizontal loads passed at this point into the structure would be excessive.
Page 46: The Sustained Load Of The Supporting Part
Operation Manual（PB28A3R） Note: After the self-climbing, oil cylinder should be retracted. The oil cylinder cannot be used to support the whole machine, but can be dummy there, act as insurance, as shown above. 5. The sustained load of the supporting part...
Page 47: Ⅸ Complementary Instructions
Operation Manual（PB28A3R） Ⅸ Complementary instructions 1. Rest position In the rest position, it is permit to keep the booms situation at idle 60°to avoid disturbing constructing, but the requires as follow: ·Must fold the placing boom, secure the arms by safety hook.
Page 48 Operation Manual（PB28A3R） · Pull the securing bolt out of the locating bolt. · Pull the locating bolt out of the tab. · Fold the tab downwards. · Put the locating bolt back in the tab. · Secure the locating bolt with the securing bolt and a cotter pin.
Page 49 Operation Manual（PB28A3R） · Connecting the tubular column head and quick mounting adapter.
Page 50: Ⅹ Transport
Operation Manual（PB28A3R） Ⅹ Transport Because of the structure of this machine is huge, it needs pay special attention to give the arm adequate stability during the journey. The parts that over-long or over-width need disposal depend on national traffic law.
Page 51: Documents
Operation Manual（PB28A3R） XI Documents 1. Certificate of competency of the machine 2. Operation Manual 3. Drawing of foundation 4. Delivery list 5. List of the components...
Page 52: Appendixⅰ: List Of The Easily-Worn Parts
Operation Manual（PB28A3R） Ⅰ List of the easily-worn parts Appendix : Name Code Position O-ring 12×2 GB/T3452.1-1992 Hose pipe and joint O-ring 10.6×2.65 GB/T3452.1-1992 Balance valve Composite pad 42 JB/T982-1977 Hydraulic hose 4SP12-15LA Hydraulic hose 4SP12-15LA/15LE Hydraulic hose 4SP12-15LA/15LF Hydraulic hose...
Page 53: Appendix Ⅱ Operation Essentials Of Concrete Jam Prevention
Operation Manual（PB28A3R） Ⅱ Operation essentials of concrete jam prevention Appendix 1. Concrete isolation is the main reason of concrete jam. 2. Concrete isolation is mainly because wrong operation. 3. Concrete jam always happens at the 90°bend pipe between the middle arm and the small arm .
Page 54: Appendix Ⅲ : Abrasion Of Pipeline Of The Concrete Placing Boom
Operation Manual（PB28A3R） Appendix Ⅲ : Abrasion of pipeline of the concrete placing boom 1. Bends In normal service ,the two 90°bends at the end of the small arm and the two between the middle arm and the small arm are in worst case.