Pumping Unit open circuit

and Placing Boom

Hydraulic System

rev.00 1
 Pumping Unit

Concrete Pump Unit

RATIO BETWEEN MAX
PUMPING CYL. CONCRETE STROKES
CIRCUIT OIL SUPPLY OIL HYDRAULIC CONCRETE CONCRETE
"S" VALVE MODEL AREA – CLS BARREL PER
TYPE SIDE PRESSURE CYLINDER SIZE OUTPUT PRESSURE
BARREL MINUTE

( bar ) ( mm ) ( mm ) ( m³/h ) ( bar )

1506 ROD 6,6 30 150 43

8" PA
909
OPEN
PISTON
280 d=120/80 x 2000
3,7
D=230 x 2000
17 90 76

9" HP 1606 H OPEN ROD 350 d=120/80 x 2100 6,6 D=230 x 2100 30 160 53

PA 15 06 S8
HP 16 06 H S9
Equipment Max flow of Max pressure H: Hydraulic Dimension of
type concrete on concrete “S” Valve

2
 Open Circuit – Close Circuit

Pumping Unit
Open Circuit
Oil Tank
Oil discharge line

Oil suction line

Hydraulic pump in
open circuit

Pumping Unit
Close Circuit Oil discharge line

Hydraulic pump in
close circuit
Oil suction line

3
 High/Low pressure configuration

Configuration of Pumping
Unit – LOW pressure

Configuration of Pumping
Unit – HIGH pressure

4
 Concrete Pressure Calculation

D2

A2

HP 16 06 H
Pc

P1 A1
P1 x A1
Configuration of pumping
D1 d1 Pc =
unit – LOW pressure A2

D2 D1  A1 = Area of pumping Cylinder ( cm²)

 A2 = Area of pumping Piston ( cm²)

A2 A1
P1
 P1 = Pressure on hydraulic line ( bar )
Pc  Pc = Pressure on concrete ( bar )

Configuration of pumping
unit – HIGH pressure

5
Concrete Flow Calculation

L
HP 16 06 H
A2

Qc = Vc x n x 60

 Qc = Concrete flow per hour ( m³/h)

 Vc = Volume of concrete barrel ( m³)

 n = Strokes per minute
 60 = Minute per hour

6
 Power Curve

POWER CURVE HP 1808 ECX

Power = Flow x Pressure

Kw mc/h bar

Gauge for oil

pressure measuring
- Pumping

7
 Pipe line pressure
How to calculate the ratio using the plate

•HP 1606 H open circuit:

Max Hydraulic Pressure / Max Concrete Pressure
350/53 = 6.6 low pressure

HP 1606 H configuration: Barrell/Cylinder ratio= 6.6

Hydraulic Cylinder Pressure

P concrete = 200/6.6 = 30.3 bar
Attività pratiche CA V1.0 8
 General Hydraulic Diagram

5
6

4
3

2 1

3
4
1. Hydraulic Pump Suction and Return Line
2. Logic-block Unit Pressure Line A
3. Pumping Cylinders
Pressure Line B
4. “S” Valve Cylinders Slave Circuit
5. Return Filter Pilot Line
6. Tank

rev.00 9
 Cardan
Shaft
Main PTO
Truck

Gear box
PTO Truck
(secondary)

Boom
Hydraulic
Pump

Boom
Hydraulic Pump

Cardan
Shaft
Cardan
Shaft
Gear Box
OMSI
PFT 3000

rev.00 10
Axial Piston Variable Pump A11VO 130 LRDH1

Power Control Pilot Pressure

Regulation Screw Port

Pressure Cut-off
Regulation Screw
Control Device LRDH1

V min V min

rev.00 11
 Axial Piston Variable Pump A11VO 130 LRDH1

Control Device LRDH1

Pressure Cut-off

Pressure Cut-off (D)

Stroke limiter H1

Power Control (LR)

Stroke limiter H1 Power Control

Pressure Cut-off (D) Stroke limiter H1 Power Control (LR)

rev.00 12
 Logic-Block Unit
Electrovalve for Concrete suction
LOGIC-BLOCK UNIT (“S” Valve ) (Pumping Cylinder) Electrovalve
(Pressure control)

Pressure
control
valve

P
T
Main plate
Electrovalve
for Concrete suction “S” Valve Pumping
Cylinder Spool valve
Cylinder

Hydraulic Pilot plate Hydraulic Pilot plate

Electrovalve
Electrovalve for Concrete suction
(Pressure control) Hydraulic Pilot plate

Pressure Oil from Oil from Pilot Line

control valve Directional Pilot Line
spool valve
Directional
Main plate spool valve

pool valve

rev.00 13
 Open Circuit Diagram and Logic Valve - Low pressure
Logic valve

Pilot Line “S” Valve

Pilot Line Pumping

P
T X1 X2
Logic Block
Pumping Cylinders

B1 B2
Logic
valve A1 A2
“S” Valve
Logic valve Section
Cylinders

rev.00 14
 Pumping Cylinders Unit

Limit
switch

By pass

Supercharging Line

By pass

rev.00 15
 “S” Valve Cylinders Unit HP 1606 H

Slave Circuit

“S” Valve Cylinders

“S” Valve
Line B Hydraulic brake
adjustment screw
Hydraulic
Brake

“S” Valve
Line A

Fast start
cylinder
valve

rev.00 16
 “S” Valve Cylinders Unit PA 1506

Hydraulic
Brake
“S” Valve Cylinders

Hydraulic brake
Slave Circuit adjustment screw

“S” Valve Cylinders Pilot line B

Drain Line
“S” Valve
Line B
Pilot line A

“S” Valve
Line A

rev.00 17
 Proportional Regulation Concrete Flow System

Control Panel

RPS Device Proportional

Valve Unit
Proportional
Valve RZGO

Filter

Plate

Tank

Remote Control

Distributor
Services
Sequence
Valve
Services line

rev.00 18
 General Hydraulic Diagram

rev.00 19
 Regulation Concrete Flow or “S” Valve Movement
Pumping unit Limit Switch
on Pumping Cylinder Pumping unit
Limit Switch

OFF ON
Control Panel

Electrical Panel
RPS Device

Potentiometer Potentiometer
Remote Control Concrete Flow “S” Valve Movement

Proportional
Valve Unit

rev.00 20
Services Unit ( Agitator unit ) HP 1606 H

Gear Motor and Agitator shaft

Hydraulic
Pump

to Oil Filter
Services
distributor

rev.00 21
 Services Unit ( Mixer unit - Hopper door unit ) PA 1506

Gear Motor and Agitator shaft

Hydraulic
Pump

Services distributor

Hopper door cylinder to Oil Filter

rev.00 22
 Return Oil Filter
Oil Filter MPH630
Joint Filter

Cover

Head

Filter

Magnet

Bypass Valve

Oil diffuser

Radiator

rev.00 23
 Hydraulic Fluid

NOTE: DO NOT MIX HYDRAULIC OILS OF DIFFERENT MANUFACTURERS. THIS MAY RESULT IN A SIGNIFICANT REDUCTION OF QUALITY.

rev.00 24
 Hydraulic Radiator air/oil Unit

Tank

to Oil Filter
Hydraulic
Motor

Regulation
Flow Valve to Tank
(oil cold)

to Radiator
(oil hot)
Maximum Screw
Valve regulation flow Thermostatic
from services line Valve

rev.00 25
 Grease Equipement

Grease distributor

Grease distributor
Grease
Pump

Graft
loading
pump

Lubrification Detail Filling grease tank

Lubrification Detail

rev.00 26
 Pumping Unit
Hydraulic Calibration

rev.00 27
 Calibration Pumping Pressure HP 1606 H

Valve pilot line Pressure adjustment

screw on pressure 1) Place the diesel engine at maximum revs and insert the
relief valve hydraulic pumps

2) Close the valve on the pilot line , turn on the pump command
until you get the hang of the pumping unit and keep it locked

3) Act on the adjustment screws mounted on the pressure relief

valve and hydraulic pumps to obtain the pressure 380 bar
shown on the pressure gauge

4) Lock the adjustment screw on pressure relief valve and act on

the adjustment screws mounted on the pumps to obtain the
pressure 350 bar

5) Open the valve on the pilot line , the pump will resume its
function
Pressure adjustment
screw on hydraulic pumps

Pressure gauge
Pumping

rev.00 28
 Calibration Pumping Pressure PA1506

Valve pilot line

(close)
1) Place the diesel engine at maximum revs and insert the
hydraulic pumps

2) Close the valve on the pilot line , turn on the pump command
until you get the hang of the pumping unit and keep it locked

3) Act on the adjustment screw mounted on the pressure relief

valve to obtain the required pressure shown on the pressure
gauge (280 bar)

Pressure 4) Lock the adjustment screw

adjustment screw
5) Open the valve on the pilot line , the pump will resume its
function

Pressure gauge
Pumping
Valve pilot line
(open)

rev.00 29
 Calibration Services Distributor HP1606 H

Plug
1. Place the diesel engine at maximum revs and insert the
hydraulic pumps

2. Enter the command with lever in plug line direction

3. If the plug line is occupied from another function, remove

pipe on close the line with plug

4. Turn the screw to adjust pressure mounted on the

Distributor Services to obtain the required pressure shown
on the pressure gauge (120 bar)

Pressure 5. Lock the adjustment screw

adjustment screw

Command lever
Water pump

Pressure gauge
Services

rev.00 30
 Calibration Services Distributor PA1506

Pressure adjustment screw

1. Place the diesel engine at maximum revs and insert the

hydraulic pumps

2. Enter the command closing door

3. Turn the screw to adjust pressure mounted on the

Distributor Services to obtain the required pressure shown
on the pressure gauge (120 bar)

4. Lock the adjustment screw

Command lever door

Pressure gauge
Services

rev.00 31
 Calibration RPS Device - Pumping Unit Open Circuit -

WARNING: Before proceeding with the calibration of the RPS Device on

Pumping Unit Open Circuit, check that the pilot pressures are correct

1. Place the diesel engine at minimum revs and insert the

hydraulic pumps

2. Connect the pressure gauge on delivery line of the valve

sequence

3. Adjust the sequence valve (1) between 38-42 bar

Sequence
valve

Services
distributor

rev.00 32
 Calibration hydraulic radiator fan

1) Place the diesel engine at maximum revs and insert the

hydraulic pumps

2) With the help of a tachometer, located near the fan, turn the
adjustment screw until you reach the desired speed of the fan
(2300g/min)

3) Lock the adjustment screw

Vite regolazione portata

rev.00 33
 Characteristics of the Pumping Unit:
Pos.1 Mounted on Pumping Cylinders botton

Pos.2 Connect Logic-block to pumping cylinders head

Pos.3 Flexible pipe from pilot PIL.1 to line MA1

Pos.4 Flexible pipe from pilot PIL.2 to line MB1

Pos.5 Valve on open position

Pos.6 Valve on closed position

Pos.7 Connect inlet PIL 2 of electro-valves block

Low Pressure Pumping Unit Pos. 8 Connection for pressure reading

Pos.9 Connect the pumping cylinder

Pos. 10 Connect inlet PIL 1.1 of electro-valves block

Pos.11 Valve on opened position

rev.00 34
 Characteristics of the Pumping Unit:
Pos.1 Mounted on Pumping Cylinders head

Pos.2 Connect Logic-block to pumping cylinders bottom

Pos.3 Flexible pipe from pilot PIL.1 to line MB1

Pos.4 Flexible pipe from pilot PIL.2 to line MA1

Pos.5 Valve on closed position

Pos.6 Valve on open position

Pos.7 Connect inlet PIL1.1 of electro-valves block

High Pressure Pumping Unit Pos. 8 Connection for pressure reading

Pos.9 To replace the hose wit blank flange

Pos. 10 Connect inlet PIL 2 of electro-valves block

Pos.11 Valve on opened position

rev.00 35
 Placing Boom
Hydraulic System

rev.00 36
 Hydraulic Layout

Boom
Cylinders

Stabilizer Cylinder Stabilizer Cylinder Bearing

Open outrigger
Cylinder Geared
motor

Outrigger sx
distributor
Boom
Outrigger dx Distributor
distributor Filter
Hydraulic Pump
A17FO…

Open outrigger
Cylinder

Stabilizer Cylinder Stabilizer Cylinder Tank

rev.00 37
 Hydraulic Layout with Load-sensing

Boom
Cylinders

Stabilizer Cylinder Stabilizer Cylinder Bearing

Open outrigger
Cylinder Geared
motors

Outrigger sx
distributor
Boom
Outrigger dx distributor
distributor Filter
Hydraulic Pump
A18VO…

Open outrigger
Cylinder

Stabilizer Cylinder Tank

Stabilizer Cylinder

rev.00 38
 Fixed Hydraulic pump A17FO… (ex KFA….)

Variable Hydraulic pump A18VO….. (ex KVA….)

rev.00 39
 Boom Pressure Filter

To Boom distributor
Filter body

Indicator plug

By pass
Filter element

Filter body

From Hydraulic Pump

rev.00 40
 Boom distributor PSL…..
PSV….. HAWE
Pressure valve First section

End plates
Accumulator
LS line Pressure
adjustment
Connection block screw

Valve element

rev.00 41
 Boom distributor PSVF….. HAWE

Plate element End plates

Pressure
adjustment
Pressure screw
adjustment
screw Pressure
adjustment
Valve element screw single
section

rev.00 42
 Block Valve for Two geared reducer

Geared
reducer
brake

Block Valve on geared reducer

rev.00 43
 Boom Cylinder DU Bushing DU Bushing

Guide ring
Piston seal

Rod seal
Guide ring
Wiper ring

Single Block Valve on Boom cylinder Double Block Valve on Boom cylinder

rev.00 44
 Outrigger distributors

Distributor
without max
valve
Carry over

Distributor
with max
valve

rev.00 45
 Block Valve on Double
outrigger system Sequence Valve
on Double
Block Valve on front cylinders
Hydraulic motor

Block Valve on
Triple telescopic
front cylinder

Single Sequence Valve on

Double front cylinders

rev.00 46
 Block Valve on
outrigger system

Single Block Valve on Double Block Valve on Block Valve on

Swing-out cylinder Swing-out cylinder Stabilizator cylinder

Stabilizator Cylinder

rev.00 47
 Hydraulic Boom Diagram

To Outrigger
Distributor

rev.00 48
 Hydraulic Stabilization Diagram

From Boom Distributor

rev.00 49
 Placing Boom
Hydraulic Calibration

rev.00 50
 Boom Distributor Calibration with fix hydraulic pump

1. Place the diesel engine at maximum revs and insert

the hydraulic pumps

2. Lift the boom and lead to stroke end first boom

section cylinder

3. Install pressure gauge in the attack or see pressure

on manometer

4. Go to boom distributor and adjust pressure through

screw to obtain the required pressure shown on the
pressure gauge

5. Lock the adjustment screws

Hydraulic
Pump A17FO
Boom Attack Pressure Pressure adjustment screw
manometer gauge on boom distributor

rev.00 51
 Boom Distributor Calibration with variable hydraulic pump

1. Place the diesel engine at maximum revs and insert

the hydraulic pumps

2. Lift the boom and lead to stroke end first section

boom cylinder

3. Turn the screw to adjust pressure mounted on the

Pressure hydraulic pump and de-setting the pressure
adjustment
screw on boom 4. Go to boom distributor and de-set max pressure
distributor valve through screw

5. Return to hydraulic pump and turn pressure screw

until obtaining the required pressure

6. Lock the adjustment screws

Boom manometer

Pressure adjustment screw

on Hydraulic Pump A18VO

rev.00 52
 Pressure valve first section boom down

1. Place the diesel engine at maximum revs and insert

the hydraulic pumps

2. Close the boom until it rests on the boom support

3. Install pressure gauge in the attack or see pressure

on manometer

4. Turn the screw to adjust pressure mounted on the

pressure valve to obtain the required pressure

Attack 5. Lock the adjustment screws

Pressure
gauge

Pressure
adjustment
screw on
pressure valve

rev.00 53
 Speed Boom Calibration

1. Place the diesel engine at maximum revs and insert

the hydraulic pumps

2. With the use of the remote control verify the timing of

lifting and lowering of the boom.
(see technical specification)

3. If the times don’t meet the specification, act on the

grains adjustment lever distributor.

Grain

Grain

Lever

4. Check again the timing, correct adjustment again,

until you get the correct time values

rev.00 54
 Single Geared motor on Turret Calibration

1. After calibrated pressure on Boom distributor

2. Tighten the brake lock screw mounted on the block

valve of geared motors

3. Install pressure gauge in the attack

4. Pressurizing hydraulic circuit and put the geared motor

in block

5. Turn the screw to adjust pressure mounted on the

distributor to obtain the required pressure shown on
the pressure gauge

6. Lock the adjustment screw

Attack Pressure
gauge 7. Repeat the same procedure on the opposite side of the
block valve

Pressure
Brake lock screw adjustment screw

rev.00 55
 Double Geared motor on Turret Calibration

1. After calibrated pressure on Boom distributor

2. Remove the fitting from the valve that sends pressure

to the brakes of the two gearboxes and close the socket
C3 on the valve body. DO NOT close the pipes that go
to the regulators because you have to ensure that they
are at zero pressure.

3. Install pressure gauge in the attack

4. Operate the right rotation; the arm must not rotate

since the torque of the hydraulic motor is always less
than the brake torque
Brake pressure
fitting Attack Pressure
gauge 5. Verify that the pressure difference between the inlet
(higher pressure) and the return (lower pressure) is
equal to the value in the table
C3
6. Correct calibration, if necessary, by turning the valve
cartridge back until you get the value indicated in the
table below

7. Lock the adjustment screw

8. Repeat the same procedure on the opposite side of the

block valve

9. After the calibration screw the fitting of the brake and

Pressure test the arm according to the usual procedures
adjustment screw

rev.00 56
 Outrigger Distributor Calibration

1. Place the diesel engine at maximum revs and insert

the hydraulic pumps
Pressure adjustment screw
2. Install pressure gauge in the attack

3. Push button manual stabilization

4. Enter the command closing outrigger

5. Turn the screw to adjust pressure mounted on the

outrigger distributor to obtain the required pressure
shown on the pressure gauge (……bar)

6. Lock the adjustment screw

Command lever
Attack Pressure gauge

Button
manual
stabilization

rev.00 57
 RATINGS DISTRIBUTOR HAWE

SETTING VALVE DISTRIBUTOR MAX PROPORTIONAL see Boom Specifications

SETTING FIRST BOOM DOWN 200 bar

SETTING ΔP GEAR ROTATION see Specification SC1028684

RATINGS OUTRIGGERS
VALUES OUTRIGGER DISTRIBUTOR 220 bar

AND BLOCK VALVE TRIPLE TELESCOPIC OUTRIGGER 50 bar

PRESSURE RATINGS SERVICES

RATINGS SERVICE DISTRIBUTOR 120 bar

HYDRAULIC RADIATOR max speed 2300 rpm

RATINGS PUMPING UNIT

PA 1506 SETTING LOGIC BLOCK 280 bar

HP1606H SETTING Hydraulic Pump 350 bar

RPS Pressure Device 5 - 30 bar

RPS Sequence Valve 38 – 42 bar

ATTENTION: these values may be subject to changes

58
 Thank you

rev.00 59