EN-32m Manual For The HG32M - PDF

HG32M Operation Manual
Contents
Foreword .............................................................................................................................................. 3
I Construction of the 32m concrete placing boom ............................................................................ 4
Ⅱ Main Technical Specifications ....................................................................................................... 6
1. Technical Specifications of the concrete placing boom............................................................... 6
2. Working range.............................................................................................................................. 7
III Erection and Dismantling................................................................................................................ 8
1. Cruciform base template, Concrete foundation ........................................................................... 8
2. Erecting and Dismantling............................................................................................................. 9
Ⅳ Electrical system .......................................................................................................................... 17
1. Cable remote control apparatus.................................................................................................. 18
2. The radio remote control ............................................................................................................ 19
3. Adjustment of the slewing limiter .............................................................................................. 28
4. Notice ......................................................................................................................................... 29
5. Diagram of electrical principle .................................................................................................. 31
Ⅴ Hydraulic system.......................................................................................................................... 32
1. The principle of the hydraulic system ........................................................................................ 32
2. Manifold valve block ................................................................................................................. 35
3. Adjustment of the hydraulic system........................................................................................... 36
4. Notice ......................................................................................................................................... 37
Ⅵ Operation & maintenance ............................................................................................................ 39
1. Safety regulations ....................................................................................................................... 39
2. Operating step ............................................................................................................................ 42
3. Maintenance ............................................................................................................................... 43
4. Analysis of the common failure ................................................................................................. 47
Ⅶ Climbing....................................................................................................................................... 49
1. Construction of climbing device ................................................................................................ 49
2. Fitting the floor frame ................................................................................................................ 53
3. Climbing..................................................................................................................................... 55
4. After climbing ............................................................................................................................ 58
5. The sustained load of the supporting part .................................................................................. 59
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Ⅷ Complementary instructions ........................................................................................................ 61
1. Rest position ............................................................................................................................... 61

2. Satellite use ................................................................................................................................ 61
Ⅸ Transport ...................................................................................................................................... 65
Ⅹ Documents ................................................................................................................................... 66
Appendix Ⅰ List of the easily-worn parts ....................................................................................... 67
Appendix Ⅱ Operation essentials of concrete jam prevention........................................................ 68
Appendix III Abrasion of pipeline of the concrete placing boom .................................................. 69
2
Foreword
Please read this manual carefully before use the equipment. Pay attention to the sentences
marked with "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.
3
I Construction of the 32m concrete placing boom
Below you will find an overview of the main important components:
4
No. Component Remark

Includes 3 arms, hydraulic cylinder and four-bar linkage.
1 Boom assembly The big arm is divided into three segments. The root of the
big arm is connected with the swivel table
2 Platform of boom
designed working platform where hydraulic pump and

3 Swivel table electrical control cabinet are set on.
4 Slewing ring support
5 Lower-support
6 Working platform
Includes hydraulic pump, manifold valve block，all kinds of

7 Hydraulic control system valves, hoses and steel pipes.
Tubular column assembly are divided into upper-tubular

8 Tubular column assembly column and lower- tubular column. The working platform is
fixed on the upper-tubular section.
mainly includes electrical control cabinet, operating device,
9 Electrical system and main power cable and sword-switch box.
The climbing device mainly is made up of 3 sets of climbing

10 Climbing device frames, 2 hydraulic cylinders and 2 long pins.
11 Cruciform base template
12 Concrete foundation
13 balance arm include counterweight
5
Ⅱ Main Technical Specifications
1. Technical Specifications of the concrete placing boom

Model HG32M
Delivery pipe dimension (outside diameter×thickness) JJ83（mm×

Φ 134×4
mm）
Delivery hose dimension (inside diameter×length) （″ ×mm） 5″ ×3000
Radius of placing boom(m) 31.7

Stationary height(to the join between the end of the boom and
22.9
Swivel table (m)
1st section 14.5m
Three hydraulic foldable arms 2nd section 9.2m
3rd section 8.0m
1st section －4.2°～＋82.5°
Boom articulation 2nd section 0°～180°
3rd section 0°～180°
Slewing range(°) 360
Power of motor(kW) 15
Pressure of hydraulic system (MPa) 28
Type of hydraulic oil ESSO NUTO H46
working pressure (MPa) 25
climbing
climbing speed (m/min) 0.56
cable remote control
Mode of operation
radio remote control
power 440V/60Hz
Placing concrete ≤ 60 km/h

wind speed
Climbing ≤ 28 km/h
working temperature 0～48℃
6
2. Working range
7
III 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
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Have the concrete foundation on which the cruciform base is to be erected prepared in
accordance with the requirements.
Ensure the verticality of the centerline of the cruciform base and level surface less than 1/500.
Deviation for 20m tubular column
2. Erecting and Dismantling

2.1 Preparing before erecting
2.1.1 Prepare a private power supply box for concrete placing boom at the worksite.
2.1.2 Connect the power supply box with transformer station of the worksite directly using
cable. The distance between the box and station is less than 30 meters.
2.1.3 According to the maximum weight of the subassemblies of the equipment, choose
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proper hoisting equipments and mounting tools(auxiliary hoisting tools, sleeper,
rigging and rope clamps).
Note: The maximum weight of the subassemblies of HG32M is 4.3 tons.
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.
2.2 General requirements of erecting and dismantling
2.2.1 The workers who erect or dismantle the equipment must be skilled, familiar with the
performance and features of the equipment, and have ability to deal with fault.
2.2.2 During erecting or dismantling, all workmen must obey the director's command.
2.2.3 Work off the court neatly, and enclose it with flag-bar, forbid other people come in.
2.2.4 Adopting valid precaution prevent workmen from being hurt by falling block.
2.2.5 The workmen must wear safety helmet and safety shoes, tie safety belt according to
the demand of working at high place.
2.2.6 In big thunderstorm, heavy snow, thick fog and the wind speed over 7.8m/s (wind
force up to 4) conditions, erecting and dismantling are forbidden.
2.2.7 Before working, check the equipment carefully to clear all the hidden trouble.
2.3 Erected on the concrete foundation
2.3.1 Erecting the tower section
2.3.1.1 Erecting the lower- tubular column. (Weight: 3950kg)
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Fitting the ladder and delivery line
Note: The ladder, delivery pipe and guard ring must be mounted on the lower-tubular
column.
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Lift the lower-tubular column on the cruciform base and screw it to the cruciform base with
16 high-tensile bolts (M30) which must be tightened with a torque 1400N.m. Each high-tensile
connection consists of a high-tensile bolt, 2 washer and 2 high-tensile nuts. The strength of the
bolts is 10.9. After erecting, use a transit to check the verticality of 4 sides of the lower-tubular
column, ensure the vertical tolerance 1/500.
2.3.1.2 Erecting the upper-tubular column (weight: 4300kg)
Note: The beams for the working platform,

ladder, delivery pipe and guard ring must be
mounted on the upper-tubular column.
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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. Pay attention to the
direction.
2.3.1.3 Fix the working platform (weight: 300kg)
1. Assembly the working platform.
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.
13
2.3.2 Erecting the rear section of big arm, swivel table, lower-support and slewing ring
support (weight: 4300kg)
Lift this assembly on the upper-tubular column，and connect the lower-support to the
quick mounting adapter.
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.
2.3.3 Erecting weight counterbalance in the balance arm and screw each other with 2
high-tensile bolts (M24). (Weight:2300kg)
2.3.4 Erecting the fore section of big arm, mid arm and small arm (weight: 3700kg)
1. Lift the assembly to the proper position, and let the pin of fore section of big arm
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locate into the U groove at the rear section of big arm, lock the pin with plates and
bolts.
2. Connect the two sections of big arm with slipknot-bolts.
2.3.5 Lift the electrical control cabinet and oil tank onto the platform of the swivel table and
fix them on the proper position.
2.3.6 Connect all delivery pipes together with pipe clamp. Use hoses to connect hydraulic
pipeline. Use conducting cable and cable to connect the electrical control system. And install a
earth-fault protection, the resistance of the earthed resistance is less than 4Ω .
2.3.7 Check the all connecting-bolts, the pipes connecting of the hydraulic system and the
connecting of the electrical control system carefully to ensure that they are all right.
Hereto, the erection of the concrete placing boom is done.
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2.4 Erected climbing placing boom

2.4.1 The erection of the climbing devices
The erection of the climbing frame is introduced in the chapter of "climbing".
2.4.2 The erection of the other subassemblies has been mentioned in the chapter 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.
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Ⅳ Electrical system
The electrical system of HG32M 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.
There are two control modes: cable remote control and radio remote control.
The cable remote control apparatus is connected with the electrical control cabinet by the
cable. The concrete placing boom can be controlled by the switch on the panel.
The radio remote control system includes two parts. The first part is the emitter. The
operator uses the function buttons on the operation panel to control the left/right slewing,
unfolding/folding of arms, and the emergent stop of the concrete placing boom. The second
part is the receiver, powered by the electrical control cabinet, which receives operation
instruction, and outputs corresponding relay switch signal, controlling all function of the
concrete placing boom. Under radio remote controlling, the emitter converts operation
instruction into radio
signal and send it out. The receiver, which is connected with the electrical control cabinet
of the concrete placing boom by the cable, receives and decodes radio signal, and executes
corresponding output.
Preparations before the equipment working:
1、Make sure all the electrical system connections are right and reliable.
2、Make sure the safeguard of the electrical connection part is installed and the door of the
electrical control cabinet is closed.
3、Make sure all switches in right initial position
4、Switch on the power.
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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. If
something emergent happens, push the "emergency" button down instantly to avoid
accidence.
1.2 "Pump on/off" switch
The switch is used to control the start and stop of the pump electromotor. The control
circuit switches on and the electromotor runs when the switch is up. Vice verse, the
electromotor stops when the switch is down.
1.3 "Slewing left/right" switch
The switch is used to control the slewing of the concrete placing boom. The concrete
placing boom slewing left when the switch is up, and slewing right when the switch is down.
1.4 "Big arm unfolding/folding" switch
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The switch is used to control the unfolding and folding of the big arm of the concrete
placing boom. The big arm unfolds when the switch is up, and folds when the switch is down.
1.5 "Mid arm unfolding/folding" switch
The switch is used to control the unfolding and folding of the mid arm of the concrete
placing boom. The mid arm unfolds when the switch is up, and folds when the switch is down.
1.6 "Small arm unfolding/folding" switch
The switch is used to control the unfolding and folding of the small arm of the concrete
placing boom. The small arm unfolds when the switch is up, and folds when the switch is down.
1.7 "Climbing up/down" switch
The switch is used to control the go up and down of the climbing cylinder. The climbing
cylinder extends 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.
1.9 "Work" indicator
The indicator is light, when the "pump on/off" switch is up, which indicates that the
electromotor runs and all actions of the arms are permitted. The indicator is unlighted when
"pump on/off" switch is down.
2. The radio remote control

Operation of transmitter:
Power supply: 2 AA-size alkaline batteries

Frequency:
Receiver : 331 MHZ
Transmitter: 321 MHZ
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Atteneion:
1. Never dismantle the equipment by any unauthorized personnel, or equipment may be
damager.
2. After finishing operation of the radio controller shut off main power to the crane, power to
receiver, and remove the transmitter key. If transmitter’s power is controlled by “rotary key
switch”, then need turn the key to “OFF” position and remove it.
Precautions(I):
To avoid any interference, the receiver must be place as far from frequency inverter and power
cable as possible.
Precautions(II):
The receiver should be installed on the top of the electrical control box, do not mount the
receiver inside the electrical control box.
Emergency:
In case of Emergency, please follow the procedure below and contact the distributor for service
immediately.
① Press EMS button of transmitter.
②Remove the key from transmitter.
③Switch off the main power of crane.
④ Contact distributor nearest you immediately.
How to use:
1. Insert 2 AA-size alkaline batteries into battery compartment.
2. Insert magnetic key to transmitter.
3. Follow the Power-On procedure to energize the receiver.
4. Operate normally according to the function settings.
5. Please follow the procedure to turn off radio controller after operation: (1) Press EMS
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pushbutton/mushroom, (2)remove the key and keep it in safe place, (3)switch off the
equipment’s main power(e.g. Crane)
How to change quartz from transmitter/receiver&identify frequency quartz
It’s simple to change frequency of the new F23 series. The system’s frequency can be changed
simply by replacing correspondent frequency quartz in both TX and RX.
Note: For replacing the new crystal, there are 2 types of frequency are available(VHF & UHF).
Do not replace the VHF crystal unit into UHF PC Board. The indication of frequency type
(VHF or UHF) is shown on the PC Board with a check mark”V”.
ID Code Remote Setting
ID Code Remote setting allows you to overwrite the receiver ID code in case Receiver or
Transmitter is damaged. Before remote setting, one must make sure both TX and RX are in
same frequency channel. By using remote setting, receiver ID code will be overwritten by
transmitter.
Prior to remote setting, please follow the instruction below:
(a) Make sure both TX and RX are same model and in the same frequency channel.
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(b) To avoid interference during remote setting, place the transmitter to RX as close as possible.
(c) Turn off RX power completely (MAIN SWITCH) for 20 seconds and turn it on again.
(d) Complete the remote setting within 4 minutes after turning on the RX. The RX will NOT
accept the remote setting signal after 4 minutes.
Instructions:
(1) Depress the TX Emergency Stop(For those systems without a Mushroom style stop button
that stays depressed, please hold down the “STOP” pushbutton)
(2) Press UP pushbutton and hold it.
(3) Press DOWN pushbutton 4 times and release “STOP&UP” pushbuttons when red LED flash.
(4) Start the system as usual.
Note:
(1) By follow the procedures above, all the radios of same model within its radio operating
distance, might be affecting by ID code remote setting
(2) ID code remote setting only transmits data of ID code only.
(3) The position of magnetic key or Rotary key will not affect to the ID code remote setting.
Transmitter Batteries
2 AA size alkaline batteries are required for the transmitter. DO NOT use rechargeable batteries.
During operation, the LED flash green when battery power is full and flash red when battery
power is low. When battery power is low, transmitter may not work properly. For safety reason,
replace new batteries immediately when battery power is low.
Power Supply
3 different AC transformers are available for F-23 series and power supplied to the F-23
Receiver as below
(1) 48/110/220 VAC
(2) 110/220/380 VAC
(3) 48/220/380 VAC
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Each AC transformer provides 3 different voltages to meet different application’s need. Please
follow the procedures below to select the voltage
Transmitter LED Malfunction Alert
(A) Red color LED flashing quickly when any pushbutton is pressed. The problem could be
following:
(1) One of the pushbuttons is jammed.
(2) The EMS mushroom has not been released.
(3) The transmitter is not properly Power-On according to the instructions.
Note: Please contact the distributor nearest you for further assistant if need.
(B) TX LED flashes slowly (every 0.5 sec intermittent). The problem could be:
The memory of the TX is defective. Contact the distributor for repair.
Troubleshooting
(A) TX LED remains ON with red light. Solution: Please remove the batteries and insert again.
(B) The RX does not respond at all. Solution: Turn the main power off for 20 secnds and
turn it on again.
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24
25
26
Stop 3rd
Note: After working, shut down the power supply
Pump on 3rd
in time to prolong the service life of the battery. Pump off 2nd
Left 2nd
Right 1st
2.1 "Stop" button 1st
Electromotor stops and all arms can't work when it is pushed down.
2.2"Pump" button
Switch on the control circuit of the electromotor and the pump works when it is pushed
down.
2.3 "Pump off" button
Switch off the control circuit of the electromotor and the pump stops when it is pushed
down.
2.4 "Slewing left" button
The concrete placing boom slewing left when it is pushed down.
2.5 "Slewing right" button
The concrete placing boom slewing right when it is pushed down.
2.6 "Unfolding small arm" button
The small arm of the concrete placing boom unfolds when it is pushed down.
2.7 "Folding small arm" button
The small arm of the concrete placing boom folds when it is pushed down.
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.
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2.10 "Unfolding big arm" button
The big arm of the concrete placing boom unfolds when it is pushed down.
2.11 "Folding big arm" button
The big arm of the concrete placing boom folds when it is pushed down.
2.12 Safe magnetic lock of remote control remitter
Safe magnetic lock controls the power of the remote control emitter. When the safe lock is
set in the groove, the emitter powers on, and the operator operates all buttons to control
the concrete placing boom working. Operation is invalid, if the safe lock is removed.
3. Adjustment of the slewing limiter

3.1 Slewing limiter
The current type is DXZ-4/3. Slewing limit switch
3.2 Adjustment
3.2.1 Remove the up-shell, check and fasten two M3×55 bolts.
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3.2.2 Unscrew M5 nut.
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.
3.2.5 Let the mechanism operate without load for several times. Check if the memorized
position is OK, otherwise repeat the adjustments mentioned above.
3.2.6 If the position is ok, fasten M5 nut and mount the up-shell.
3.2.7 The device must be checked regular in case the memorized position is changed. So it
can be reset in time.
3.3 How to adjust slewing limiter (The adjustment is shown as 3.2)
3.3.1 Adjust the slewing limiter after the machine has been erected.
3.3.2 The adjustment is conducted without load. Press micro-switches one after another
with
finger, confirm if the micro-switches for right and left limit work correctly.
3.3.3 Slew to the left for 360°, shown as 3.2, adjust the shaft (4Z) to actuate cam (4T) and
press micro-switch (4WK), fasten M5 nut.
3.3.4 Slew to the left for 720°, shown as 3.2, adjust the (1Z) shaft to actuate cam (1T) and
press micro-switch (1WK), fasten M5 nut.
3.3.5 Check the right and left slewing operations.
4. Notice
(1) Read the instruction carefully before work or maintenance.
(2) The operation is permitted only under security status.
(3) Choose a safe and suitably observational working place.
(4) The operation is only permitted without eyesight obstacle.
(5) Check the validity of the emergency button before work.
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(6) Shut off the system instantly if failure or danger happens until they are solved.
——Push the "emergency" button down on the panel of the cable or radio remote control
apparatus.
—— Remove the safe lock of the emitter when controlled by the radio remote control.
——Shut off the main power switch and the switch of the electrical control cabinet.
(7) Only professional maintenance man is permitted to deal with the failure of the electrical
system.
(8) The emergency button must be push down if the operator is off the position or at
interval, and the safe lock of the emitter should be removed.
(9) Push the "pump stop" button down firstly, the "emergency" button secondly, and then
the power switch after work.
(10) Shut off the power before maintenance to avoid accidence.
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5. Diagram of electrical principle
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Ⅴ Hydraulic system
1. The principle of the hydraulic system
The diagram of the hydraulic system
32
No. Name
1 Oil tank
2 Filter installed on pump inlet
3 Globe valve
4 Motor
5 Oil pump
6 Shock-proof manometer
7 Twin pressure relief valve
8 Oil lever indicator with thermometer
9 Air cleaner
10 Filter installed on return line
11 Solenoid directional valve
12 Solenoid directional valve
13 Twin throttle check valve
14 Fast coupling
15 Balance valve
16 The hydraulic cylinder of the big arm
17 The hydraulic cylinder of the mid arm
18 The hydraulic cylinder of the small arm
19 Balance valve
20 Climbing hydraulic cylinders
21 Normally close brake
22 Slewing motor
23 Pressure relief valve
24 Slewing cushion valve
25 Check valve (open pressure 0.3Mpa)
33
1.2 Logic relation table of the solenoid directional valves
Valve 12(3)
Valve 12(1) Valve 12(2) Valve 12(4) Valve 12(5) Valve
（small
(slewing) （climbing）（mid arm）（big arm） 11
arm）
A B A b A B A B A B A B
Pump starting × × × × × ⊙ ×
Unfolding small arm × × √ √
Folding small arm × × √ √
Unfolding mid arm × × √ √
Folding mid arm × × √ √
Unfolding big arm × × √ √
Folding big arm × × √ √
All cylinder of arms
× × × × × ⊙ √
finish working
Left slewing √ × × × × √ √
Right slewing √ × × × × × ×
Stop slewing × √ × × × ⊙ √
Extending the cylinder
× √ × × × × √
of climbing device
Pump stopping × × × × × × ×
√ Power on ×Power off
⊙ Means that the valve power off after powering on 3 seconds.
1.3 Introduction of working principle
After starting, hydraulic oil flows through valves 11、 filter 10, back to oil tank. The function
of pressure relief valve 7 is safety insurance (designed pressure is 28MPa).
When a cylinder working, the valve 11(b) powers on, supplies hydraulic oil for the cylinder
working.
When the slewing motor working, the valve 12(1) and 11(b) powers on, the brake releases.
Hydraulic oil drive the slewing motor to drive the placing boom slewing.
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2. Manifold valve block
In order to keeping hydraulic system compact and reducing failure, all the valves are integrated
on a manifold block.
Manifold valve block
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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" position, retract the cylinder of the big arm to
the limit position, at this moment the hydraulic pressure is the maximum working pressure.
Adjust the handle of the valve 7 to alter the value of the manometer reaching to 28MPa. Then
lock the loose-proof nut of the valve 7.
3.2 Adjusting extending and retracting speed of the small arm cylinders
Adjust the opening width of the corresponding twin throttle check valve13 to alter the
extending and retracting speed of the small arm cylinders. The method as follow: Use the
inner-hexagon spanner to screw the valve cores at 2 sides of the valve13. Screw the valve cores
clockwise to decrease the extending and retracting 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. The method as follow: Firstly, dismantle 2 oil pipes of the slewing reductor, use
2 screw plugs to plug the 2 screw holes. Loose the lock nut of the adjusting screw at the left
side of the valve 23. Switch to the "left slewing" position. Assure that the relief pressure of valve
7 is 28MPa, then rotating screw of the valve to adjust relief pressure of the slewing motor,
when value of the manometer reaching to 12MPa, stop adjusting and lock the loose-proof nut.
Use the same method; adjust the relief pressure of other pressure relief valve for "right
slewing", then lock the loose-proof nut. Reconnect the 2 pipes without problem of the relief
pressure.
Relief pressure of the hydraulic system, cylinder extending and retracting speed,
and slewing speed are adjusted and locked before shipped. Don't adjust them freely.
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4. Notice
· It is forbidden to open the globe valve at working.
·The hydraulic oil is specified in technical parameter without impurity.
· At normal condition, the hydraulic oil level reaches the 80% height of the tank. But it is
forbidden that the hydraulic oil level is lower than the 50% height of the tank.
· Clean out the filter installed on return line periodically.
·When the equipment has failure, firstly check the electrical system, and then check the hydraulic system..
· It is forbidden to bring impurity into components at dismantling or fixing hydraulic
components condition.
·Don't adjust the relief pressure of the pressure relief valve freely after adjusted.
·When the balance valve with failure, change it in time. Taking it apart is prohibited.
Oil pump rotating direction
· Faced with the output of the motor, the pump rotating direction is counterclockwise.
·Slewing reductor: Correctly connect pipes. Use one inlet of the 2 brake inlets.
Notice! It is prohibited to connect them wrong.
Dismantle the counter bolt of viewing port, and pour lubricating oil into the motor until
lubricating oil outflow from viewing port.
37
Slewing reductor
38
Ⅵ 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.
· It is forbidden to run the equipment while wind speed over 13.8m/s（wind force up to 6）,
and to erect or dismantle the equipment while wind speed over 7.78m/s(wind force up to 4).
· Keep certain distance between the placing equipment and high voltage cable .
Rated voltage (V) safe clearance (m)

≤ 1 kV 1.0
1 kV to 110kV 2.0
110 kV to 220kV 3.0
220 kV to 380kV 4.0
Unknown rated voltage 5.0
· The end hose must be secured by a retaining rope. The maximum permitted length is 3
meters.
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·The end hose must be allowed to hang freely, never bend the end hose over or insert it in
the concrete.
· 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.
·The machine operator must be capable of seeing the working range at all time and under
all circumstances. If he cannot, he should be indicated by a signalman.
·Extend the placing boom is not permitted.
·Never open the pipe union of delivery line under pressure!
40
·It is prohibited to dismantle the end hose, and connect the arm tip with other rigid delivery
line.
· If the delivery pipe is worn, you must use the same type pipe(outside diameter ×
thickness Φ 133×4mm).
·During slewing, it is prohibited to change the slewing direction.
· Unfolding or folding two arms at the same time is forbidden. After the tower section not
wobbling, then operate the other arm.
· The pressure of the hydraulic system must not be over 31.5Mpa .
·When the balance valve is fail, you should alter it in time. The failing performance of the
balance valve is that the placing boom fall naturally, cannot be locked at a certain position.
Firstly the placing boom fall slowly, time after time, then fall like a freely falling body and make
a bad accident.
· After working, the operator must fold the placing boom, secure the arms by safety hook,
set the big arm horizontally and shut down the power supply finally.
· The placing boom must not be used for lifting and transporting loads.
· Do not deliver concrete in these positions as fig.
41
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.
（3）Push on the power switch of the remote control apparatus.
（4）Push on the "oil pump start" button to start the motor of oil pump.
o
（5）Push on the "unfolding big arm" button, unfold the big arm approximately 45 angle of
elevation, then push on the "folding mid arm" button to release the safety hook completely,
and push on the "unfolding mid arm" button to unfold the mid arm.
（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
42
horizontally finally.
（9）Push on the "oil pump stop" button to stop the motor of oil pump.
（10）Shut down the power switch of the cable remote control apparatus.
（11）Shut down the main switch on the electrical control cabinet.
Use cable or radio remote control apparatus to realize step (4)～(9) function.
3. Maintenance
In order to guaranteeing maintenance man safety, it is necessary to build up a platform for
checking and maintaining the placing boom on the floor.
3.1 Periodic inspection
3.1.1Daily inspection
· Inspect if the electrical control system works normally or not before operating.
· Inspect whether the hydraulic oil level which is lower than the half of the oil tank or not,
and the hydraulic oil is emulsified or not.
·Check if the hydraulic system lines leak.
· Check the direction of rotation of the pump.
· Check if the balance valve which work reliably or not.
3.1.2 Weekly inspection
· Check whether the connecting bolts, the
end clamping plates, pins and lock nuts looseness or not.
·Check the delivery pipes and change the pipes immediately when the thickness of the
pipes is less than 2 millimeters.
Act as the following to prolong the service life after approximately 6000m3 pumped
volume：
o
--- Rotate the bends through 180 of the delivery line.
43
o
--- Rotate the all delivery pipes through 120 of the delivery line.
· 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.
· Check the shaft coupling of the motor.
· Check the motor, the insulation resistance of the circuit, the metal shell of the electrical
equipment, and the earthed resistance of the metal structure.
· Visual inspection of electrical cable, repair and change it after burn in or breakage.
· Fully check and maintain all the parts of the equipment including hydraulic and electrical
components.
3.2 Lubricate
Pour grease to the mobile pins periodically.
44
Schematic diagram of lubricating points of the equipment
No. Position
1 Slewing supporting bearing and gear rim

2 The choke at the end of rear section of the big arm
3 The choke at the linkage pin of the hydraulic cylinder of big arm and the swivel
table
4 The choke at the linkage pin of the mid arm and the small arm
5 The choke at the linkage pin of the small arm and the small straight link
6 The choke at the linkage pin of the hydraulic cylinder of big arm and the rear
section of the big arm
7 The choke at the linkage pin of the mid arm and the hydraulic cylinder of the small
arm
8 The choke at the linkage pin of the fore section of big arm and the hydraulic
cylinder of the big arm
9 The choke at the linkage pin of the hydraulic cylinder of the mid arm and the big
straight link
10 The choke at the linkage pin of the big crooked link and the big straight link
11 The choke at the linkage pin of the big crooked link and the fore big arm
12 The choke at the linkage pin of the fore big arm and the mid arm
13 The choke at the linkage pin of the mid arm and the big straight link
14 The choke at the linkage pin of the hydraulic cylinder of the small arm and the small
crooked link
15 The choke at the linkage pin of the small crooked link and the small straight link
16 The choke at the linkage pin of the small arm and the small crooked link
45
3.3 Clean out the delivery pipes
Use the concrete pump or water pump for pumping water to clean out the delivery pipes.
Clean out the delivery pipes in proper occasion, and use the remainder concrete in the
delivery line for building. The remainder concrete in 1-meterφ 125 delivery pipe is about 12.3
liters.
（1）Use the concrete delivery pump of the equipment for pumping water to clean out the
delivery pipes as follow: After pumping, open the door of the hopper of the equipment, drain
away the remainder concrete, dismantle the taper pipe at the export of the hopper, clean the
taper pipe, start the delivery pump oppositely to drain away the remainder concrete in the
concrete cylinder, clean the hopper with water, fix the taper pipe again with 2 sponge balls in it,
close the door of the hopper, pour water into the hopper and start the pumping until the
sponge balls are drained out from the end of the delivery line.
（2） The method of using water pump for cleaning out the delivery pipes as follow: After
pumping, dismantle the vertical pipes to drain away remainder concrete, then connect the
pipes again, dismantle the taper pipe at the export of the hopper, put 2 sponge balls into the
delivery line, connect the delivery line with high-pressure pipe of the water pump, fix them with
pipe clamps, start the water pump and send pressurized water into the delivery line until the
sponge balls are drained out from the end of the delivery line.
Notice! The delivery pipes must be cleaned out in any occasion after pumping.
46
4. Analysis of the common failure

Failure Reasons Solutions
The direction of the oil pump's Check the direction of the
rotation is incorrect. oil pump' rotation
The value of the manometer is Check the circuit and
The overflow valve is failure
zero overflow valve 7
Change the pressure
The pressure gauge is fault
gauge
The oil inlet of the oil pump is The filter 2 installed on pump Change or clean out the
compressed inlet is blocked filter
The oil pumped by oil pump The inlet hose has leak and air
Change the oil inlet
generates foam penetrate into the oil
The balance valve leaks Change the balance valve
The placing boom sinks down The joint ring of cylinder is
Change the joint ring
breakage.
All hydraulic cylinders is The pressure of the relief valve 7
Adjust the pressure again
powerless is too lower
Failure Reasons Solutions
The solenoid directional valve is Check the circuit and clean
One cylinder cannot move
failure out directional valve
The brake torque of slewing is
The oil pressure of brake is lower Adjust the throttle valve 24
not enough
1 、 Switch on the power
1、The main power switch or the
switch or the breaker.
breakers in the electrical control
2 、Reset the "emergency"
cabinet -QFZ, -QFY, -QFA, -QFB
button.
don't be switched on.
3 、Check the– KM control
2 、 The "emergency" button on
circuit, remove junction
the panel of the cable remote
Failure to start electromotor, malfunction or replace
control is not released.
and the power indicator is electrical component.
3、The contact -KM doesn't work
unlighted 4 、 Check the power
or be damaged.
indicator and the lamp
4 、 The power indicator is
base, replace or reinstall
damaged, or badly touches with
the indicator
the lamp base.
5 、Check the junction of
5 、 The junction of the power
the power switch or
switch is loose or damaged.
replace one
1、Main power switch or the
breaker in the electrical control 1、Switch on power switch
All operation of the cable cabinet doesn't be switched on. or breaker.
remote control has no 2、The "emergency" button on
responses. 2、 Reset the "emergency"
the remote control panel is not
button.
released
1、The corresponding socket of 1、Open the receiver box of
Some arm doesn't work with the arm in the receiver is defect the radio remote control,
radio remote control. of contact. fasten all socket and screw
2、The corresponding relay of the all bolts
47
arm is damaged in the receiver. 2、Choose the model of the
3、The communication frequency cable remote control.
of the radio remote control is 3、
interfered Use with the cable remote
control
1、The power is defect of contact. 1、Fasten the power line.
The radio remote control fails 2 、 The fuse of the receiver is 2 、 Check the fuse in the
to send signal out, or some resolved receiver.
switch has no reaction or can't 3、Fasten the interior circuit
3 、 The receiver is defect of
start board in the receiver.
contact interiorly.
48
Ⅶ Climbing
1. Construction of climbing device
Climbing device consists of 3 sets of Climbing frames, 2 sets of hydraulic cylinders and 2
locating bolts etc.
1.1 Floor frame
The floor frame with its climbing bolt carries the boom once this is no longer standing on
the cruciform base. In addition the climbing system is located on the 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.
climbing 3.0～4.2
Interval of climbing frame (m)
placing concrete
6.0～8.4
resting
1.1.1 Floor frame
49
Damage may be caused to the placing boom or to the floor when the column climbs if the
floor do not precisely match the dimensions specified.
The holes in the floor must lie precisely one over the other. The placing boom may be skewed
if they are not precisely one over the other. This leads to loading in the slewing gear and can
also be detrimental to stability.
Hole in floor
1.1.2 Wall frame
50
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 arranged regularly, the dimension is shown as following.
The holes prepared in wall
51
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.
The balance valve relief pressure is 22Mpa.
52
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. In addition, the climbing system is located on the floor frame.
2.1 Place the floor frame on the floor around the tubular column
Note: Be aware of the limits when fitting the floor frame. The boom can tip over if the limits
are not observed.
53
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.
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.
54
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
55
① Mount the climbing system on the middle climbing frame, Open the fast coupling of
climbing and start the pump to extend and retract the cylinders without loads for 5 minutes to
ensure the oil circle is ok.
② Fold the arms to level position and shift it to almost vertically upwards position.
③ Tubular column must be vertical.
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.
3.2 Climbing process
① Use the cable remote control to start hydraulic pump.
②Push down the climbing button and retract all cylinders back.
③ Insert the locating bolt into the hole of tubular column which is nearest the piston
groove.
④ Extend the piston of the cylinder slowly until the locating bolt is in the piston groove to
let the vertical force of the concrete placing boom sustained by the cylinder. Keep going, and
then pull the locating bolt which sustained the machine out.
⑤ After extending the piston of the cylinder about 100mm then retract it to check whether
system, connect part and safety device are ok or not.
56
⑥ If there is no trouble, keep the piston going to raise the placing boom.
⑦ Step change. When the placing boom has moved up 520mm, stop the cylinder and
insert the locating bolt in the hole in the tubular column again then retract the cylinder slowly.
Let the whole vertical force sustain by locating bolt.
⑧ Retract the piston to the end ,then pull out the locating bolt in the piston groove then
insert it to the next hole.
57
⑨ Repeat ④ ⑥ ⑦ ⑧, then the machine can raise step by step .
⑩ Stop climbing when the second hole (count down )of the lower tubular column higher
than upper surface of the climbing frame fitted the climbing cylinders. Insert the locating bolt
into this hole then retract the cylinder slowly until the pin fall into the groove of mid-frame. The
climbing operation has finished.
NOTE: In order to avoid collapse, the bottom of the lower tubular column is prohibited from
higher than the climbing frame fitted the climbing cylinders.
You must never hoist the tubular column from a climbing frame unless the tubular column is
held by at least two further climbing frames.
4. After climbing
(1) Mount the lower-frame to the upper holes prepared in the wall. fix the climbing frame
together with iron plate .
(2) Place wedges only on the lower and upper climbing frames.
58
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.
The placing boom is now resting on a single climbing bolt located at the climbing cylinder
bracket and held in place by two climbing frames.
5. The sustained load of the supporting part

From the first time of inside climbing, the load of whole machine is transferred to the building
through the climbing frame and extension legs (Not only in climbing, but also in placing
concrete or in rest position); the load is sustained by the building. For the reasons above,
the supporting wall must have ability to bear it. the loads schematic diagram of the placing
boom showing as following:
59
60
Ⅷ 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.
· Users must check the balance valve and big arm cylinder weekly to ensure which work
reliably. There is inside-leakage in the balance valve and big arm cylinder, the boom maybe fall
down a little in several days. Start the hydraulic system to raise the boom necessarily.
2. Satellite use
If you own a number of tubular columns and quick mounting adapters for the tubular
columns, you can quickly move the boom pedestal from one tubular column to another. This is
known as “satellite use”.
61
2.1 Removing the arm assembly
· Fold the arm assembly, secure the arms by safety hook.
· Slew the folded arm assembly to the central position.
· Separate the delivery line at the boom pedestal.
· Hook the crane hook into the lifting eye on the boom pedestal.
62
· 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.
· Then repeat these steps for the remaining tabs on the tubular column head.
2.2 Moving the arm assembly and fitting it to another tubular column.
·Transport the boom pedestal to the other tubular column.
· Carefully locate the boom pedestal on the tubular column head.
63
· Connecting the tubular column head and quick mounting adapter.
64
Ⅸ 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. The safety hook should be put up .The arm assembly must be
supported by its forward end on a support trestle of adequate load-bearing capacity. In order
to avoid oil pipe from extrusion, crosstie under the arms is needed.
In order to transporting conveniently, divide the machine into some big units. Their weight
and dimension is shown in followed table (Total weight is about 24 tons):
Dimension
Part name Weight (kg) Qty.
(m)
Cruciform base template 1000 1 2.31×2.31×0.68
Lower tubular column 3500 1 0.88×0.88×10.4
Upper tubular column 3800 1 1.08×1.1×10.6
Working platform and railings 800 1 2.1×2.75×0.25
Fore section of big arm, mid arm and small arm 3900 1 9.4×1.3×1.9
Supports, slewing ring support and rear section

4300 1 4.72× 2.6×2.51
of big arm
Floor frame 520 3 1.6×1.3×0.45
Hydraulic system 500 1 1.2×0.65×1.3
Middle section of big arm 720 1 4.25×0.94×0.73
Balance arm 300 1 2.56×0.61×0.54
Electric control box 100 1 0.5×0.24×1.3
65
Ⅹ Documents
1. Certificate of competency of the machine
2. Instruction
3. Drawing of foundation
4. Delivery list
5. List of the easily-worn parts
6. Spare Parts Manual
66
Appendix Ⅰ List of the easily-worn parts
Name Code Position

O-ring 13.2×1.8 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 2SN12-15LA
Hydraulic hose 2SN12-16SA/15LF
Hydraulic hose 2SN12-16SF/15LA
Hydraulic hose 2SN12-12LA/12LF
Hydraulic hose 2SN12-15LA/15LF
17 Lozenge airproof ring DRV100147

Placing boom and tubular
Straight delivery pipe
column
General 0039902A0001 Big arm
R275-90° Bend Mid and small arm
Molten 0039903A0001
Lower-support
HG32M.2.6
Nonstandard bend Upper-support
（0030102A6000）
Diode IN5408 Cable board of magnetic valve
Fuse RT18 Electrical control cabinet

Terminal block 870-540/281-40 Electrical control cabinet
67
Appendix Ⅱ Operation essentials of concrete jam prevention
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 .
4、 Essential operation of concrete jam prevention
① The process of pumping water and sand slurry before pumping concrete must be
continuous. If it stops during working, the water refluence may isolate the sand slurry.
② The concrete quality must be up to desire. Containing too much or too little water will
result in concrete jam.
③ Pipe cleaning must strictly follow the operation rules. Clean ball and concrete bag is
easily broken by wrong operation, which will result in concrete isolation and jam.
④ Pipes cleaning must reach every inch, No sand is permitted leave in the pipes, or else
concrete jam may happen in next time.
⑤ It cannot wait more than 40 minutes for concrete during pumping (If no concrete
isolation prevention device installed), otherwise, the concrete is isolated and jam at the
bend.
68
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.
2. Straight pipes
In normal service, the straight pipe on the small arm will be abraded worst. Then the one on
the middle arm will be secondary. But compare to the bends, service life of the straight pipe is
longer.
3. Measures of prolong the service life of the pipeline
① Install concrete isolation protection device for reducing abrasion.
② Turn the bend pipe 180°after a period of time.
③ Ensure the quality of the concrete.
69

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HG32M Operation Manual

Ⅷ Complementary instructions ........................................................................................................ 61

1. Rest position ............................................................................................................................... 61

Truemax for more consultation.

I Construction of the 32m concrete placing boom

Below you will find an overview of the main important components:

No. Component Remark

designed working platform where hydraulic pump and

4 Slewing ring support

Includes hydraulic pump, manifold valve block，all kinds of

Tubular column assembly are divided into upper-tubular

The climbing device mainly is made up of 3 sets of climbing

11 Cruciform base template

13 balance arm include counterweight

Ⅱ Main Technical Specifications

1. Technical Specifications of the concrete placing boom

Delivery pipe dimension (outside diameter×thickness) JJ83（mm×

Delivery hose dimension (inside diameter×length) （″ ×mm） 5″ ×3000

Radius of placing boom(m) 31.7

Placing concrete ≤ 60 km/h

III Erection and Dismantling

1. Cruciform base template, Concrete foundation

Cruciform base template

accordance with the requirements.

Deviation for 20m tubular column

2. Erecting and Dismantling

rigging and rope clamps).

Note: The maximum weight of the subassemblies of HG32M is 4.3 tons.

2.1.5 Users make concrete foundation according to our requirements.

2.2 General requirements of erecting and dismantling

the demand of working at high place.

force up to 4) conditions, erecting and dismantling are forbidden.

2.3 Erected on the concrete foundation

2.3.1 Erecting the tower section

2.3.1.1 Erecting the lower- tubular column. (Weight: 3950kg)

Fitting the ladder and delivery line

column, ensure the vertical tolerance 1/500.

2.3.1.2 Erecting the upper-tubular column (weight: 4300kg)

Note: The beams for the working platform,

2.3.1.3 Fix the working platform (weight: 300kg)

1. Assembly the working platform.

with cotter pins.

support (weight: 4300kg)

quick mounting adapter.

(2) Fold the tab upwards.

high-tensile bolts (M24). (Weight:2300kg)

2. Connect the two sections of big arm with slipknot-bolts.

fix them on the proper position.

earth-fault protection, the resistance of the earthed resistance is less than 4Ω .

Hereto, the erection of the concrete placing boom is done.

2.4 Erected climbing placing boom

The erection of the climbing frame is introduced in the chapter of "climbing".

2.5 The dismantling of the concrete placing boom

dismantling of the climbing frames please go to chapter 7.

The electromotor provides power for hydraulic pump.

control circuit of magnetic valve.

Preparations before the equipment working:

electrical control cabinet is closed.

3、Make sure all switches in right initial position

4、Switch on the power.

The diagram of cable remote control apparatus

1.1 "Emergency" button

1.2 "Pump on/off" switch