Placing Boom

and
Stabilization Training

rev.02 1
  What it does

The function of Placing Boom is to put

concrete at long distances by means of
dedicated piping lines.

rev.02 2
rev.02 3
 Folding Systems Sections number
4 5 6 7
K30L
K31L
K36-
K35L
K38L

K20L

K37L K39H K52L

K41L K45H K58L
K42L K53H
K48- K62H
K55L

K60H K80H

rev.02 4
 Stabilization Systems

Front : Single telescopic horizontal Front : Single telescopic X style

Rear : Fixed Rear : Swing-out

Front : Single telescopic X style Front : Double telescopic X style

Rear : Fixed Rear : Swing-out

Front : Single telescopic X style Front : Triple telescopic X style

Rear : Single horizontal Rear : Swing-out

rev.02 5
 Mechanical components

rev.02 6
 Articulations
joint

Sections

Pipes line

Turret

Rear
Front Main Outrigger
Outrigger Frame

rev.02 7
 Front outriggers Rear outriggers
Single telescopic horizontal
Fixed
Single telescopic X style

Double telescopic X style Single horizontal

Triple telescopic X style

Swing-out

rev.02 8
 Steel
components

Steel
components
Carbon
components

rev.02 9
 Placing Boom Section

rev.02 10
 ADVANTAGES

• Lower weight/mass unit respect standard

construction materials

•High stiffness and strength

•Good performance for cycling loads

(High fatigue life)

• Multiplicity of shapes that can be obtained

• Can be built stronger and stiffer structure

than steel ones
COMPOSITE CARBON MATERIAL
• No crack propagation in the material
SAME DAMAGE

DIFFERENT PROPAGATION

CARBON SKINS RESISTANT BREAK

rev.02 11
 Placing Boom Articulations joint
Angular performance 90° Angular performance 180°
Triangle Angular performance 360°
First Section

Rod lever
Actuator
Cylinder
Turret

Angular performance 260° Rod lever

Triangle

Angular performance 370° Cylinder

Angular performance 180°- 240° Angular performance 90°

Bearing Rod lever

Cylinder
Geared riducer
Cylinder Triangle

rev.02 12
 Placing Boom Pins and Bushings
First Section Boom Section
Turret
Triangle
Hollow pin Pin
Lubricating
Lubricating nipple
nipple

Bushing Blocking
pin system DU Bushing

Boom Section

Cylinder Pin

Triangle or Boom
Triangle or Pin DU Bushing
Pin Rod Level Section
Rod Level

rev.02 13
 Concrete pipes DN5”

Collar Steel pipe Collar Type

Hardened
Steel pipe
Pipes LLH
Gasket GU Gasket OR../Z

Pipes LLN Gasket GUV Gasket OR../Z

Concrete Pipes
identification plate Max pressure

Carbide pipe Size

Weight with concrete
Pipes LLS
Net Weight
Code number

rev.02 14
 Concrete pipe lines Layout

IMPACT Curve
LLN-SS
Curve Pipe
LLN-SS

Curve
LLN-SS

Rubbe pipe

Pipe
LLS-SS
Pipe
LLN-SS
Curve
Pipe LLH-SS
Curve LLH-SS
LLH-PS
Reducer
LLH

rev.00 15
 Concrete pipe lines Layout

Bend
*Bend LLN-SS Pipe LLN-
IMPACT
PP
Bend
LLN-PS
Bend
LLN-SS

Rubbe pipe

Pipe LLS-
SS
Pipe LLN-
SS
Bend
Pipe LLH- LLH-SS
Bend SS
LLH-PS

Riduction pipe
LLH-PR

rev.00 16
 Hydraulic System

rev.02 17
 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.02 18
 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.02 19
 Hydraulic pump A17FO… (ex KFA….)

Hydraulic pump A18VO….. (ex KVA….)

rev.02 20
 Boom Pressure Filter

To Boom distributor
Filter body

Indicator plug

By pass
Filter element

Filter body

From Hydraulic Pump

rev.01 21
 Boom distributor PSL…..
PSV….. HAWE
Pressure valve First section

End plates
Accumulator
LS line Pressure
adjustment
Connection block screw

Valve element

rev.02 22
 Boom distributor PSVF….. HAWE

Plate element End plates

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

rev.02 23
 Block Valve for Two geared reducer

Geared
reducer
brake

Block Valve on geared reducer

rev.02 24
 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.01 25
 Outrigger distributors

Distributor
without max
valve
Carry over

Distributor
with max
valve

rev.02 26
 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.02 27
 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.02 28
 Hydraulic Boom Diagram

To Outrigger
Distributor

rev.02 29
 Hydraulic Stabilization Diagram

From Boom Distributor

rev.02 30
 Electrical System

rev.02 31
 Electrical Layout Remote
control
trasmitter
Control Panel

Main Panel

Remote
control
receiver
Left Outrigger
enable box

Limit switch

Outriggers
distributor

Boom
Right Outrigger distributor
enable box

rev.02 32
 Boom and Outriggers commands (Open Circuit)

rev.02 33
 Boom and Outriggers commands (Closed Circuit)

rev.02 34
 Boom Limit switch and Oil filter sensors

rev.02 35
 BOOM MOVEMENTS
REMOTE CONTROL commands
Concrete
flow

Start/Stop
truck engine

Start/Stop
Remote Control
JOY STICK

rev.02 36
 REMOTE CONTROL commands
JOY STICK

Flashing light
Radio control
status

Concrete
flow

Start Remote
Control
Start/Stop
truck engine

rev.02 37
 Optional

rev.02 38
 Shut off Valve

Shut-off function
Optionally the shut-off valve can be installed on the machine and managed by
software (parameter “Shut-off valve”): this device is used to avoid the spillage of
concrete from the end hose.
The shut-off management can be used when remote controls are switched on.
When the pumping unit switch (forward or reverse) is deactivated, the controller
closes the shut-off valve and stops the pumping unit simultaneously.
When the pumping unit switch is activated, the controller opens immediately the
shut-off valve and starts the pumping unit after 4 seconds.

rev.02 39
 Automatic lubrication boom system

Light on boom system

Air on boom system

rev.02 40
 Components Calibration

rev.02 41
 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.02 42
 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.02 43
 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.02 44
 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.02 45
 Calibration of the Radio control

rev.02 46
 Calibration of RONIC radio control
MODES OF OPERATION
ATTENTION

All operations must be carried out in

compliance with general safety norms

ATTENTION

During adjustment procedures, the control manipulators must be slowly

activated. If functions are not adjusted correctly, boom sections may start
abruptly. If this should happen, the initial and/or final values must be reduced.

1 The calibrations to be made concern the "start" and the "fast" and "slow" arrival values (both in slow and fast drives)
of currents to the solenoid valves of the proportional distributor.

a - With the "start" current adjustment, you will need to set the manipulator deviation from the central position starting
from whichever boom starts operation first.

b - With the "fast" arrival value adjustment, you will have to have the maximum excursion of the control rod of the
distributor correspond with the maximum excursion of the radio control manipulator

2 Calibrations must be carried out under the following conditions:

a -mechanical calibration of the boom distributor for the maximum speed already performed

b -radio control activated by means of the corresponding red key (a) in position "P“

rev.02 47
 Calibration of RONIC radio control

Operate as follows:
1. Start up the machine.

2. Stabilise the machine (see instructions manual).

3. Open the boom (see instructions manual).

ATTENTION
Operate on the radio control with extreme caution and,
if possible, bring the boom to a vertical position (fully extended).

4. Move near the distributor (usually on the right side of the machine

Operating on the radio control, position the potentiometer (b)

at the centre.

rev.02 48
 Calibration of RONIC radio control

1. Insert the red key (c) in the radio control outlet.

2. Turn the red key (c) clockwise, bringing it to position "I”

3. Start up the radio control, moving the "START" (d) lever selector to the
right. You will hear a "beep" confirming correct start-up.

4. Turn the red key (c) clockwise, bringing it to position "P”

rev.02 49
 Calibration of RONIC radio control

Calibrating the "start" current:

These calibrations must be performed both in "Slow" and "Fast" modes.

Selector "b.

Gently move the manipulator of the section you wish to adjust until you
reach the point at which the distributor permission lever ("dead man's"
lever) starts to move.

"Dead man" lever

In this condition, adjust the current using the "GAS" (d) lever selector
(moving to "+" or "-") until you reach the required starting point

rev.02 50
 Calibration of RONIC radio control

Choosing the "FAST" arrival mode:

Move the "SLOW-FAST" (b) lever selector to "FAST" ( )

Gentle move the manipulator (m) forward until the horn begins to honk.

Move the manipulator of the section you wish to adjust until you arrive at
maximum stroke

Keep the manipulator in this position and adjust the current using the "GAS"
(d) lever selector (moving to "+" or "-") until you reach the maximum stroke
of the respective distributor lever

Release the manipulator and the "GAS" (d) lever selector.

rev.02 51
 Calibration of RONIC radio control

Choosing the "SLOW" arrival mode:

Move the "SLOW-FAST" (b) lever selector to "SLOW“ ( ).

Gentle move the manipulator (m) forward until the horn begins to honk.

Move the manipulator of the section you wish to adjust until you arrive at
maximum stroke.

Keep the manipulator in this position and adjust the current using the "GAS" (d)
lever selector (moving to "+" or "-") until you reach the point corresponding to
60/70% of the stroke of the respective distributor lever.

Release the manipulator and the "GAS" (d) lever selector.

Repeat these same operations for each boom movement.

Once you have finished using calibration mode, switch off the machine and remove the
red key (c) from the radio control, turning it counter-clockwise to set it in position "0".
Store it in a safe place.

rev.02 52
 Calibration of the Radio control

rev.02 53
 Calibration of radio control
MODES OF OPERATION
ATTENTION

All operations must be carried out in

compliance with general safety norms

ATTENTION

During adjustment procedures, the control manipulators must be slowly

activated. If functions are not adjusted correctly, boom sections may start
abruptly. If this should happen, the initial and/or final values must be reduced.

1 The calibrations to be made concern the "start" and the "fast" and "slow" arrival values (both in slow and fast drives)
of currents to the solenoid valves of the proportional distributor.

a - With the "start" current adjustment, you will need to set the manipulator deviation from the central position starting
from whichever boom starts operation first.

b - With the "fast" arrival value adjustment, you will have to have the maximum excursion of the control rod of the
distributor correspond with the maximum excursion of the radio control manipulator

2 Calibrations must be carried out under the following conditions:

a -mechanical calibration of the boom distributor for the maximum speed already performed

b - radio control activated by means of Tele-Teach- In (a) type (charged) battery insertion.
(two different types of batteries depicted)

rev.02 54
 Calibration of radio control

Operate as follows:
1. Start up the machine.

2. Stabilize the machine (see instructions manual).

3. Open the boom (see instructions manual).

ATTENTION
Operate on the radio control with extreme caution and,
if possible, bring the boom to a vertical position (fully extended).

4. Move near the distributor (usually on the right side of the machine

Operating on the radio control, position the potentiometer (b)

at the centre.

rev.02 55
 Calibration of radio control

1. Switch off the radio control.

2. Replace the standard battery with a Tele-Teach-In (a) type, necessary for radio
control programming.

Make sure that the Tele-Teach-In battery is charged.

3. Activate the radio control in programming mode, keeping the two buttons “+” and
“-” on the Tele- Teach-In (a) battery pressed and pressing the “On/ Off” button.

4. Keep the two “+” and “-” buttons pressed until the green LED (b) on the radio
control (c) starts to flash quickly. Release the buttons.

5. The radio control is now in programming mode

rev.02 56
 Calibration of radio control

Calibrating the "start" current:

These calibrations must be performed both in "Slow" and "Fast" modes.

Selector “h”.

Gently move the manipulator of the section you wish to adjust until you reach the
point at which the distributor permission lever ("dead man's" lever) starts to move.

"Dead man" lever

In this condition, adjust the current using the "+" and "-" buttons on the Tele-Teach-In
battery until you reach the starting point required by the section involved.

rev.02 57
 Calibration of radio control

Choosing the "FAST" arrival mode:

Move the "SLOW-FAST" (h) lever down to "FAST" ( ).

Move the manipulator of the section you wish to adjust until you arrive at
maximum stroke.

Keep the manipulator in this position and adjust the current using the "+" and
"-" buttons on the Tele- Teach-In battery until you reach the maximum stroke of
the respective distributor lever.

rev.02 58
 Calibration of radio control

Choosing the "SLOW" arrival mode:

Move the "SLOW-FAST" (h) lever up to "SLOW" ( ).

Move the manipulator of the section you wish to adjust until you arrive at
maximum stroke.

Keep the manipulator in this position and adjust the current using the "+" and
"-" buttons on the Tele- Teach-In battery until you reach the point
corresponding to about half of the stroke of the respective distributor lever

Repeat these same operations for each boom movement.

rev.02 59
 Calibration of radio control

Storage of calibration occurs in the receiver (d) when the transmitter is turned off (c). This
operation is shown to be in progress by the yellow LED (f) lights up while saving and by the
green LED (e), both present on the receiver lid (d).

After each adjustment, save data by switching off the radio control and waiting for successful
data saving before switching it back on.

Once the calibration process has been completed,

switch off the machine and switch off the radio control

rev.02 60
 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.02 61
 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.02 62
 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.02 63
 CENTRE BEARING PROCEDURE -Single geared reducer-

1. The centre bearing must be positioned with the 3 coloured

teeth in contact with the pinion gear (look at the picture below)

2. Before tightening the bolts of the centre bearing, you must

control the maximum clearance gd between the centre bearing
and the pinion gear is : gd max = 0.05 x module (see TABLE
below). The measure of the value of gd between the teeth is
possible using calibrated shim to put between the teeth of the
centre bearing and the pinion.

3. Fix the bearing with bolts to the correct torque.

For this connections we only use screws class 10.9 or higher,
burnished or thinly oiled, the bolts must be self-locking
and in class 10K or higher and high resistance plane washer
under the head of the screw and/or under the bolt.

You can’t use elastic washer (Grover) or other unlocking system

that put any elastic element between the head of the bolt or of the
screw and the structure, because this element can’t grant the
transmission of the tightening torque.

Tightening sequence scheme

rev.02 64
 CENTRE BEARING PROCEDURE -Double geared reducer-

1. The centre bearing must be positioned with the 3 coloured

teeth in the middle position between the 2 pinion gears (look
at the picture below)

2. Before tightening the bolts of the centre bearing, you must

control the maximum clearance gd between the centre
bearing and the pinion gear is : gd max = 0.05 x module (see
TABLE below). The measure of the value of gd between the
teeth is possible using calibrated shim to put between the
teeth of the centre bearing and the pinion.

3. Fix the bearing with bolts to the correct torque.

For this connections we only use screws class 10.9 or higher,
burnished or thinly oiled, the bolts must be self-locking
and in class 10K or higher and high resistance plane washer
under the head of the screw and/or under the bolt.
You can’t use elastic washer (Grover) or other unlocking systems
that put any elastic element between the head of the bolt or of the
screw and the structure, because this element can’t grant the
transmission of the tightening torque.

Tightening sequence scheme

rev.02 65
 Outrigger bearing regulation

1. Open outrigger and stabilize

2. Regulate bearing distance 2mm

3. Fix bearing with ring nut

4. Close the outrigger and verify that bearing works well

rev.02 66
 Troubleshooting

rev.02 67
 THE BOOM DOES NOT OPEN OR DOES NOT MOVE WHEN IN A PARTICULAR POSITION

Probable causes
No pressure
Insufficient pressure
Load anomalies
Solenoid valve blocked or solenoid burnt out

Remedies
The Hydraulic pump that acts on the boom circuit normally feeds the pump circuit. Only when a boom command is
sent is the oil flow directed towards the relative circuit. It must thus be verified whether the distributor solenoid
is activated.

If the solenoid works it is a sign that the maximum pressure valve has its shutter blocked. Clean it carefully.

If the maximum calibration value prescribed for the functioning of the boom is not reached, check whether the
maximum pressure valve is out of tune. If this intervention does not solve the problem it is a sign that the pump
is worn and must be replaced.

Check that additional loads are not imposed on the boom. This is strictly prohibited since it will render the boom
unsafe and structurally unsound. Eliminate any loads or impediments to the manoeuvre.

If, after having checked the previous points the problem is not solved, the command solenoid for the individual boom
section must be checked (direct command solenoid valve or pilot solenoid valve of the lever distributor) to see if
it works. If not, there is a blockage of the cursor or the solenoid is burnt out.

Replace the parts involved.

rev.02 68
 THE BOOM WOBBLES CONSIDERABLY IN A VERTICAL OR HORIZONTAL DIRECTION
Abnormal backlash:
In the joints (between the pins and their seats).
In the thrust bearing (between the fixed parts of the thrust bearing and the rotating part).
Loose thrust bearing bolts

Remedies
Replace the worn parts and respect scrupulously the lubrication frequency.
Replace the thrust bearing, tightening to the prescribed degree.
Tighten/replace the bolts.

THE BOOM STOPS TOO SLOWLY AFTER ROTATION

Probable causes
Dirty valve block
The pump axis is not horizontal
The multiple disc parking brake in an oil bath has worn linings
The springs of the multiple disk parking brake are worn out

Remedies
Clean stop and replace valve
Position the pump level after having closed the boom.
Replace the linings.
Replace the springs

rev.02 69
 THE BOOM DOES NOT STAY IN POSITION UNDER LOAD
Probable causes
The blocking valve on cylinder is wrongly adjusted or dirty or damaged

Remedies
Adjust the cut-off valves or clean them or replace them
Replace the gasket pack. Check that the cylinder pipes are not damaged

BOOM PINS CANNOT BE LUBRICATED

Probable causes
Greaser blocked or damaged
Lubrication channels blocked by dirt

Remedies
Replace the greaser
Extract the pin. Free the channels and check the causes

BOOM PINS CANNOT BE EXTRACTED

Probable causes
The pin is seized

Remedies
Using a de-oxidising liquid, introducing it through the
greaser hole and in the coupling area.
If this has no effect, heat the external hub in which the pin
is located. The pin and the bushes must be replaced.

rev.02 70
 THE PIN TURNS, BREAKING THE BLOKING PIN
Probable causes
The pin is seized due to lack of lubrication

Remedy
Extract the pin to check the state of wear and backlash of the
coupling. Consult the CIFA service department.

REMOTE COMMANDS NOT FUNCTIONING OR PARTIALLY FUNCTIONING

Probable causes
Remote command plug not inserted or inserted badly
Plug short-circuited or power interrupted
Selector or button broken down

Remedies
Check the union between the plug and socket and connect properly
Check the connection to the plug, the socket and the cable. Replace part not working

PUSHING THE BUTTON FOR A FUNCTION ACTIVATES ANOTHER FUNCTION AT RANDOM

Probable causes
Short circuit in the push-button panel between two wires.
Short circuit in the remote control electric cable.
Short circuit in the electrical cable on the pump.

Remedy
Look for the short circuit and repair it
Look for the short circuit and repair it
Look for the short circuit and repair it

rev.02 71
 Operating Procedures
and Safety

rev.02 72
 POSITIONING AND STABILIZING
Having reached the site, place warning notices and barriers around the area of action of the
machine, near the traffic or pedestrian routes so to prevent access in the area by any
person or vehicle.

With the exception of the operator (in charge of the machine or its working), nobody must
stay near the working area of the machine.

Take the machine to the workplace and ensure that the ground is solid and flat.

Ensure that there are no persons or objects in the range of action of the machine.

Actuate the parking brake.

Insert the key and turn the selector switch enabling panel/remote controls to the panel
position to enable the same.

Turn the selector switch-engine acceleration/deceleration to increase the number of revs of

the engine.

Remove the mechanical clamp from the removable part of the stabilizer.

Press the stabilization consent push-button on the stabilization control unit and use the
lever to: - withdraw the front and rear stabilizers.
- lower the front stabilizer.
- lower the rear stabilizer.

rev.02 73
 WARNING:
During the maneuvers do not stand in the path of the stabilizer.
Repeat the operations of the previous point for the opposite side and bring the
machine visually into a horizontal position.
Use a spirit level to achieve this position of the machine

.
WARNING:
The MAX inclination must be less than or equal to 3°.

WARNING:
- check that the ground below the stabilizers does not yield.
- check that all the mechanical clamps have been returned.
-check that all the stabilization controls are set to “0”.

Should the ground not be sufficiently solid, use distribution plates or compact
wooden panels for better distribution of the stabilizers on the ground (square
15 x 15 joists).

The pump operator is obliged to stabilize the machine in accordance with the
various conditions of the ground.

This means that, according to the degree of stability of the ground (kN/m2),
the original support plates of the stabilizers must be “enlarged” by applying
larger rest surfaces in order to avoid sinking of the support feet.
rev.02 74
 As accessories CIFA provides 4 support plates (60 x 60 cm or 50 x 50 cm) in plastic which, used as a simple support base, can
cover a more extensive area in relation to the vertical loads and to the permitted contact pressure.
If a larger support surface is required, the user must provide adequate square wooden joists (15 x 15 cm) - four for each
support plate.

The Table indicates to what extent the support surfaces are sufficient or whether the above joists also have to be applied.

The Table also gives the measurements of the joists, expressed in cm

Example: Granulated ground 350 kN/mq

Vertical charge on bearing stool 175 kN
Dimensions of bearing surface 50x50 cm
Length of square wooden joists 84 cm

Example: Compacted gravel 500 kN/mq

Vertical charge on bearing stool 150 kN
Dimensions of bearing surface 50x50 cm
Length of square wooden joists not necessary

Example: Natural ground 150 kN/mq

Vertical charge on bearing stool 200 kN
Dimensions of bearing surface 60x60 cm
Length of square wooden joists not suitable ground

rev.02 75
 MOVEMENTS OF THE BOOM

Sequence for opening out the boom.

After stabilized the concrete pump, turn selector on the control panel from local to remote and then proceed
to open boom with remote control.

The sequence for opening out the boom must follow the instructions below and the relative illustrations:

WARNING:
The distribution boom should not be extended before completely stabilizing the machine as described in the
chapter "POSITIONING AND STABILIZATION.”

WARNING:
Before extending the boom, the machine should be placed on a completely flat surface.
The maximum permissible inclination is 3°. An inclination greater than that would overload the distribution
boom’s rotation system and jeopardize the machine’s stability.
If one or more outriggers lift from the ground while the distribution boom is in operation, they should be
repositioned.
All outriggers must rest firmly on the ground.

rev.02 76
 Placing Boom Diagram

DANGER

WORKING AREA NOT PERMITTED

rev.02 77
 ZR = OPENING SEQUENCE

rev.02 78
 Z = OPENING SEQUENCE

rev.02 79
 R = OPENING SEQUENCE

rev.02 80
 RZ = OPENING SEQUENCE

rev.02 81
 RZ = OPENING SEQUENCE (Boom above cabin)

rev.02 82
 RRZ = OPENING SEQUENCE

rev.02 83
 DANGERS and IMPROPER USE

Prohibition for unauthorized persons Nobody must stand under the arm,
to stand in the working area including during waiting times
Do not use the arm to lift or drag weights

The minimum distance of the arm near overhead During movements of the arm, In strong winds or gusts of winds take
electricity lines must be 7 m. avoid contact with any the necessary precautions and fold the
DANGER OF ELECTROCUTION. obstacles arm

rev.02 84
 HAND SIGNALS

WARNING:
Use hand signals when:

-the movement of the arm is not in the field of vision of the operator;
-
- the operator cannot check the distances observed on account of a
false perspective.

rev.02 85
 Structural controls

rev.02 86
WHY YOU MUST CHECK ONE MACHINE?

TO PREVENT PROBLEMS MORE SERIOUS

• Topic of this course is the Structural Control:

Verification of the regular routine maintenance;
 Search for damage, wear, corrosion;

rev.02 87
 CIFA SpA, as part of the strategy to ensure the reliability
and safety of the pumps fleet and in harmony with the
existing European Standards regarding the safety of
machines, has prepared an operating procedure to
identify and certify the actors involved in the activity
of Structural Controls to which our machines must be
periodically subjected.

•The standard specifies the security

Reference standards: requirements for the transport machines,
projection and distribution of concrete and
mortar.

•The standard deals with the significant

hazards, hazardous situations and events
relevant to machines, when used for its
intended purpose and in conditions of misuse
reasonably foreseeable by the manufacturer.

•The standard specifies the appropriate

technical measures to eliminate or reduce
risks arising from the significant hazards
during transportation, assembly,
dismantling, decommissioning, disposal,
operation and maintenance.

rev.02 88
 EN 12001
According to section 7.3 is fixed periodic monitoring
• The customer is informed of the need to periodically check the structure to be
given to authorized personnel.
• The test must be performed at least once a year or sooner, depending on the
number of hours worked measured by the counter supplied with the machine.
• Machines older than five years will have to perform additional inspections as
specified by the instruction manual.

PROGRAM CONTROLS STRUCTURAL CIFA

Years/hours Periodical control Inspection type

Within 5 years Yearly/max 1000h

EN12001: Controls and update sections and structure

From 5 to 10 years Yearly/max 500h

Over 10 years Yearly/max 250h EN12001: Controls and update sections and structure

•The customer of the pump must organize control.

rev.02 89
 EN 12001
• Control the conditions of components and functions, with particular attention to
for cracks, damage, wear, corrosion and other changes.
Completeness and efficiency of the safety functions.

The planned activities must be registered on the SERVICE BOOK .

rev.02 90
 The inspection includes:

a. Check on the parts and structural components in

relation to: damage, wear, corrosion or other
alterations.
b. Check on full installation and efficiency of the safety
devices.
c. Check that the techical data of the machine
correspond to those indicated on the sheet “Basic
data of the concrete pump and distribution boom”.
d. Check that regular maintenance has been carried out.
e. Check that the instructions and Maintenance Manual
is complete and legible.

rev.02 91
 All concrete pump manufactures require inspection of certain placing boom and
pump components as a part of routine maintenance procedures.
Look the following five points:
1. The owner of a concrete pump with placing boom is responsible for its
inspection for structural integrity.
2. This inspection should cover all structural components of the boom, pedestal
and outriggers assemblies.
3. Frequency-inspections should be made:
• Annually for the first four years
• Thereafter every six months of work.
4. If cracks or other distressed parts are found, they shall be repaired according to
the producer recommendations and by qualified personnel.
5. Special events:
• In the event of road accidents
• Structural members failure
• Contact with fixed object, or boom overloads
The boom shall be inspected as above and before being returned to the work.

rev.02 92
Visual inspection is a search for the following types of problem areas which must be for
safe operation:

1. Cracks
2. Stressed or deformed areas
3. Worn pivot points
4. Worn pins or bushing
5. Pivot pins not taking grease
6. Loose or missing pin retainers
7. Damaged hydraulic cylinders
8. Loose or missing bolts or connectors

Visual inspection requires a minimum of equipment but it does require careful

preparation of the pump and boom and the development of a checklist for the
specific model being inspected.

rev.02 93
 The boom and outriggers areas must be thoroughly cleaned prior to
inspection. All grease, oil, concrete and rust must be removed. To accomplish
this use solvent, soap, and high pressure hot water or steam.

This method is especially

important in the
following areas:
• outriggers and boom;
• pedestal or frame;
• pump and subframe;
• truck frame.

The equipment should be set

up on level ground where the
boom can be opened and
fully extended safely.

rev.02 94
 1

2
1
3
4 4

Pos. Areas description

1 Boom connections
5 2 1st Boom and turret connection
6
3 Turret area
4 Outriggers devices
5 Electrical system ( emergency devices)
6 Hydraulic system

rev.02 95
 The most used non-destructive methods:

• Eddy current
• Acoustic emission
• Liquid penetrant
• Magnetic particles

rev.02 96
 •The eddy current method is
extremely versatile in that it can Special small
be used for all applications probe big like a
pen point
suitable to be correlated to
variations in the chemical-
physical properties of any
conductor.
The sensing coil can detect even
the slightest lack of homogeneity
of material, whether caused by
geometric, electric or magnetic
Oscilloscope
variations. used for eddy
current method

rev.02 97
 • The result of acoustic emission tests
are not conventional. This method must
in fact not be used for detecting the
type and size of defects in a structure,
but rather for recording the
development of such defects during the
application of the types of stress to
which the structure will be subjected,
provided that the loads are sufficient to
generate local strains, defected
growing, slag detachment,
delamination, friction etc.

rev.02 98
 Underlined
Crack
•The test method with liquid
penetrants is suitable for
detecting defects occurring on
all types of surfaces, provided
that they are “open”.
The method is not restricted to 1 2 3
any particular material or
structure.

1 bio remover solvent BC1

2 penetrant DP 51
3 developer D100

rev.02 99
 Magnetic
field

• The magnetic particle testing,

also known as magnetoscopyc
testing, is used to detect
surface and sub-surface
defects in ferro-magnetic
matarials: cracks, cold joints, 1 2
inclusions, folds, delamitations,
lack of weld penetration etc..

1 strip film contrast paint

2 black magnetic liquid

rev.02 100
 For more information on spare parts and electrical diagrams, see the
following manuals supplied with the machine

rev.02 101
 Thank you

rev.02 102