Pumping Unit

Mechanical components
Differences between PA1506 and HP1606H

rev.00 1
 Differences between PA1506 and HP1606H

Pumping Unit PA1506 S8

Pumping Cylinders

Logic-block Unit

Water box Unit

Concrete Barrels

Hopper Unit

Pumping Unit HP1606H

rev.00 2
 Hopper Unit

PA1506 S8 (Max Capacity 550 lt) HP1606H (Max Capacity 600 lt)

Hopper Hopper

Concrete
chamber

1500 - 1550

1300 - 1350
rev.00 3
 Hopper Unit

Hopper

Hopper

Hopper door

PA1506 S8 HP1606H
Wear Ring
“S” Valve Compensating “S” Valve
8” inch Ring 9” inch

Wear Ring
Compensating Wear Plate
Gasket
Detail Wear Plate Detail
Wear Ring-Wear Plate Wear Ring-Wear Plate

rev.00 4
 Hopper Unit

Detail Detail
Gasket and Bushing
front PA1506 S8 Gasket and Bushing
rear

Lubrification Detail Lubrification Detail

HP1606H

Detail
Detail Gasket and Bushing
Gasket and Bushing rear
front

rev.00 5
 Hopper Unit

PA1506 S8 HP1606H

“S” Valve
lever

“S” Valve
Cylinders

Regulation
“S” Valve screw
Cylinders

Support
Cylinder

rev.00 6
 Hopper Unit

PA1506 S8 HP1606H

rev.00 7
 Hopper Unit

PA1506 S8 HP1606H

Agitator Agitator
Hydraulic Hydraulic
Gear Motor Motor

Hopper door
Hopper door

rev.00 8
 Concrete Barrels and Pumping Cylinders

Limit

Concrete barrels PA1506 S8 switch

Tie-rods
Water box

Pumping
Concrete barrels Cylinders

Tie-rods
Water box HP1606H Limit
switch
Pumping
Cylinders

Concrete barrels
Tie-rods

rev.00 9
 Water Box Unit

PA1506 S8 HP1606H

Half flange
Concrete Concrete Joint
Piston Piston flange

Joint
flange

rev.00 10
 Water Box Unit

PA1506 S8 HP1606H

Cover
Cover

Gasket

Grid
Grid

Water
box

Water discharged Water

box

rev.00 11
 Pumping Unit
Mechanical Maintenance

rev.00 12
 PA1506 S8

2 3
1
Replace Wear Ring
1. Shut down engine , take out Hopper grid and Agitator shaft
2. Remove collar (1)
3. Replace Wear ring (2) and Compensation ring (3).
4. Install the new Wear ring 1

Replace wear plate

1. Repeat the procedure of replacing Wear ring
2. Remove all fitting bolts of wear plate (4) and replace Wear plate
3. Install the new wear plate

rev.00 13
 PA1506 S8

Replace Concrete Piston

1
1) Start the engine and insert the hydraulic pumps
2) Close the valve (1) on the pilot line , turn on the pump command
until you get the hang of the pumping unit and keep it locked
3) Turn off the engine
4) Unscrew the bolts connecting (2) ,remove the joint flange (3)
5) Remove the joint flange (4)
6) Replace concrete piston
7) Install the new concrete piston

2 3

4 3

rev.00 14
 HP1606H

Replace Wear Ring

1. Shut down engine, release accumulator pressure and
take out hopper grid.
2. Remove plate (1)
3. Loosen bolt (2) for 20 mm. Remember not to loosen too
much, or else, when the S valve moves back, the bearing 3
may come out of bearing bush, which will result in sealing 1
damage and shortening the life of S valve.
4. Remove flange on outlet, pry S valve toward outlet until 2
the clearance between Wear ring and spectacles wear
plate is about 20 mm and then take the Wear ring out.
5. Check whether rubber spring is damaged. If damaged,
replace it at the same time.
6. Install the new Wear ring
7

6 4 5
Replace wear plate
1. Repeat the procedure of replacing Wear ring
2. Remove all fitting bolts of wear plate (7) and shake the plate
slightly, it will easily taken out.
3. Install the new wear plate
7

rev.00 15
 HP1606H

Replace Concrete Piston

1
1. Start the engine and insert the hydraulic pumps
2. Close the valve (1) on the pilot line , turn on the pump
command until you get the hang of the pumping unit
and keep it locked
3. Turn off the engine
4. Unscrew the bolts connecting (2) ,remove the joint
flange (3) and replace concrete piston (4)
5. Install the new concrete piston

rev.00 16
 PA1506 S8

Compensation Proper wear ring fitting

Ring 1 - 1,5mm MAX

1) Fit the wear ring and compensation ring , on "S" valve

through the collar. “
“S”
Valve
2) Before tightening the collar, place the wear ring at a distance
of 1 - 1.5 mm from the wear plate
Collar

3) Lock the collar on the valve "S“

Wear Ring Wear Plate

4) Verify that the wear ring rotates freely in its seat

rev.00 17
 HP1606H

Proper wear ring fitting 1

After pumping 2000m3 concrete, check the distance between wear

plate and cutting ring.
If the distance is more than 2mm and the wear is uniform, adjust the
distance as the following procedures:
2
1. Clean hopper and “S” valve;

2. Remove plate (1)

3. Tighten nut (2), pull “S” valve towards the back wall of the hopper to
reduce the distance between Wear ring and wear plate at 0.2mm. 0.2 mm

4. Replace plate (1)

rev.00 18
 Placing Boom
Mechanical components

rev.00 19
 Articulations
joint

Sections

Pipes line

Turret

Rear
Front Main Outrigger
Outrigger Frame

rev.00 20
 Steel
components

Steel
components
Carbon
components

rev.00 21
 Placing Boom Section

rev.00 22
 Construction techniques development
CIFA structural boom and frame
YEAR TYPE BOX MATERIAL and POSTION CUT WELDING MODELS (Boom
meters)
METOD
Frame Outriggers Bush Boom

1970 I first CIFA S490 S355JR S470 Oxigene Electrod CERVINIO, IMALAIA, MONTE
boom
ROSA, MONTE BIANCO,
KILIMANGIARO
S355JR
1980 T1 S490(K2) S690 S355JR Magnum S490(K2) Plasma M.A.G. K44(44), K3XL-K3R-
1990 ”Old”
S690 S690 Laser INVETTA(36), K2(32), KZ26(26),
MAGNUM28(28),
MAGNUM24(24)

1997 T2 “Middle S490(K2) S355JR(Metro) S490(K2) M.A.G. K5(52), METRO35(35),

line”
S590 S690 S690(Metro) METRO31(31), KZR24(24),
S690 S900(K5) MAGNUM28New(28),
MAGNUM24New(24)

2000 T3 S690 Hd
S600 S690 S690 K58L(58), K52L(52), K48(48),
“New” Plasma
S690(K62H) S900(K62H) K41L(41), K36(36), K35-
Laser
M.A.G. T.I.G. K35L(35), K31(31), MK28(28),
MK20(20)

2010 T4 S690 S690 S690(Std) K101H(101), K80H(80),

“New”
2014 + S900 S900 S900+Carb K63H(63), K62H(62), K50H(50),
Carbon K45H(45)

rev.00 23
 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.00 24
 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.00 25
 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.00 26
 Concrete pipe lines Layout
Curve Curve
IMPACT
Curve LLN-SS
Pipe
*IMPACT LLN-SS Pipe
Curve LLN-PP
LLN-SS
Curve
LLN-PS
Curve Curve
LLN-SS LLN-SS

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

Reducer
LLH

rev.00 27
 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.00 28
 Placing Boom
Mechanical Maintenance

rev.00 29
 Control concrete piping line

-check the state of wear of the pipes,

- check for the presence and the state of wear of the

terminal rubber safety stop,

30
- Control fifth wheel boom rotation
Remove the fifth wheel protective casings,

-Apply a dial guage by fixing the magnetised

part (x) on the structure of the sub turret and the
comparison tool (k) on the lower part of the
outer ring of the fifth wheel

- position the entire outstretched arm in a vertical position,

- reset the dial gauge
-using the radio control and keeping the arm outstretched
lower the turret cylinder until, at the end of movement, the
arm is extended in a horizontal position in a position that is
diametrically opposite to the position of the dial gauge,

-take the reading on the dial guage, indicative of the

clearance on the rolling tracks of the fifth wheel,

-check to see if this clearance is within the limits of the data

provided by the CIFA technical office, limit are 2.5 to 5.5mm

- repeat the same test by moving the dial guage 90° on the circumference
of the fifth wheel.

-(if the value is over 5.5mm , change the fifth wheel)

31
- Control pinion and fifth wheel
-Using a thickness gauge check the distance between
the teeth of the pinion and those of the fifth wheel,

gdmax=0.05 x TEETH MODULE

- Check correct tightening of the bolts of the fifth wheel

(see “BOLT TIGHTENING TORQUES TABLE” )
Check tightening bolts hammering

Replace loose bolts and the two closer on each side

-DO NOT USE HIGH RESISTANCE BOLTS GALVANIZED-

Because have undergone treatment making them brittle if
tightened to torque
•HIGH RESISTANCE 8.8, 10.9
•VERY HIGH RESISTANCE 12.9

32
33
 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.00 34
 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.00 35
 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.00 36
 Thank you

rev.00 37