DIRECTOR GENERAL
BORDER ROADS
GENERAL MAINTENANCE
INSTRUCTION NO. 250
ON OPERATION AND MAIN TENANCE OF
CONCRETE PUMP MAKE
GREAVES MODEL BP 350D CAP 46 CUM/HR
INTRODUCTION:-
(a) Concrete
Pump Greaves BP 350 D capacity 46 Cum/hr, portable type powered by Kirloskar HA
494 air cooled, 4 Cylinder diesel engine fitted with Cold starting device developing
66 HP at 2300 rpm along with quick flushing system (cleaning system) having
suitable capacity air compressor, air lines, valves, pressure gauges etc. for
cleaning of concrete delivery lines and shall be capable for pumping concrete
of water cement ratio up to 0.4 mm and aggregate up to 40 mm size through a
pipe line of 125 mm dia up to 300 Mtrs horizontally or 80 Mtrs vertically at a
pressure of 60 bar.
(b) This
GMI gives the technical specification and knowhow on the operation, maintenance
and repair procedure of subject equipment. Assuming that the technicians in the
workshop are fully conversant with the repair and maintenance practices of subject
equipment. This GMI emphasizes the special features compliance with procedures
enabling to get maximum desire service from the Concrete Pump Greaves BP 350D.
(c) The
periodic maintenance must be carried out according to the ‘Periodic Maintenance
Schedule’ described in this GMI to prevent frequent breakdown, reduce maintenance
cost, to reduce wear and tear, to give more mileage which in turn prolong the
life of equipment. The failure in adhering the guide lines given in this GMI
can result in personal injury or serious damage to the eqpt/plant. All
information and instruction in the GMI is based on the latest owner’s manual
and service booklet.
AIM:- The instructions are issued as guidelines
for schedule of preventive maintenance, lubrication of Concrete Pump Greaves BP
350 D manufactured by M/s Greaves Cotton Ltd for regular attention to keep the eqpt/plant
in good mechanical condition which must be strictly followed.
ACTION BY:-
a)
|
User unit: To carryout periodic inspection and
monitor regular/periodical maintenance as laid down in this instruction and
record the tasks done in log book.
|
|
b)
|
Field Workshop:
|
|
i)
|
To carryout and monitor maintenance
schedule and oil changes as per periodical maintenance laid down in the
maintenance instruction and to check the record of maintenance including
lubrication.
|
|
ii)
|
To advise the user unit in respect of any
lapse noticed.
|
|
c)
|
Mobile Maintenance Team: To ensure that proper maintenance is
carried out and submit report accordingly to Task Force Commander and OC Wksp
for their necessary action.
|
|
DETAILS:-
This instruction includes the following
aspects:-
a)
|
Operating
Procedure – Do’s and Don’ts.
|
Appendix ‘A
|
b)
|
Technical
Specification.
|
Appendix ‘B’
|
c)
|
Recommended
Lubricants with Filling Capacity and
oil change frequency/periodicity.
|
Appendix ‘C’
|
d)
|
Periodic
Maintenance schedule.
|
Appendix ‘D’
|
(M B Negi)
EE (E&M) SG
Joint Director (Tech)
For Dir Gen Border Roads
Appendix ‘A’
OPERATING PROCEDURE
Concrete Pumps is oil-hydraulic twin cylinder type driven by a diesel
engine. The pressure and suction passages in the gate valve housing are round
and unobstructed to ensure free flow of concrete. The single rod gate valves
are practically maintenance free and enclosed flushing system type. The pumping
pistons are lubricated by water and atmospheric pressure from a water
container. Concrete pump is equipped with adjustable hydraulic pumps. Concrete pump
is portable type and is suitable for towing at speed of up to 20 Kmph.
Working System
The concrete in the hopper is sucked from pumping pistons in to the
pumping cylinder and then pumped in to the pipeline. There are two
reciprocating pistons, i.e. while the piston performing the return stroke sucks
the concrete out of the hopper and fills the cylinder with concrete, the piston
moving forward pumps the concrete in to the delivery pipe line. Both gate valve
plates are arranged in such a manner that during the suction stroke the
aperture in the hopper stays open whereas the delivery aperture remains closed.
The pistons and gate valves are actuated by the hydraulic cylinders which
hydraulically control each other. The suction of concrete back from the pipe
line is possible by reversing the stroke cycle.
Jacking the Concrete pump
When jacking the concrete pump, it must be ensured that the pump is
standing on adequately solid ground. In soft ground timber chocks should be
used. Lower front of concrete pump by retracting the tail wheel. Remove pins of
rear jacks. Lower jacks to the ground and secure with pins (insert pins in last
hole). Lift front part of concrete pump with tail wheel. Remove pins of front
jacks. Lower jacks and secure with pins by inserting the latter in the last
hole. Take off the load from tail wheel.
General instructions
1. The pipeline provided
to the pouring point be laid with as few bends as practically possible. The
horizontal pipeline should be supported. Vertical pipelines are best supported
at the bottom of the first vertical pipe.
2. Each additional pipe should be secured
on or to the structure. If possible, the pipeline should run with structure.
When placing concrete at great heights, the proportion of the horizontal to the
vertical length should be 1:2. When using concrete from batching plants the
pump should be positioned in such a manner that the mixer can discharge
directly in to the charging hopper. To prevent segregation, chutes, conveyors
or similar should be avoided, if possible.
3. When using ready mixed concrete, if
possible, position the pump in such a manner that it can be fed by ready mix
trucks from both sides to speed up the
turn round of the trucks.
4. If concrete has to be pumped downward,
the concrete pump should be positioned to ensure that the taper pipes are
followed by at least 3 Mtr = 10 feet of horizontal pipe (facilitates
dismantling of taper pipes).
5. After the sloping pipelines, S-bends or
further horizontal pipes should be used to prevent breakage in the concrete
flow column.
Checks and Maintenance
before pumping concrete
a)
|
Check
oil level in oil level indicator provided in hydraulic tank.
|
b)
|
Check
hydraulic system for leaks (tighten all loose connections).
|
c)
|
Top
up water container (water level should reach to edge of pumping cylinders).
|
d)
|
Check
lubricant (flushing) for gate valve rods.
|
e)
|
Correct
reversing of cylinders with reduced delivery of hydraulic pump.
|
Gate valve plates must travel up to the
stop when pump has been started. If necessary, slowly close throttle valves on
control block until gate valve hits stop gently. Should the gate valve hit the
stop too hard both throttle valves should be opened partially.
Lubrication of
pipeline
1. Before pumping concrete it is necessary to
pump into the pipeline a lubricating grout of 2 parts cement and 1 part sand.
2. Before putting the lubricating grout into
the hopper it should be sprinkled with water.
3. The quantity of the lubricating grout is
determined by the diameter and length of pipeline. For a 100 mm = 4” dia
pipeline, 100 mtr = 330 feet long, approx. 150kg=330 lbs cement and 75 kg=165
lbs sand are required.
4. The lubrication grout should preferably be
mixed before it is put into the hopper.
5. First pump the lubricating grout and then
the concrete, steadily increasing output. For short distances or for ready
mixed concrete a lubrication grout of cement and water can be used.
Putting concrete pump
into operation
When the concrete pump is ideally positioned, then proceed as follows:
a)
|
Jack up concrete pump.
|
b)
|
Lay pipeline.
|
c)
|
Start engine and set the prescribed speed.
|
d)
|
Check before concrete placing.
|
e)
|
Engage Agitator.
|
f)
|
Fill with lubricating grout.
|
g)
|
Engage concrete pump.
|
Once the lubricating
has been pumped into pipeline, the concreting can commence. Now place concrete
steadily increasing output. The output of the hydraulic pump is adjustable by
means of the flow control valve. Turning clockwise reduces output and turning
anticlockwise increases output.
a)
|
Do not allow the
hopper to be pumped empty and it may cause air locks and running the pumping
pistons dry results in increased wear. (concrete erupts in hopper due to
compressed air in the cylinder).
|
b)
|
If the flushing
agent is excessively contaminated it should be replaced after concrete
placing and the gate rod packing set should be replaced as required.
|
c)
|
Check level in
water box.
|
d)
|
If stones have
jammed the Agitator, engage reverse momentarily.
|
e)
|
If blockages occur
(concrete pump stops, safety pressure has been reached) engaged lever to
reverse for a few strokes to position ‘failure’ (reverse pumping), if this
does not cure the blockage, i.e. after the concrete pump has been switched to
‘operation’, the concrete pump should be switched off . Then establish where
the blockage is, check the last batch of concrete for pump-ability. Normally
the blockage occurs in the reduction pipes of the hose.
|
f)
|
Check hydraulic oil
level and tighten all connections of the hydraulic system.
|
Cleaning after
operation
After concreting, the
pipeline and pump must be cleaned carefully. The supply of concrete should be
terminated in good time so that the concrete within the pipeline can be still
used on the site. The pipeline contents of the concrete per meter length is as
follows:-
a)
|
Pipeline size 100
mm (4”) dia
|
7.8 l/m
|
b)
|
Pipeline size 125
mm (5”) dia
|
12.3 l/m
|
c)
|
Pipeline size 150
mm (6”) dia
|
17.5 l/m
|
a)
|
Stand clear of pipe end.
|
b)
|
There must not be a bend
or hose at end of pipe line.
|
c)
|
Keep an eye on the gauge.
If after shutting the air connection the pressure drops, it is a sign that
due to expansion of the compressed air the concrete is being pushed out of
the pipeline. If the pressure drops rapidly, (shortly before the end of the
blowing out procedure) then the concrete is flowing too fast. Immediately
open cock to enable surplus air to escape. The pipeline may whip and the
concrete escaping at high velocity may damage shuttering and injure people.
|
d)
|
The pipeline connections
must be tight.
|
e)
|
The rubber ball must be a
tight fit. Otherwise the cement grout will be blown out and the concrete will
lose its lubricating properties. There is also a danger of blockage.
|
The reduction pipes
have to be emptied and flushed manually. Only the delivery of, equal diameter
can be blown out. Fit cleaning head, open cover press in a water soaked jute or
paper sack large enough that the trap basket is adequately filled by this plug
and rubber ball to prevent “shot-lie” escape of compressed air after completion
of the blowing out procedure. Switch on compressor and steadily open air cock,
when blowing out the pipeline. Observe the following:-
Flushing of pipeline
By subsequent
flushing of the pipeline, remains of cement are removed from the pipe walls. For
this purpose, open cleaning head and insert a rubber ball. Close cleaning head.
Open air cock briefly so that the rubber ball is some-what pushed into the
pipeline. Vent the pipeline and insert another rubber ball via the water
connection till space between two rubber balls with water depending upon the
length and diameter of pipeline approx. 20 to 50 Ltrs. Then push the two balls
with the water cushion through the pipeline by means of compressed air. Same as
Blowing out procedure.
Cleaning Concrete pump
It is advisable to
hose down the concrete pump occasionally during operation to prevent setting of
spilled concrete. When pumping is completed, the water container, Agitator and Gate
valve housings should be cleaned inside and out.
For cleaning of the
gate valve housing alternatively bring pumping pistons forward, switch off
concrete pump and scrap off any concrete.
Apply a strong water
jet to pumping cylinders and inner walls of control housing, particularly the
path of gate valve rods in the half sections of gate valves, until clear water
flows. Pour some oil in the suction openings and gate valve rods and then run
the pump for a few strokes. If the pump is laid off for a long period all Gate
valve parts should be greased.
Periodically apply to
the whole pump concrete removal agents and then hose down. After drying apply a
wax or silicon corrosion inhibitor. Do
not at any time allow hands or arms anywhere near gate valves during cleaning
operations.
Do’s
1.
|
Before
starting the machine, make sure that nobody is standing in the immediate
vicinity of the engine or driven machine.
|
2.
|
Engine
oil level should never be below minimum mark and same should not also exceed
maximum mark.
|
3.
|
Check
tension and change belts only when engine is at standstill. Refit belt guard,
if provided. When new belts are fitted, check the belt tension after 15
minutes running time and retighten new V-belts.
|
4.
|
If
the speed regulator has been removed for any reason, the engine must not be
started under any circumstances.
|
5.
|
If
the V-Belt fails, shut down he engine immediately to prevent engine
overheating.
|
6.
|
Increase
Engine oil change frequency when operating below -100C.
|
7.
|
If
the engine is to remain idle for an extended time, it is necessary to take
protective measures to prevent rust formation.
|
8.
|
If
the engine runs fewer hours than the prescribed utilization norms, oil should
be changed at least once in a year.
|
9.
|
The
pipeline provided to the pouring point be laid with as few bends as
practically possible.
|
Don’ts
1.
|
Do
not fill oil into the Dust collector of the pre-cleaner, if provided.
|
2.
|
Never
fill the fuel tank while the engine is running. Observe cleanliness and do
not spill any fuel.
|
3.
|
Do
not actuate the starter for more than 10 seconds. If the engine does not
start wait a minute then try again.
|
4.
|
Never
clean air cleaner with gasoline/petrol/fuel. Never clean the inner element
(Dry type Air cleaner) and always replace it.
|
5.
|
Do
not allow battery acid to come into contact with skin or clothing and do not
rest tools on the Battery.
|
6.
|
Do
not at any time allow hands or arms anywhere near gate valves during cleaning
operations.
|
Appendix
‘B’
TECHNICAL
SPECIFICATION
Description
|
:
|
Concrete Pump make Greaves model BP 350D
Cap 46 Cum/Hr.
|
Engine
|
:
|
Kirloskar HA 494 vertical inline, 4 stroke,
4 Cylinder air cooled direct Injection diesel engine.
|
Power output.
|
:
|
66
BHP @ 2300 rpm.
|
Torque.
|
:
|
20.56
Kgm.
|
Bore x Stroke.
|
:
|
100
x 120 mm
|
Total
displacement.
|
:
|
3770
CC.
|
Compression
Ratio.
|
:
|
18
: 1.
|
Direction of rotation.
|
:
|
Counter
Clockwise looking from FEW.
|
Starting Arrangement.
|
:
|
Electric
start.
|
Firing Order.
|
:
|
1-3-4-2.
|
Lubrication.
|
:
|
Forced
feed ‘G’ rotor pump.
|
Lube
oil temperature.
|
:
|
90
to 1250C.
|
Minimum
Oil pressure.
|
:
|
1.5
Kg/cm2 at Idle, 3.0 to 4.5 Kg/cm2
at Rated speed.
|
Valve
clearance in cold condition.
|
:
|
0.15
mm.
|
Injector
opening pressure.
|
:
|
260 + 10 Kg/cm2.
|
Fuel
timing.
|
:
|
90
at 1500 – 1800 rpm, 140 at
2300 – 2500 rpm.
|
Bumping Clearance.
|
:
|
0.9
to 1.1 mm.
|
Dry weight of engine.
|
:
|
421
Kg.
|
Concrete
Pump
|
||
Maximum theoretical concrete output.
(Rod / Piston side)
|
:
|
46
/ 33 cum/hr.
|
Maximum
concrete Pressure. (Rod / Piston side)
|
:
|
60
/ 86 bar.
|
Maximum
number of (Rod / Piston side)
|
:
|
25
/ 18 per minute.
|
Maximum
Horizontal placing distance. (Rod / Piston side) *
|
:
|
300
/ 430 meter.
|
Maximum
Vertical placing distance. (Rod / Piston side) *
|
:
|
80
/ 120 meter.
|
Piston
displacement 2 cylinders.
|
:
|
61
liters.
|
Pumping Cylinder dia X stroke.
|
:
|
180
x 1200 mm.
|
Drive power.
|
:
|
48.6
Kw.
|
Driving speed.
|
:
|
2100
rpm.
|
Dia of concrete delivery pipe.
|
:
|
125
to 150 mm.
|
Compressor
maximum air pressure / flow.
|
:
|
7
bar / 35 Cfm.
|
Feeding Hopper height.
|
:
|
1380
mm.
|
Dimensions. (L x B x H)
|
:
|
4550
x 2160 x 1950 mm.
|
Dead
weight inclusive of Hydraulic oil
& Fuel.
|
:
|
3000
Kg.
|
Battery.
|
:
|
12V
88 AH x1.
|
* Depending
upon job site conditions and concrete mix.
|
||
Appendix
‘C’
RECOMMENDED
LUBRICANTS WITH FILLING CAPACITY
AND OIL CHANGE
FREQUENCY/ PERIODICITY
Particular
|
Specification
|
Grade of Lubricants
(IOC Grade)
|
Filling
capacity
|
Periodicity/Frequency.
|
Engine. (with Oil filter)
|
SAE
15W 40
|
Servo
Pride XL 15W40
|
12.5
ltrs
|
After every 500 Hrs.
|
Engine.
(without Oil filter)
|
11
ltrs
|
|||
Hydraulic Tank.
|
Greaves
HI 68 Oil
|
Servo
System HLP 68
|
300
ltrs (Approx.)
|
First
change at 500 Hrs and thereafter every 2000 Hrs.
|
Gear box Agitator.
|
Gear
oil SAE 90 EP
|
Servo
Gear Super 80W 90
|
0.65
ltr
|
First
change at 50 Hrs and thereafter every 500 Hrs.
|
Compressor.
|
SAE
20W40
|
Servo
Pride XL 15W40
|
1.00
ltr
|
First
change at 150 Hrs and thereafter every 1000 Hrs.
|
Flushing
system single rod valve system.
|
Greaves
HI 68 Oil
|
Servo
System HLP 68
|
6.00
ltrs
|
If
flushing oil is excessively contaminated, replace flushing oil and packing
set of gate valve rods.
|
Cooling System.
|
-
|
-
|
-
|
Recommended
cleaning intervals after every 250 Hrs.
|
Fuel tank capacity.
|
Diesel
Fuel
|
-
|
65
ltrs (Approx.)
|
Appendix ‘D’
PERIODIC MAINTENANCE
SCHEDULE
|
S/No
|
Operation
|
Daily
|
Weekly
|
Monthly
|
Maint interval in Hours
|
||||||||
|
50
|
150
|
250
|
500
|
750
|
1000
|
2000
|
5000
|
9000
|
|||||
|
A
|
ENGINE
|
||||||||||||
|
1
|
Check
oil level in the sump and top up if necessary. Check oil leakage and rectify
if any.
|
*
|
|
|
|
|
|
|
|
|
|
|
|
|
2
|
Check
oil level in the Air Cleaner (oil bath type) and top up if necessary. Check
condition of Air Cleaner. (dry type)
|
*
|
|
|
|
|
|
|
|
|
|
|
|
|
3
|
Drain
the Sludge from the fuel tank
|
|
*
|
|
|
|
|
|
|
|
|
|
|
|
4
|
Check
condition of Battery and lead connections.
|
|
|
|
|
|
*
|
|
|
|
|
|
|
|
5
|
Check
condition of Fuel strainer.
|
|
|
|
|
|
*
|
|
|
|
|
|
|
|
6
|
Check
V-Belt tension.
|
|
|
|
|
|
*
|
|
|
|
|
|
|
|
7
|
Check
Safety system provided in engine.
|
|
|
|
|
|
*
|
|
|
|
|
|
|
|
8
|
Check
the condition of Fasteners.
|
|
|
|
|
|
|
|
*
|
|
|
|
|
|
9
|
Check
the function of Starter Motor & Alternator.
|
|
|
|
|
|
|
|
|
*
|
|
|
|
|
10
|
Check
the Valve clearance.
|
|
|
|
|
|
|
|
|
*
|
|
|
|
|
11
|
Check
the condition & function of the Injector.
|
|
|
|
|
|
|
|
|
*
|
|
|
|
|
12
|
Check
the function of Flame heater.
|
|
|
|
|
|
|
|
|
*
|
|
|
|
|
13
|
Clean
the Cooling system.
|
|
|
|
|
|
*
|
|
|
|
|
|
|
|
14
|
Change
oil in Air cleaner. (oil bath type)
|
|
|
|
|
|
|
*
|
|
|
|
|
|
|
15
|
Change
Air cleaner element. (Dry type)
|
|
|
|
|
|
|
|
*
|
|
|
|
|
|
16
|
Change
Engine Lube oil.
|
|
|
|
|
|
|
*
|
|
|
|
|
|
|
17
|
Change
Lube oil filter element/cartridge.
|
|
|
|
|
|
|
*
|
|
|
|
|
|
|
18
|
Change
Fuel filter insert. (Pre-filter element/Cartridge)
|
|
|
|
|
|
|
*
|
|
|
|
|
|
|
19
|
Change
Fuel filter insert. (Micro filter element/Cartridge)
|
|
|
|
|
|
|
*
|
|
|
|
|
|
|
20
|
Change
V-Belt.
|
|
|
|
|
|
|
|
|
*
|
|
|
|
|
B
|
CONCRETE
PUMP
|
||||||||||||
|
21
|
Check
oil (Hyd tank) and water level . (Water Container),top up if necessary
|
*
|
|
|
|
|
|
|
|
|
|
|
|
|
22
|
Clean
the Concrete pump.
|
*
|
|
|
|
|
|
|
|
|
|
|
|
|
23
|
Check
oil level in Agitator gear box and Compressor, Top up if necessary.
|
|
*
|
|
|
|
|
|
|
|
|
|
|
|
24
|
Check
operating pressure of safety valve.
|
|
*
|
|
|
|
|
|
|
|
|
|
|
|
25
|
Clean
Suction filter-Compressor
|
|
|
*
|
|
|
|
|
|
|
|
|
|
|
26
|
Check
fixing bolts of components mounted on chassis frame for tightness.
|
|
|
*
|
|
|
|
|
|
|
|
|
|
|
27
|
Check
& Replace throw-away filter cartridge when the warning Buzzer blows up.
|
*
|
*
|
*
|
*
|
*
|
*
|
*
|
*
|
*
|
|
*
|
*
|
|
28
|
Change
oil in Agitator gear box.
|
|
|
|
*
|
|
|
*
|
|
*
|
*
|
|
|
|
29
|
Change
oil in Compressor.
|
|
|
|
|
*
|
|
|
|
*
|
|
|
|
|
30
|
Change
oil in Hydraulic tank.
|
|
|
|
|
|
|
*
|
|
|
*
|
|
|
Note:
a) Daily, Weekly and Monthly
maintenance is based on average pumping operation of 8 Hrs per day.
b) If the flushing oil is
excessively contaminated, replace packing set of gate valve rods and flushing
oil.
__________
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