Scorpion User Manual

MAINTENANCE AND USER MANUAL FOR SCORPION CONCRETE PUMP WITH 4x4 HYDRAULIC PROPULSION SYSTEM

MAINTENANCE OF SCORPION AND USER MANUAL

1.00 1.01 1.02 1.03

GENERAL INFORMATION – LEARNING ABOUT THE SCORPION ENGINE DETAILS WHY KAWASAKI? UNIQUE FRAME LAYOUT

2.00 2.01 2.02

FIRST START START - (START UP) BATTERY INSPECTION AND MAINTENANCE VISUAL CHECKS

3.00 3.01 3.02 3.03 3.04

MOVEMENT HYDRAULIC PROPULSION SYSTEM MOVEMENT CONTROL BY CONTROL PANEL MOVEMENT CONTROL BY REMOTE CONTROL DEVICE HYDRAULIC BRAKE

4.00 4.01 4.02 4.03

INSTALLATION CAUTIONS TO BE TAKEN DURING THE INSTALLATION OUTRIGGERS INSTALLATION AND FOLDING OPENING AND CLOSING THE HYDRAULIC FEET

5.00 5.01 5.02 5.03

BOOM POSITIONING BOOM OPENING OPENING AND CLOSING THE BOOMS BY CONTROL VALVE OPENING AND CLOSING THE BOOMS BY REMOTE CONTROL

6.00 6.01 6.02

SLEW GEAR TURNING THE TOWER BY CONTROL VALVE TURNING THE TOWER BY REMOTE CONTROL

7.00 7.01 7.02 7.03

LEARNING ABOUT THE PUMP UNIT PUMPING CONTROL FROM CONTROL PANEL PUMPING BY REMOTE CONTROL CAUTIONS TO BE TAKEN DURING PUMPING

8.00

SUCTION SYSTEM

9.00

CONTROL BY CONTROL PANEL

10.00 10.01 10.02

REMOTE CONTROL REMOTE CONTROL LOCK RECEIVER FOR REMORE CONTROL

11.00 11.01 11.02

MAINTENANCE & CLEANING GENERAL MAINTENANCE CHART HIGH PRESSURE WASHING SYSTEM

12.00 12.01

OILING AUTOMATIC GREASING GREASING UNIT

13.00

CAUTIONS FOR LOADING AND UNLOADING FOR TRANSTPORT

14.00

VEHICLE DIMENSIONS

15.00

ORIGINAL PARTS MANUAL

16.00

TROUBLESHOOTING

2


Image: 1.00 1.00

GENERAL INFORMATION – LEARNING ABOUT THE SCORPION; It is a concrete pump called SCORPION with hydraulic boom that has a unique and proven design throughout the world in its sector.

1.01

ENGINE DETAILS;

R O T O M

CP 25.318 K

CP 40.318 Y

CP 40.318 K

CP 60.318 Y

CP 60.318 K

Make

KUBOTA

YAVUZ

KUBOTA

KUBOTA

Type

Air Cooling, 4 cylinder, diesel



39,5 kW @ 2.800rpm 48,10 hp

62 kW @ 2.200rpm 83,10 hp

49,8 kW @ 2.600rpm 66,80 hp

YAVUZ Air Cooling, 4 cylinder, turbo diesel, intercooler 39,5kW @ 2.800rpm 134,10 hp

Power kW@rpm HP

Image:1.01

3

Air Cooling, 4 cylinder, turbo diesel, 39,5kW @ 2.800rpm 84,50 hp


1.02

WHY KAWASAKI; The main hydraulic pumps of SCORPION are Kawasaki brand hydraulic pumps and they are imported from Japan. They have superior features of their kind, and these pumps are available all over the world with authorized service network. The pumps have variable flow rate and also automatic torque control system.

1.03

UNIQUE FRAME LAYOUT With a totally unique design and unique geometry of the chassis are manufactured to high strength levels and difficult/rough site conditions.

Image:1.03

4


2.00

FIRST START; ! Warning: The first run must be done under the supervision of authorized staff or trained service personnel. Using the ignition key that was delivered with the vehicle on the control panel (Image: 2.00), turn the ignition on and release it when the engine starts running. ! Warning: In order to allow the engine and hydraulic oil to warm up, you must run the engine at least 25 minutes in winter months and 15 minutes in summer months before moving the vehicle. ! Warning: It may cause serious damage to the engine if the warm up is not done. ! Warning: It may cause serious damage to the hydraulic system if the system is used without warming up. CONTROL PANEL

Image: 2.00

2.01

BATTERY INSPECTION AND MAINTENANCE; 12V 135Ah battery on the vehicle is ready for use. It can be reached to the battery as shown in below image (Image: 2.01).

Image: 2.01

5


The battery in vehicle only loses water (H2O) through evaporation and not acid (H2SO4). Lost water can be replaced by adding the same amount pure water exceeding the separators by 1 cm. ! Warning: Battery liquid level should be checked and required amount of (only) pure water should be added if the water is under the minimum required level.

In order to avoid sparking and any danger this may cause when installing and removing the battery; connect the (+) positive cable end to (+) positive battery pole first then (-) negative cable end to (-) negative battery pole. Disconnect the (-) negative cable first when removing the battery.

! Warning: Battery change or removal must be done by authorized service personnel. ! Warning: Battery repair is not possible, Do not attempt to repair or do not let anyone repair it for you. ! Warning: Batteries contain sulfuric acid which is caustic and corrosive. Gases that may leak out of batteries during usage can be explosive. Do not approach with flame and protect your eyes.

2.02

VISUAL CHECKS; ! Warning: Visual checks must be done before turning the engine on. Any conditions that may cause engine failure must be removed or changed to required condition for engine to work. If this is not possible please turn the engine off and contact nearest service engineer. Please do the following checks before starting the engine and make sure that all necessary corrections are done.             

Inside Hopper (any unwanted substance) Wheel nuts Wheel air pressures Fuel level Hydraulic oil level Engine cooling water Engine oil Battery connections Batteries for remote control (Is spare battery available?) Is the Hopper lid closed? Are the clamps installed correctly to the concrete section? Are the safety pins on clamps fitted? Is the brake system installed? ( confirmation of point 3.04 )

6


3.00

MOVEMENT;

The vehicle is 4x4 “off -road” and designed as heavy duty Points 2.00, 2.01 and 2.02 must be verified before starting and moving the vehicle.

3.01

HYDRAULIC PROPULSION SYSTEM;

Image: 3.01

Vehicle movement is done by hydraulic propulsion system. Vehicle driveline should be serviced and maintained regularly for good drive and movement. Driveline system maintenance: It should be done by opening the back covers of driveline and greasing the chains. Vehicle movement (drive) is controlled either by control panel or remote control device. 3.02

MOVEMENT CONTROL BY CONTROL PANEL; Point 3.00 must be verified before starting the movement. ! Warning: Movements must be controlled by remote control device unless otherwise is required.

3.03

MOVEMENT CONTROL BY REMOTE CONTROL DEVICE; Point 3.00 must be verified before starting the movement. For using the remote control device (Image 3.02); REMOTE CONTROL/CONTROL PANEL button should be switched to REMOTE CONTROL option. Engine rev (power) is controlled by ‘’E’’ and “B” buttons in remote control device.

“E” button increases the power “B” button decreases the power Vehicle direction is controlled by “«” and “»” buttons in remote control device. “«” button will turn the vehicle to the left “»” button will turn the vehicle to the right

“select A/B” button will move the vehicle forward “Aux” button will move the vehicle backwards

7


Remote Control Device

Image: 3.02 3.04

HYDRAULIC BRAKE; Brake system is special design and heavy weight brake system. It works with nitrogen and set for normal working conditions on flat surface at 60 bar. For very steep conditions, pressure of nitrogen tube can be increased or decreased with the help of brake valve (Image: 3.04).

Image:3.04

8


4.00

INSTALLATION; After vehicle transfer to the site, the container section should be facing where concrete load is done. OUTRIGGERS should be positioned to open safely. In order to spread the weight to wider area on the surface, wide and strong wooden beams or metal sheet should be used under the feet and should remain there during the work.

4.01

CAUTIONS TO BE TAKEN DURING THE INSTALLATION; 















Vehicle must not be placed on a sloping surface (downhill or uphill) if the site is on a sloping area, vehicle should be leveled to have zero slope. Vehicle must not be set on sewage line, sewage hole, water pipe line, telephone line. When filling foundations, the surface should be considered as soft surface and the OUTRIGGERS must be placed away from the foundation area. If vehicle is set as stationary pump, the pipe lines should be connected very well. Especially they should be supported by wall, post or appropriate support where bends are used due to high pressure on bends.

Pipes and clamps should be chosen very carefully when setting vertical pipe lines. So dismantling of the first pipes is easier. Because wear will be more on nearer pipes to the pump due to height pressure. When pouring with parallel pipe line, the line should be supported by wooden supports from the floor. If installed near Power Transmission Line: It must be installed at least 10 meter away from the transmission line. It should never be underneath transmission line. As there is more risk of arc (sparking), power supply should be cut off in rainy and damp weathers during pouring. The surface where the OUTRIGGERS are positioned must be strong enough to take the weight of the vehicle and any dynamic weight.

9


4.02

OUTRIGGERS INSTALLATION AND FOLDING; ! Warning: Hydraulic pistons must be closed when OUTRIGGERS are being installed and folding. Vehicle has four OUTRIGGERS. Feet are installed and folded manually as shown in below image 4.00 (looking at the vehicle from behind )

FRONT

BACK Image: 4.00 

Left back OUTRIGGER installation and folding:

OUTRIGGER is separated from the body manually by opening the SAFETY BOLT, foot is opened

90° resting on the SUPPORT ARM and fixed to the SUPPORT ARM by its own bolts. Folding process is the opposite of opening: removing the safety bolt from the SUPPORT ARM and fixing the foot to the body with the bolt.

Image: 4.01

10




Right BACK-OUTRIGGER installation and folding:

OUTRIGGER is separated from the body manually by opening the SAFETY BOLT, foot is opened

90° resting on the SUPPORT ARM and fixed to the SUPPORT ARM by its own bolts. Folding process is the opposite of opening: removing the safety bolt from the SUPPORT ARM and fixing the foot to the body with the bolt.

Image: 4.02 

Front Left OUTRIGGER installation and folding:

OUTRIGGER is separated from the body manually by opening the SAFETY BOLT. Also bolt is removed from the Front Left SUPPORT ARM and opened until it meets with Front Left OUTRIGGER and fixed together with its own bolt.

Folding process is the opposite of opening: Removing the safety bolt from the SUPPORT ARM and fixing the OUTRIGGER and the SUPPORT ARM back to the body with the bolts.

Image: 4.03

11




Front Right OUTRIGGER installation and folding:

OUTRIGGER is separated from the body manually by opening the SAFETY BOLT. Also bolt is removed from the Front Right SUPPORT ARM and opened until it meets with Front Right OUTRIGGER and fixed together with its own bolt.

Folding process is the opposite of opening: Removing the safety bolt from the SUPPORT ARM and fixing the OUTRIGGER and the SUPPORT ARM back to the body with the bolts.

Image: 4.04 ! WARNING: OUTRIGGERS must be checked constantly during pumping. The feet should be rebalanced safely if any changes or disfigurement is noticed on surface where the OUTRIGGERS are originally positioned.

Image: 4.05

12


4.03

OPENING AND CLOSING THE HYDRAULIC FEET: ! Warning: Make sure that OUTRIGGERS are installed and fixed correctly before opening HYDRAULIC FEET. After making sure of OUTRIGGERS are fixed correctly, HYDRAULIC FEET are opened and closed one by one until the wheels are tangent to the floor. Control of HYDRAULIC FEET is done only by control panel. ! Warning: In order to spread the weight to wider area under OUTRIGGERS, wide and strong wooden beams or metal sheet should be used under the feet and should remain there during the work. The installed four OUTRIGGERS are controlled (opening & closing) by HYDRAULIC FEET VALVE UNIT as shown in image 4.06. Each hydraulic valve controls the opening and closing of related foot only. The valves control each foot as shown in images 4.07 & 4.08 FEET CONTROL VALVES

Image: 4.06

Image: 4.07

Image: 4.08

13


FRONT

BACK Image: 4.09 

Opening and closing the back left HYDRAULIC FOOT:

HYDRAULIC VALVE for back left foot is opened. HYDRAULIC FOOT is opened or closed by using the HYDRAULIC CONTROL VALVE as shown in image 4.09. HYDRAULIC FOOT is opened when the lever is pulled down and closed when lever is pushed up. 

Opening and closing the back right HYDRAULIC FOOT:

HYDRAULIC VALVE for back right foot is opened. HYDRAULIC FOOT is opened or closed by using the HYDRAULIC CONTROL VALVE as shown in image 4.09. HYDRAULIC FOOT is opened when the lever is pulled down and closed when lever is pushed up. HYDRAULIC SERVICE CONTROL VALVE ‘’FEET’’

Image: 4.10

14




Opening and Closing the front left HYDRAULIC FOOT

HYDRAULIC VALVE for front left foot is opened. HYDRAULIC FOOT is opened or closed by using the HYDRAULIC CONTROL VALVE as shown in image 4.09. HYDRAULIC FOOT is opened when the lever is pulled down and closed when lever is pushed up.



Opening and Closing the front right HYDRAULIC FOOT

HYDRAULIC VALVE for front right foot is opened. HYDRAULIC FOOT is opened or closed by using the HYDRAULIC CONTROL VALVE as shown in image 4.09. HYDRAULIC FOOT is opened when the lever is pulled down and closed when lever is pushed up.

15


5.00

BOOM POSITIONING; ! Warning: OUTRIGGERS must be completely open before moving BOOM. BOOM positioning can be done after vehicle is correctly positioned and all four OUTRIGGERS are fixed to the floor. BOOM can be controlled by control panel or remote control.

Image: 5.00

5.01

BOOM OPENING; BOOMs are opened one by one starting from the tower BOOM. They are opened according to the site conditions such as height & dept. ! Warning: BOOMs are only used for transferring concrete to required area and must not be used for any other purpose.

5.02

OPENING AND CLOSING THE BOOMS BY CONTROL VALVE: 

1st BOOM (tower boom) is opened and closed by using 1st BOOM VALVE as shown in image 5.01



2nd BOOM is opened and closed by using 2nd BOOM VALVE as shown in image 5.01



3rd BOOM is opened and closed by using 3rd BOOM VALVE as shown in image 5.01

16


BOOM CONTROL VALVES

Image: 5.01 5.03

OPENING AND CLOSING THE BOOMS BY REMOTE CONTROL; 





1st BOOM (tower boom) is opened using Crane 1 button and closed by using Channel 1 button as shown in image 5.02 2nd BOOM is opened using Crane 1 button and closed by using Channel 1 button as shown in image 5.02 3rd BOOM is opened using Crane 1 button and closed by using Channel 1 button as shown in image 5.02 REMOTE CONTROL DEVICE

Image: 5.02

17


6.00

SLEW GEAR; The tower is capable of turning 360° Assuming the vehicle being in good position for pouring, open BOO M can be adjusted 360° to pour concrete to desired spot. ! Warning: Tower turn is 360° in total and turn needs to be undone before closing the BOOM.

Image:6.01

6.01

TURNING THE TOWER BY CONTROL VALVE TOWER TURN is controlled by lever shown in image 5.01. Tower will turn clockwise when the lever is pulled down and it will turn anticlockwise when the lever is pushed up.

6.02

TURNING THE TOWER BY REMOTE CONTROL; TOWER TURN is controlled by “«” and “»” buttons shown in image 5.02 “«” button is used for turning the tower clockwise “»” button is used for turning the tower anticlockwise

18


7.00

LEARNING ABOUT THE PUMP UNIT;

Image: 7.00 PUMP UNIT is designed to be installed on the back of the vehicle and has below components:

HOPPER

S-Tube Mixer Hopper Lid Bunker Grill



  

 

 

 

S-Tube cylinders S-Tube control fork Pool Pump cylinders

HOPPER; This is the first area where the pump meets concrete. So inside of this area must be checked before using and remove any substances that may cause problem. 

S-Tube; This determines which DISPATCH CYLENDER to use sending the concrete from HOPPER 

Mixer; This is used keeping the concrete runny (as fluid) inside the HOPPER at all times. It should be working all the time for sending the concrete to the DISPACTH CYLENDERS. Control of MIXER is done by control lever shown in image 4.10 

Hopper Lid; This is a hydraulic lid underneath HOPPER, used for evacuating the excess concrete from HOPPER after finishing pumping process. HOPPER lid control is done by control lever shown in image 4.10 

Bunker; This is a part on HOPPER to control the flow of concrete. 

Grill; This is a grill inside BUNKER to stop any bigger pieces to enter HOPPER 

S-Tube Cylinders; This controls S-tube 

19


S- Tube control fork This is used for pumping or suction of concrete 

Pool; This is used for cooling, changing or maintenance of dispatch wedges. 

Pump cylinders ; This is a unit generating the necessary power for pumping or suction of concrete. 

7.01

PUMPING CONTROL FROM CONTROL PANEL; After preparing the vehicle for pumping process, inside walls of the pipes need to have layer of special liquid coating easy concrete transfer. This will renew itself as the concrete passes through the pipes. The liquid coating may vary according to the pipe length and seasonal conditions. For Example: For 25 meter of piping, you will need 100 kg of cement, 50kg sand and half full bunker of water are enough

Image:7.01 SUCTION mode should be selected on control panel for pumping the prepared liquid coating in to the pipes (Image 7.01) Concrete can be pumped after the liquid coating is pumped. Pumping speed can be adjusted by increasing or decreasing the power of engine rev. (Image 7.02)

Image:7.02

20


7.02

PUMPING BY REMOTE CONTROL; Pumping process can be controlled by remote control device as well as control panel. (Image 3.02)

Press ‘’E’’ button to pump the ready mixed liquid coating (Image 5.02). Concrete can be pumped after the liquid coating. Pumping speed can be adjusted by “«” and “»” buttons increasing or decreasing the power of engine rev.

7.03

CAUTIONS TO BE TAKEN DURING PUMPING; Operator must make sure that the Boom does not touch the molds during the pumping process. End of the Boom must not be rested on the decks. You must prevent concrete accumulation on the decks. Unbalanced pouring will cause mold opening and deck crashes. Elephant hose must never be held by hand. Movement of Elephant hose must be control by Boom remote control device.

21


8.00

SUCTION SYSTEM This the process to collect any excess concrete left in Hopper after the pumping is completed. Cleaning ball must be used for cleaning the system after every pumping process is completed. Cleaning ball should be wet enough to suck the waste (Image 7.01). Correct position for Booms is shown for ball suction cleaning (Image 8.00) ! Warning: There should be no concrete left in the system after pumping process is completed.

Image:8:00

22


9.00

CONTROL BY CONTROL PANEL; All functions can be controlled by control panel on vehicle.              

Starting up diesel engine by electric ignition. Forward and backwards vehicle movement Vehicle turn to left and right Opening and Closing OUTRIGGERS Opening and Closing Booms Tower turn Starting the pump, doing and completing the concrete pumping process. Speeding or slowing the dispatch cylinders according to concrete fluidity. Controlling S Tube movements Controlling Shift cylinder Starting and completing Suction process. Controlling Hopper evacuation cylinder Controlling High Pressure washing pump. Controlling air cooling fans

23


10.00

REMORE CONTROL; Remote control works in two different modes: Remote control operations:



Vehicle movement Pumping



Vehicle movement ;





Moving the vehicle forward and backwards Turning the vehicle to right and left Adjusting the engine power



Pumping;

 

   

Starting and stopping pumping process. Adjusting the engine power Moving the vehicle forward and backwards Turning the vehicle to right and left

Remote Control device works with two AA batteries. Battery change is done by opening the back lid on the device shown in image 10.00

Image:10.00 10.01

REMOTE CONTROL LOCK; Red button on remote control device will lock the device (Image 10.00). To open the lock; turn the button clockwise.

24


10.02

RECEIVER FOR REMOTE CONTROL; RECEIVER FOR REMOTE CONTROL (Image:11.00) is mounted to the protection cover on the control panel (Image 9.00).

Image:11.00 ! Warning: When the REMOTE CONTROL does work, check the batteries first. If the problem continues, take the receiver’s cover off (Image 12.00) and make sure that all the breakers are tight enough. If the breakers are not tight, then tighten them by turning the screws clockwise.

Image:12.00

25


11.00

MAINTENANCE AND CLEANING; In order to use the vehicle in long term with no problems; necessary maintenance and cleaning must be done regularly.

11.01

GENERAL MAINTENANCE CHART: EVERY 10 HOUR

WORKING HOUR DIESEL ENGINE HIDRAULIC SYSTEM

TOWER WHEEL (gear) AUTOMATIC CENTRAL OILING MOVEMENT SYSTEM

OIL FILTERS OIL FILTERS OIL BOLT OIL FILTERS OIL

GERGİ

CLUTCH PRESSURE REMOTE CONTROL BATTERY WATER RADIATOR ANTIFREEZE BOLT & NUTS CONTROL TOWER REDUCER OIL HIGH PRESSURE OIL WASH (Power wash)

11.02

CONTROL

◊

GREASE

○

CHANGE

●

EVERY 50 HOUR

EVERY 100 HOUR

◊

EVERY 250 HOUR

EVERY 500 HOUR

EVERY 1000 HOUR

●

◊ ◊

● ● ○ ◊

● ◊ ○ ◊ ◊ ◊ ◊ ● ◊ ◊ ● ◊

●

HIGH PRESSURE WASHING SYSTEM; Vehicle must be washed and cleaned with high pressure wash (power wash) that is installed on vehicle after every use. Cleaning must be done when the pump is in suction.

26


12.00

OILING; Oiling should be followed carefully in maintenance chart.

12.01

AUTOMATIC GREASING UNIT; Program of automatic greasing unit is done by the manufacturer. Program must not be changed unless otherwise is stated.

27


13.00

CAUTIONS FOR LOADING AND UNLOADING FOR TRANSTPORT; Loading or unloading of vehicle for transportation must be done by authorized personnel.

14.00

VEHICLE DIMENSIONS;

15.00

ORIGINAL PARTS MANUAL; 







What are the SCORPION’s original parts? SCORPION’s original parts are what TUNA BETON MAKINALARI DIŞ TIC. LTD. STI used in manufacturing process. The parts are chosen and checked meticulously for best performance and also for our customer’s safety. Why use original parts? SCORPION is designed and manufactured using specific parts that are suitable with the design for the best performance. Warranty will be void in the event of using imitation or secondhand parts for replacements. TUNA BETON MAKINALARI DIS TIC. LTD. STI. will not be responsible for any damage or break down caused by imitation or secondhand parts used on SCORPION. Original spare part must be used for any replacement.

28


TROUBLESHOOTING; 16.00

PROBLEM

REASON

SOLUTION

► Ignition key will not start

► Battery is not connected or

► Check battery connection

the engine

cables not tightened properly

and make sure all cables tightened properly.

► Ignition connection is not

► Check the ignition

done or damaged

connection from the control panel. Correct the connection if connected wrong or change the cables if the cables are damaged.

► No electric power in control

►Check the sockets

panel

► Battery charge is low

underneath the control panel and change them if necessary, using original parts. ► Charge the battery

► No fuel in the tank

► Fill the fuel tank with good quality fuel

► Poor quality fuel

► Empty the fuel tank and fill with good quality fuel.

► Engine starts but stops

► The temperature is too low

►

immediately

for engine to work ► No fuel in the tank

► Fill the fuel tank with good quality fuel

► Engine is working but

► Not enough fuel in fuel tank

making too much noise

► The temperature is too low

► Engine is working but

► Engine fan is rubbing

making different noises

► Ignition works but engine

► Fill the fuel tank with good quality fuel ► Run the engine for 15 minutes to warm up before the operation

► Find out where it is rubbing and stop it rubbing.

► Noise is coming from

► Find the source of noise

hydraulic unit, not from the engine.

and call service engineer for help.

► No fuel in fuel tank

► Fill the fuel tank with good

► Injectors are loose

quality fuel ► Tighten the injectors

► No fuel delivered to engine

► Check the fuel delivery line

does not start up.

/pipes for any leakage and correct the fault or call service engineer.

29

Scorpion User Manual

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