City Pump Technical Specification

ZOOMLION 10020R
 Contents

Chapter 1 Main technology parameter ................................................................... 1

Charpter 2 Pumping performance diagram ........................................................... 2

Charpter 3 Part names ............................................................................................ 3

Charpter 4 Main technical feature ..........................................................................4

4.1 Capability feature ................................................................................................................ 4
4.2 Power system ........................................................................................................................ 4
4.3 Chassis ...................................................................................................................................4
4.4 New type appearance ...........................................................................................................4
4.5 lubrication system ................................................................................................................ 4
4.6 Cool system ...........................................................................................................................5
4.7 Electric control system ........................................................................................................ 5
4.8 Hydraulic system ..................................................................................................................6
4.9 Laying concrete material .....................................................................................................7
4.10 Pumping unit ...................................................................................................................... 8

Chapter 5 Guaranteed means ................................................................................11

5.1 Research and development ability ....................................................................................11
5.2 Manufacture ability ........................................................................................................... 11
5.3 Testing ability .....................................................................................................................11

Charpter 6 Main assembly .................................................................................... 14

6.1 Main assembly components .............................................................................................. 14
6.2 Hydraulic system configuration ....................................................................................... 14
6.3 Electric system configuration ........................................................................................... 14

Chapter 7 Reference to the standards ...................................................................15

 Chapter 1 Main technology parameter

Items Units ZLJ5140THBEE-10020R

Max. theo. concrete output (L./H.) m /h
3
100/55
Max.concrete pumping pressure (H. /L.) MPa 20/11
Pumping frequency min-1 30/17
Distribution valve type S 管阀
Pumping uint

Oil cylinder dia.×stroke mm Φ150×1650

Concrete cylinder diameter×stroke mm Ф200×1650

Hopper capacity×feeding height L×mm 600×1500

Outlet diameter mm Ф180

Max. aggregate dimension mm Slick scree: 50、Scree: 40
Recommended concrete slump cm 12~23
Chassis model DFL1160BX1V
Engine model
Chassis and the whole machine

EQH180-52
Engine displacement 4.752
Maximum net engine power/speed 132/2400
Driving mode 4×2
Wheelbase mm 4700
Tail gas exhaust standard Chinese Ⅴ
Total weight kg 13800
Dimensions：length×width×height mm 9000×2450×3140
Diesel engine model BF6M1013-25T3R/1
Power system

Rated power kW/(r/min) 186/2100

Engine moment N.m/(r/min) 1000/1600
Maximum displacement cc 7145
Circuit type open loop
Pumping system pressure MPa 35
Hydraulic system

Distribution system pressure MPa 19

Mixing system pressure MPa 12
H. /L concrete pumping pressure switching Electric
Capacity of oil tank L 720
Cooler for Hydraulic Wind
Maximum water pressure MPa 7
Water tank volume L 200
Other

Lubrication mode Automatic lubrication

Control mode Manual+remote control
Pipe diameter mm Ф125/Ф150

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Charpter 2 Pumping performance diagram

2
 Charpter 3 Part names

Part names：

No. Name No. Name No. Name

Hydraulic
1 Chassis 2 Guard rail 3
system

4 Cooling system 5 Power system 6 Oil tank

7 Cover 8 Spare tare 9 platform

Lubricating
10 Auxilary frame 11 Pumping system 12
system

Distributing
13 Electric cabinet 14 Water tank 15
system

16 Agitator 17 Hopper

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 Charpter 4 Main technical feature

4.1 Capability feature

The machine is equipped with Dongfeng Kingrun chassis ， Deutz (Dalian) 186KW diesel

engine. The output is 100m3/h, and the Max pumping pressure is 20MPa.

4.2 Power system

The world famous diesel engine of DEUTZ(Dalian) has excellent performance and high

reliability.

4.3 Chassis

The Dongfeng vehicle chassis has grand ornament, with air-condition and Dongfeng

Fengshen engine, mission standards: Chinese

4.4 New type appearance

The new design conception that the body is in accord with the cab, which makes the machine

beautiful. The cover adopts “V”style and the cover door adopts gemel connection. It makes the

machine maintain conveniently. New type hopper,tank and stairs unify with the machine.

4.5 lubrication system

The synchronous boost lubrication pump is adopted, which has the features of high working

pressure, less blockage, compact structure, low noise, constant grease feeding, easy operation and

maintenance, etc.

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 4.6 Cool system

Air-cooled heat dissipation: The system circuit adopts a forced air-cooled heat dissipation

device to effectively control the oil temperature of the system and ensure the normal operation of

the hydraulic system components

4.7 Electric control system

4.7.1 High reliability

The device uses an industrial controller with a bus as the control core, with high reliability,

powerful functions, and high protection level, which is fully adapted to the harsh working

conditions of construction machinery.

The key electrical control components are used by the first-line brands such as Germany IFM,

Germany Baumer, France Schneider, Beijing Kai Shang, etc., which ensures the reliability of the

components.

4.7.2 Smart human-machine interface

High-definition color touch screen is adopted for easy access to machine work status,

input/output help and real-time alarm information. The system parameters can be easily set up after

authorized.

4.7.3 Remote control

Cable remote cotrol is provided for long-distance operation (radio remote control is optional).

4.7.4 Backup revesal system

Non-contact reversal is adopted by means of the proximity switch in the hydraulic clyinder to

ensure the reliability, and an auxiliary signal sensor is fitted so that the system can immediately

switch to the auxiliary sensor in case the main sensor fails.

4.7.5 Soft reversal technology

It effectively reduces the reversing impact and improves the pumping stability.

4.7.6 GPS

Remote positioning and monitoring of the machine is enabled.

4.7.7 Stroke optimization control

Equipped with the reversing stroke optimization control function, which can automatically

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adjust the oil intake of the master cylinder according to the stroke of the master cylinder, thereby

realizing the optimal control of pumping, ensuring the best suction performance during pumping,

and achieving high efficiency pumping.

4.7.8 Energy saving control

When pumping, the system automatically matches the engine's working speed and main pump

displacement to achieve the best energy-saving working state; after pumping stops, the diesel

engine will automatically drop to idle speed to save fuel.

4.8 Hydraulic system

4.8.1 Dual-pump dual-loop hydraulic system

Dual-pump dual-loop hydraulic system: the pump hydraulic system adopts large-displacement

plunger pump(open/closed type) connected with main cylinder to form self-contained pumping

circuit.The distribution hydraulic system adopts constant pressure pump connected with distribution

cylinder to form self-contained distribution circuit. The pump circuit and distribution circuit work

together without interferring one another.The professional soft reversal technology makes less

hydraulic impact and longer life for the system elements.The dual-loop design makes it easier to

realise the logic control,and to upgrade the control function so that the hydraulic system is given

into full play.

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 4.8.2 Multiple protection of main pump

The pump hydaulic system has not only overflow protection, but also overpressure protection,

if the system pressure exceeds the safety value, the pump pressure will automatically cut off the

flow to protect the pump.

4.8.3 One-button high-low pressue switching

High and low pressures are switched over electrically by cartridge valve, which saves the

trouble of detaching and attaching the oil pipes.

4.8.4 High-efficient emulsification protection

Both active and passive emulsification protection are adopted.

4.8.5 H. /L concrete pumping pressure switching

Intelligent switching, automatic matching pumping conditions, to ensure smooth pumping.

High and low pressure switching channel patent design, reduce the pressure loss of large flow

pipeline, while reducing the size of the valve block, and reducing vehicle load. Easy maintenance.

4.8.6 International Brand hydraulic component

International Brand hydraulic component is used on the machine，High reliability. Follow the

standard of DIN and ISO.

4.8.7 Fluid connectors

Fluid connectors such as hoses and joints use seals and connectors with reliable sealing

performance. Good sealing effect and high reliability. Comply with DIN standard and international

ISO standard, with good interchangeability.

4.9 Laying concrete material

Laying is an important problem to the concrete pump. If laying isn’t on time, the phenomenon

of pipe jam will happen. The methods are as follows:

4.9.1 Laying with groove

Laying with placing boom can quick and conveniently laying and the phenomenon of pipe jam

isn’t easily happen. In construction, the placing boom can laying at any places in available scope, it

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improves the efficiency and lighten the labor intensity.

4.9.2 Laying with the handcart

It’s used to affuse few concrete and some special places which the hose can’t reach.

4.9.3 Laying with hose

In small pipe condition, laying with hose is very suitable. The hose’s length has 3m and 4m

and the minimal bend radius is no less than 1.5m.

4.9.4 Laying with placing boom

Laying with placing boom can quick and conveniently laying and the phenomenon of pipe jam

isn’t easily happen. In construction, the placing boom can laying at any places in available scope, it

improves the efficiency and lighten the labor intensity.

4.10 Pumping unit

4.10.1 High reliability pumping unit

Using the finite element analysis software, analysis the strength and stiffness of the main

components of the pumping unit under different working conditions. Ensure the structural

reliability of pumping unit

4.10.2 High suction rate

The fluidity inside the concrete cylinder is simulatedly analyzed by applying the professional

software Finite-element Analysis, the sunction rate of the pumping unit is 10% above the average in

the industry.

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 4.10.3 Mixing blade of high wear-resistance

The computer-simulated blade curve design and axial bolt connection design make the blade

more compact and beautiful, its service life increased by more than 60% if regular concrete (C30

and below) is pumped.

4.10.4 Wear-resistant spectacles wear plate and cutting ring

The spectacles wear plate and cutting ring are reinforced with highly wear-resistant material,

its service life is improved by over 30% and in the industry-leading position.

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 4.10.5 New type of concrete piston

The heat and hydrolyzation protection material of polyester being adopted makes the piston

more site-adaptable and wear-resistant, the service life is up to 12000m3 if regular concrete

(C30,below 30 storeys) is pumped.

4.10.6 New type of S transfer tube

The channels of S transfer tube are optimized by the simulated analysis of inside fluid with

the professional software of Finite-element Analysis, the pumping resistance inside the S tube is

reduced and the service life improved by 30%.

4.10.7 Reinforced concrete cylinder

The electric plating of the latest technology is adopted, the hard chrome layer has far less

phenomena of being broken, and its wear resistance is improved by at least 10%.

4.10.8 Concrete pipe

The concrete pipe adopts double-layer structure. By introducing the Italian CIFA quenching

machine, the surface quenching is made in four sections at axial speed, which not only ensures the

high hardness and wear resistance of inside surface, but also keeps the best toughness to prevent

pipe busrting as occurs frequently for other manufacturers.

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 Chapter 5 Guaranteed means

5.1 Research and development ability

5.1.1 Zoomlion has made great efforts and investment on composite material research, which has

now paid off and is applied in truck-mounted concrete pumps with long booms, establishing our

world-leading position in the sector. It is fully represented by 80m truck-mounted concrete pump

which has made historic breakthrough to assemble 80m boom on six-axle chassis.

5.1.2 Extractive design: ZOOMLION introduces into PRO/E、ANSYS、ADMAS、IDEAS software,

and so on. Through analysis for the boom、base structure and outriggers, stress is very reasonable.

According to the calculation, engineers rectify the design, so this will make the boom system more

reasonable and unparalleled.

5.2 Manufacture ability

ZOOMLION has very big workshop 、 high exact machining machine and high making

employee; ZOOMLION has horizontal machining center 、 numerical control double-face boring

lathe、numerical control boring-milling machine, and so on; ZOOMLION has advanced paint line

used for painting parts and whole machine; ZOOMLION has instrument which can calculate

granule and control cleanness degree, so hydraulic system cleanness degree can be assured;
ZOOMLION has numerical control flex machine 、 plasma cutting machine working under the

water、automation welding machine、three coordinate lineation machine 、ultrasonic detector, and

so on ,so structure parts quality can be assured.

5.3 Testing ability

5.3.1 ZOOMLION Concrete Machinery Co. test fields: as an important part of ZOOMLION

R&D system, the test field is built for the developing testing and production testing of new products,

so that it may provide trial base and sophisticated measuring means for special research within each

basic discipline. Presently we have test center covering three large test fields, i.e. Lugu, Yuanjiang

and Hanshou. The heavily invested test center is all-around, of high standard and globally leading

level. The TDM (Test Data Management) system initiated by ZOOMLION is domestically the first

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in the sector to manage the testing procedure in a standardized, normalized, and accurate way. The

test center is currently capable of meeting the demands of developing 30 new models of vehicles

and production testing of 10000 newly manufactured vehicles.

5.3.2 The international leading boom fatigue test: Will reappear the boom’s dynamic load

spectrum from the construction site to fatigue test table, to the entire boom for fatigue test. By the

pressure sensor and position sensors, etc and through the special measuring instrument to watch

wether the boom is distorted or appears cracks and the extend of the damage. To provide the

scientific basis for the improvement of the design scheme, and ensure the quality of the boom is

reliable and the service life is longer and meet the design requirements.

5.3.3 The international leading pump unit fatigue test: This test table is used to simulate the

using situation of truck-mounted concrete pump in fact works. By using the high pressure pump

water and the concrete stimulant, etc, to do the fatigue test of the products’ key parts and delicate

parts in the pump unit and the capability experiment of the pump unit.

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 Charpter 6 Main assembly
6.1 Main assembly components

SN Name Company Country

1 Chassis Dongfeng China

2 Diesel engine Duetz, FAW etc. China

6.2 Hydraulic system configuration

SN Name Company Country

1 Main hydraulic pump Rexroth/Danfoss Germany/Denmark

2 Constant pressure pump Rexroth/Zoomlion etc. Germany/China

Rexroth/Eaton/ATOS/
3 Main hydraulic valve Germany/USA/Italy etc.
DUPLOMATIC etc.

4 Hydraulic motor EATON/XINFA/ZHONGYI USA/China

6.3 Electric system configuration

SN Name Company Country

1 Controller KAI SHANG/IFM China/Germany

USA/France/SOUTH
2 Breaker Eaton/Schneider/LS
KOREA

3 Relay Panasonic JAPAN

4 Remote control Zoomlion China

Wireless remote
5 HBC Germany
control (optional)

Water tank approach

6 IFM/Baumer/ etc. Germany
switch

7 Touch screen Schneider France

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 Chapter 7 Reference to the standards

1. P. R. China national standard Concrete pump

Standard No.: GB/T 13333-2004
2. P. R. China industrial standard Concrete conveying pipes-Types and dimensions
Standard No.: JB/T 11187-2011
3. P. R. China industrial standard Technical specifications for pumping construction of concrete
Standard No.: JGJ/T 10-2011
4. P. R. China national standard Limits of dimensions, axle load and masses for load vehicles
Standard No.: GB 1589-2004

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