SYG5360THB 47

SYG5360THB 47
Truck-mounted Concrete Pump
Operation and Maintenance Manual

WARNING
Read and follow the safety precautions and instructions in this manual and on the machine
decals. Failure to do can cause serious injury, death or property damage. Keep this manual
with the machine for reading and future reference.
 SANY GROUP
SANY AUTOMOBILE MANUFACTURING CO., LTD.
SANY Industry Town,
Economic and Technological Development Zone,
Changsha, Hunan China 410100
http://www.sanygroup.com.cn

China
Email: [email protected]
Tel: 0731- 84031888
Fax: 0731- 84031999
Service Hotline: 4008 87 8318
Complaint Hotline: 4008 87 9318

Overseas
Email: [email protected]
Service Hotline (Complaint/Enquiry): 0086 4006098318

© 2015 by SANY Group. All rights reserved. No part of this publication may be reproduced,
used, distributed or disclosed except during normal operation of the machine as described
herein. All information included within this publication was accurate at the time of publica-
tion. Product improvements, revisions, etc., may result in differences between your
machine and what is presented here. SANY Group assumes no liability. For more informa-
tion, contact SANY Group.
 SPECIFIC DECLARATION

The truck-mounted concrete pump is a special vehicle which integrate the pumping system for
concrete pumping and the boom system for concrete placing on the vehicle chassis. Any other
use or any operation beyond the specified working range is not authorized use. Sany expressly
bears no liability for any consequence due to any unauthorized use.

Information on this manual is used to guide qualified operators to operate and maintain truck-
mounted concrete pump correctly. Sany expressly bears no liability for any consequence due to
any use not observing the information on this manual.

It is forbidden to convert the truck-mounted concrete pump without authorization. Sany

expressly bears no liability for any consequence. When crack or electrical malfunction on the
truck-mounted concrete pump occurs, please contact the supplier, and don’t conduct welding or
make changes without permission, or else, for any consequence due to such contravention,
Sany shall not bear any liability.

Use genuine spare parts from Sany. Sany expressly bears no liability for any machine damage
or accident due to the use of untested or unauthorized spare parts or tools.Operate and
maintain parts (such as engine, a/c) on the truck-mounted concrete pump, and observe related
regulations on Users' guide supplied from their manufacturer.

Sany expressly bears no liability for any machine failure or damage due to force majeure of
natural disasters (earthquake, typhoon) and wars.

Sany cannot predict every circumstance that might involve a potential hazard in operation or
maintenance. Operators and owners should highly attach importance to safety. Local specific
safety rules of the countries may be stricter. If they differ from the regulations on this manual,
observe the stricter one.

Duty of Sany

• Be responsible for providing qualified products.

• Fulfill their promises on after-sales service, and document all maintenance and repair working
done by after-sales service personnel.

• Train the operation and maintenance personnel based on their needs.

Duty of Owners or Other Authorized Personnel

• Only after each person involved in the product’s operation, maintenance and repair is trained
and fully understands the Parts Book and Operation and Maintenance Manual, can they
operate and maintain the truck-mounted concrete pump.

• Ensure the operation and maintenance personnel are qualified and know their related
responsibilities.

• Periodically check related personnel's safety consciousness during working.

• If any fault which will lead to unsafety occurs, stop the truck-mounted concrete pump
immediately.

• If necessary Sany service personnel have the right to check the truck-mounted concrete pump
for safety.

• Besides check items regulated by Sany, observe local laws and regulations to check the
truck-mounted concrete pump.

• Ensure timely maintenance and repair on the truck-mounted concrete pump.

• Carefully plan the use of the truck-mounted concrete pump.

• Sany expressly bears no liability for any consequence due to use of informality accessories, not
comply with the provision for maintenance, or start the machine without authorization after it is
locked.

Duty of all working personnel

• If there is any abnormal symptom which may cause abnormal working of the truck-mounted
concrete pump or potential hazard, report to your leader. If possible, correct fault in time.

• All personnel working around the truck-mounted concrete pump must observe all warning
signals and take care of their own and others' safety.

• All personnel should know their working tasks and procedures.

• Watch something like high voltage wire, unrelated personnel and poor ground for potential
danger, and report to the operators and signalmen.

Duty of managers

• Ensure the operators are trained and fully understand the Operation and Maintenance Manual
supplied by Sany. Ensure they are in physical fitness and have the certification of operation.
Otherwise, it is forbidden to operate the truck-mounted concrete pump.

• Ensure the operators have good judgment ability, teamwork consciousness and psychological
quality. Otherwise, it is forbidden to operate or repair the truck-mounted concrete pump.

• Ensure the signalmen have good vision and acoustic judgment, master standard command
signals. At the same time, they should have enough experience in recognizing danger factors
correctly, and inform the operators of danger factors to avoid them in time.

• Ensure assistant workers can identify the model and working condition to choose a proper
truck-mounted concrete pump.

• Publicize safety consciousness to working personnel, and make them aware of safety
precautions and their related responsibilities.
 Table of Content
SYG5360THB 47

Table of Content
1 Introduction
1.1 Manual Section Descriptions ............................................................................. 1-4
1.1.1 Introduction .................................................................................................. 1-4
1.1.2 Safety ........................................................................................................... 1-4
1.1.3 System functions .......................................................................................... 1-5
1.1.4 Operation ..................................................................................................... 1-5
1.1.5 Maintenance................................................................................................. 1-5
1.1.6 Troubleshooting............................................................................................ 1-5
1.1.7 Specifications ............................................................................................... 1-5
1.1.8 Appendix ...................................................................................................... 1-5
1.2 Machine Serial Number & Information ............................................................... 1-6
1.3 Contact Information ........................................................................................... 1-7
1.4 Icons and Symbols ............................................................................................ 1-7

2 Safety
2.1 Definition of terms .............................................................................................. 2-4
2.1.1 Concrete pump............................................................................................. 2-4
2.1.2 Boom pedestal ............................................................................................. 2-4
2.1.3 Arm assembly............................................................................................... 2-4
2.1.4 Placing boom................................................................................................ 2-4
2.1.5 Base structure .............................................................................................. 2-4
2.1.6 Truck mixer................................................................................................... 2-4
2.1.7 Delivery line systems.................................................................................... 2-5
2.1.8 Machine........................................................................................................ 2-5
2.1.9 Operator ....................................................................................................... 2-5
2.1.10 Machine operator ....................................................................................... 2-5

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2.1.11 Hoseman.................................................................................................... 2-6

2.1.12 Signaller and other auxiliary personnel ...................................................... 2-6
2.1.13 Truck mixer driver ...................................................................................... 2-6
2.1.14 Authorized inspector .................................................................................. 2-6
2.1.15 Subject expert ............................................................................................ 2-7
2.1.16 Qualified personnel .................................................................................... 2-7
2.1.17 After Sales Service personnel.................................................................... 2-7
2.1.18 Maintenance............................................................................................... 2-7
2.1.19 Place of work, working area, danger zone ................................................. 2-8
2.2 Designated use .................................................................................................. 2-13
2.2.1 Inspection intervals ...................................................................................... 2-14
2.3 Use contrary to designated use ......................................................................... 2-15
2.3.1 Transporting goods ...................................................................................... 2-15
2.3.2 Lifting loads .................................................................................................. 2-15
2.3.3 Removing obstacles..................................................................................... 2-15
2.3.4 Extending the reach ..................................................................................... 2-16
2.3.5 Extensions.................................................................................................... 2-16
2.3.6 Impermissible end hose ............................................................................... 2-16
2.3.7 Impermissible working area ......................................................................... 2-16
2.3.8 Climbing the placing boom ........................................................................... 2-17
2.3.9 High-pressure delivery ................................................................................. 2-17
2.3.10 Accessories and attachments .................................................................... 2-17
2.4 Exclusion of liability ............................................................................................ 2-17
2.5 Personnel ........................................................................................................... 2-18
2.5.1 Requirements............................................................................................... 2-18
2.5.2 Qualifications................................................................................................ 2-19
2.5.3 Responsibility of the machine operator ........................................................ 2-19
2.6 Operating Instructions, operating procedures and other regulations ................. 2-19
2.6.1 Operating Instructions .................................................................................. 2-19

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2.6.2 Operating procedures................................................................................... 2-20

2.6.3 Other regulations.......................................................................................... 2-21
2.7 Personal protective equipment .......................................................................... 2-21
2.8 Before starting work ........................................................................................... 2-23
2.8.1 Checking that the machine is ready for operation ........................................ 2-23
2.8.2 Rendering the machine ready for operation ................................................. 2-23
2.9 Danger due to high-voltage ............................................................................... 2-24
2.9.1 High-voltage lines......................................................................................... 2-24
2.9.2 Discharge voltage pattern ............................................................................ 2-24
2.9.3 Clearances ................................................................................................... 2-25
2.9.4 High-voltage warning devices ...................................................................... 2-26
2.9.5 Procedure in the event of a flash over.......................................................... 2-26
2.9.6 Earthing in the event of electrostatic charging ............................................. 2-27
2.10 Stationary machines .......................................................................................... 2-27
2.10.1 Set-up site .................................................................................................. 2-27
2.10.2 Stationary booms ....................................................................................... 2-28
2.10.3 Lifting machines and components.............................................................. 2-28
2.10.4 Loading and transporting............................................................................ 2-28
2.11 Mobile machines ................................................................................................ 2-29
2.11.1 Set-up site .................................................................................................. 2-29
2.11.2 Supporting ground...................................................................................... 2-29
2.11.3 Corner bearing loads.................................................................................. 2-30
2.11.4 Supports ..................................................................................................... 2-31
2.11.5 Driving ........................................................................................................ 2-32
2.11.6 Towing........................................................................................................ 2-33
2.11.7 Loading ...................................................................................................... 2-33
2.12 Placing booms ................................................................................................... 2-34
2.12.1 Unfolding the placing boom........................................................................ 2-34
2.12.2 End hose .................................................................................................... 2-35

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2.12.3 Procedure in storms ................................................................................... 2-36

2.12.4 Concreting in cold weather......................................................................... 2-37
2.13 Delivery line systems ......................................................................................... 2-37
2.13.1 Suitable delivery lines ................................................................................ 2-37
2.13.2 Securing delivery........................................................................................ 2-37
2.13.3 Tightness and blockages ........................................................................... 2-38
2.13.4 Opening delivery lines................................................................................ 2-38
2.13.5 Clearance to delivery lines ......................................................................... 2-38
2.13.6 Fastening delivery lines.............................................................................. 2-39
2.13.7 Continuation delivery lines ......................................................................... 2-39
2.14 Pumping operations ........................................................................................... 2-39
2.14.1 Place of work.............................................................................................. 2-39
2.14.2 Safety ......................................................................................................... 2-40
2.14.3 Remote control........................................................................................... 2-40
2.14.4 Moving machine components and hot surfaces......................................... 2-41
2.14.5 Constant observation of the machine......................................................... 2-41
2.14.6 Truck mixer ................................................................................................ 2-42
2.15 Cleaning ............................................................................................................. 2-42
2.15.1 General ...................................................................................................... 2-42
2.15.2 Cleaning agents ......................................................................................... 2-43
2.15.3 Hazards...................................................................................................... 2-43
2.15.4 Cleaning with compressed air .................................................................... 2-43
2.15.5 Protection against water............................................................................. 2-45
2.15.6 Post-cleaning procedure ............................................................................ 2-46
2.16 Maintenance and special work .......................................................................... 2-46
2.16.1 Requirements for special work................................................................... 2-46
2.17 Welding .............................................................................................................. 2-48
2.18 Working on the placing boom ............................................................................ 2-49
2.19 Safety-relevant components .............................................................................. 2-50

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2.20 Software ............................................................................................................. 2-50

2.21 Protective and safety ......................................................................................... 2-50
2.22 Electrical power ................................................................................................. 2-51
2.22.1 General ...................................................................................................... 2-51
2.22.2 Electrical components ................................................................................ 2-52
2.22.3 Power at the construction site .................................................................... 2-52
2.23 Hydraulic systems .............................................................................................. 2-53
2.23.1 General ...................................................................................................... 2-53
2.23.2 Replacing hydraulic hoses ......................................................................... 2-54
2.23.3 Noise emissions ......................................................................................... 2-54
2.24 Exhaust fumes ................................................................................................... 2-55
2.25 Functional fluids ................................................................................................. 2-55

3 System Functions
3.1 General Overview .............................................................................................. 3-3
3.1.1 Main component locations............................................................................ 3-3
3.1.2 Main characteristics...................................................................................... 3-4
3.2 Boom System .................................................................................................... 3-6
3.2.1 Boom overview............................................................................................. 3-6
3.2.2 Boom components ....................................................................................... 3-6
3.2.3 Boom control ................................................................................................ 3-7
3.3 Outrigger System ............................................................................................... 3-9
3.3.1 Outrigger overview ....................................................................................... 3-9
3.3.2 Outrigger components.................................................................................. 3-9
3.3.3 Outrigger control........................................................................................... 3-10
3.3.4 Outrigger pads.............................................................................................. 3-11
3.4 Truck Chassis .................................................................................................... 3-12
3.4.1 Truck chassis overview ................................................................................ 3-12
3.4.2 Truck chassis components........................................................................... 3-13

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3.5 Pumping System ................................................................................................ 3-14

3.5.1 Pumping system overview ........................................................................... 3-14
3.5.2 Pumping system & related components....................................................... 3-14
3.5.3 Pumping system operation........................................................................... 3-15
3.5.4 Pumping controls ......................................................................................... 3-16
3.6 Hydraulic System ............................................................................................... 3-17
3.6.1 Outrigger controls......................................................................................... 3-17
3.6.2 Outrigger and boom backup hydraulics ....................................................... 3-19
3.6.3 Pump hydraulics........................................................................................... 3-20
3.6.4 Mixing control valve and mixing cutoff valve ................................................ 3-20
3.6.5 Accumulator and Unloading Ball Valve of Accumulator ............................... 3-21
3.6.6 Self-sealing Device of Main Oil Pump Oil Inlet and Gear Pump Oil Suction Cut-
off Valve ................................................................................................................ 3-22
3.6.7 Water pump.................................................................................................. 3-23
3.6.8 Filter ............................................................................................................. 3-23
3.7 Electric Control System ..................................................................................... 3-24
3.7.1 Electric Control Cabinet ............................................................................... 3-24
3.7.2 Small operation box ..................................................................................... 3-29
3.7.3 Maintenance and operation box................................................................... 3-32
3.7.4 Electromagnetic valves for mixing................................................................ 3-36
3.7.5 Electromagnetic valve of boom .................................................................... 3-37
3.7.6 System gauges & indicators......................................................................... 3-37
3.7.7 Light ............................................................................................................. 3-41
3.7.8 E-STOP buttons ........................................................................................... 3-45
3.8 Remote Control System ..................................................................................... 3-47
3.8.1 In-Cab receiver............................................................................................. 3-47
3.8.2 Remote controller ......................................................................................... 3-48

4 Operation

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4.1 Pre-operational Checks ..................................................................................... 4-3

4.2 Set-up Site ......................................................................................................... 4-5
4.3 Starting Up ......................................................................................................... 4-7
4.3.1 Test run ........................................................................................................ 4-7
4.3.2 Start the machine and engaging the transfer gearbox power take- off ........ 4-9
4.4 Outrigger Set-Up ................................................................................................ 4-10
4.4.1 Working area ................................................................................................ 4-10
4.4.2 Danger zone................................................................................................. 4-11
4.4.3 Operation of outriggers................................................................................. 4-12
4.4.4 OSS.............................................................................................................. 4-15
4.4.5 Levelling the machine................................................................................... 4-16
4.5 Function Checks ................................................................................................ 4-18
4.5.1 Pump functions............................................................................................. 4-18
4.5.2 Filter functions .............................................................................................. 4-19
4.5.3 E-STOP function .......................................................................................... 4-20
4.5.4 Function check on the boom control block ................................................... 4-21
4.5.5 Function check on the agitator safety cutout................................................ 4-21
4.6 Boom Movements .............................................................................................. 4-23
4.6.1 Restrictions on use....................................................................................... 4-23
4.6.2 Danger zone................................................................................................. 4-25
4.6.3 Spontaneous retraction of the boom and support cylinders ......................... 4-26
4.6.4 Uncontrolled boom movements.................................................................... 4-27
4.7 Hand Signals for Boom and Pump Operations .................................................. 4-28
4.7.1 Standard boom hand signals........................................................................ 4-28
4.7.2 Pump operation hand signals....................................................................... 4-31
4.8 Extending the Boom .......................................................................................... 4-34
4.8.1 Preparing the Remote Controller.................................................................. 4-35
4.8.2 Unfolding the boom ...................................................................................... 4-36
4.8.3 Unlocking the end hose................................................................................ 4-38

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4.8.4 Checking outrigger stability .......................................................................... 4-38

4.9 Pumping Operations .......................................................................................... 4-39
4.9.1 Safety precautions ....................................................................................... 4-39
4.9.2 Notes on correct pumping ............................................................................ 4-44
4.9.3 Pre-operational checks ................................................................................ 4-45
4.9.4 Pumping ....................................................................................................... 4-46
4.9.5 Possible faults .............................................................................................. 4-49
4.9.6 Special cases ............................................................................................... 4-52
4.10 Equipment Clean-up ......................................................................................... 4-53
4.10.1 Cleaning the Boom Piping.......................................................................... 4-53
4.10.2 Hopper, delivery cylinder and S-tube ......................................................... 4-57
4.10.3 Truck superstructure and post-cleaning procedure.................................... 4-59
4.11 Retracting the Boom & Outriggers .................................................................... 4-61
4.12 Driving, Towing and Loading ............................................................................ 4-62
4.12.1 Driving ........................................................................................................ 4-62
4.12.2 Towing........................................................................................................ 4-65
4.12.3 Loading ...................................................................................................... 4-66
4.13 Machine Decals ................................................................................................ 4-67
4.13.1 Locations of safety marks on the complete vehicle................................... 4-68
4.13.2 Mark descriptions ...................................................................................... 4-70
4.13.3 Detailed explanation to safety marks ........................................................ 4-71

5 Troubleshooting
5.1 General .............................................................................................................. 5-3
5.2 Troubleshooting Mechanical System ................................................................. 5-3
5.3 Troubleshooting Hydraulic System .................................................................... 5-6
5.4 Troubleshooting Lubrication System ................................................................. 5-10
5.5 Troubleshooting Electric System ....................................................................... 5-11

6 Maintenance

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SYG5360THB 47

6.1 Routine Maintenance & Mandatory Overhaul .................................................... 6-3

6.2 General Tightening Torques .............................................................................. 6-8
6.3 Lubrication ......................................................................................................... 6-11
6.3.1 Lubrication Method....................................................................................... 6-11
6.3.2 Lubricant Recommendation ......................................................................... 6-15
6.4 Visual Checks .................................................................................................... 6-20
6.4.1 General check .............................................................................................. 6-20
6.4.2 Check the hydraulic system ......................................................................... 6-24
6.4.3 Check the electrical system.......................................................................... 6-25
6.5 Pumping System ................................................................................................ 6-25
6.5.1 Pumping cylinder piston ............................................................................... 6-26
6.5.2 Agitator shaft and leaf .................................................................................. 6-30
6.5.3 S-valve Assembly......................................................................................... 6-31
6.5.4 Hopper ......................................................................................................... 6-50
6.5.5 Delivery cylinder ........................................................................................... 6-51
6.5.6 Delivery line.................................................................................................. 6-51
6.6 Slewing Mechanism ........................................................................................... 6-62
6.6.1 Overview ...................................................................................................... 6-62
6.6.2 Slewing gear transmission ........................................................................... 6-64
6.6.3 Ball-Bearing Slewing Ring............................................................................ 6-66
6.7 Transfer Case and Drive Shaft .......................................................................... 6-67
6.7.1 Transfer case ............................................................................................... 6-68
6.7.2 Drive shaft .................................................................................................... 6-70
6.8 Hydraulic System ............................................................................................... 6-71
6.8.1 Overview ...................................................................................................... 6-71
6.8.2 Changing the hydraulic fluid ......................................................................... 6-72
6.9 Accumulator ....................................................................................................... 6-75
6.9.1 Overview ...................................................................................................... 6-75
6.9.2 Checking the nitrogen pressure of accumulator........................................... 6-77

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6.9.3 Nitrogen filling and pressure adjustment of accumulator ............................. 6-77

6.10 Oil Filter ............................................................................................................ 6-79
6.10.1 Replacing hydraulic oil filters..................................................................... 6-79
6.11 Air Filter ........................................................................................................... 6-81
6.12 Hoses ................................................................................................................ 6-82
6.12.1 Checking the hoses.................................................................................... 6-82
6.12.2 Replacing the hoses................................................................................... 6-83
6.12.3 Identifying the hoses .................................................................................. 6-84
6.13 Electrical System .............................................................................................. 6-84
6.13.1 Electric control cabinet ............................................................................... 6-85
6.13.2 Maintenance operation box........................................................................ 6-88
6.13.3 Small operation box ................................................................................... 6-89
6.13.4 Outrigger operation box ............................................................................. 6-89
6.13.5 Mechanical encoder .................................................................................. 6-90
6.13.6 Temperature sensor................................................................................... 6-91
6.13.7 Liquid level sensor ..................................................................................... 6-91
6.13.8 Limit switch of boom................................................................................... 6-92
6.13.9 Limit switch of outrigger ............................................................................. 6-92
6.13.10 Proximity switch of transfer case.............................................................. 6-93
6.13.11 Rocker switch .......................................................................................... 6-93
6.13.12 Electromagnetic valve and its plug........................................................... 6-94

6.13.13 Wire.......................................................................................................... 6-94

6.13.14 Wireless remote control system ............................................................... 6-95

7 Specifications
7.1 Technical Data ................................................................................................... 7-3
7.2 Dimension .......................................................................................................... 7-5
7.3 Boom Operating Range ..................................................................................... 7-6

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8 Appendix
8.1 Hydraulic Basic Diagram ................................................................................... 8-3
8.2 Electrical Basic Diagram .................................................................................... 8-5
8.3 Specifications of twin pipes ........................... ..................................................... 8-14

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SYG5360THB 47

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 Introduction
SYG5360THB 47

Introduction
1 Introduction
1.1 Manual Section Descriptions ............................................................................1-4
1.2 Machine Serial Number & Information ..............................................................1-6
1.3 Contact Information ..........................................................................................1-7
1.4 Icons and Symbols ...........................................................................................1-7

1-1
Introduction
SYG5360THB 47

WARNING
Always read the Safety section of this
manual before attempting to operate this
equipment. Failure to do this could result
in machine damage, personnel injury or
death.

1-2
 Introduction
SYG5360THB 47

1 INTRODUCTION
● SANY-built equipment offers high-quality
performance and excellent after-sales
service support.
● SANY-built equipment is widely used
throughout the industry for various types
of applications.
● SANY is a leading manufacturer of
heavy construction equipment worldwide.

This manual provides safety, technical

descriptions, operation, troubleshooting and
maintenance. In order to properly use your
equipment, it is important to read this manual
carefully before beginning any operations.

Items addressed in this manual are designed

to help you:

● Understand the structure and performance

of your equipment.
● Reduce improper operation and point out Fig.1-1
possible hazardous situations when
using equipment.
● Increase equipment efficiency during operation.
● Prolong the service life of your equipment.
● Reduce maintenance costs.

Always keep this manual nearby and have all

personnel involved with any work operations
read it periodically. If this manual should
become damaged or lost and can not be
read, it is advised to request a replacement
copy from your SANY distributor as soon as
possible.

If a copy of the manual i s not with the

machine at the time of use, do not use the
equipment until you have obtained a
replacement copy from your SANY distributor.

1-3
Introduction
SYG5360THB 47

If you sell the equipment, be sure to give this

manual to the new owner.

NOTE:Continuing improvements in the design

can lead to changes in detail which
may not be reflected in this manual.
Always consult your SANY distributor
for the latest available information on
your equipment or if you have questions
regarding information in this manual.

1.1 Manual Section Descriptions

This operator's manual covers use and
maintenance of your equipment. There are
seven sections to this manual, with each
section providing information you should be
familiar with before performing any operations
or repairs. Keep this manual with the machine
for your reference at all times. Replace it
immediately if it is damaged or lost.

NOTE:Due to improvement and updating of

products, some information may differ
from your equipment. If you have any
question on your equipment, contact
your SANY distributor before operating
or repairing the equipment.

1.1.1 Introduction
This section provides an overview of what is
covered in the rest of this manual, including
machine label information and SANY contact
information.

1.1.2 Safety
This section covers basic safety information
relating to this equipment. Make sure you
fully understand all the precautions described
in this manual and the safety labels on the
machine before operating or maintaining this
machine.

1-4
 Introduction
SYG5360THB 47

1.1.3 System functions

This section provides an overview of all the
controls and operating systems on your
equipment. It is important to study and
become familiar with all controls and systems
before proceeding with any operations.

1.1.4 Operation
This section provides the basic operating
procedures for the job. It is important to study
and become familiar with all procedures
before performing any operations with the
equipment.

1.1.5 Maintenance
This section provides all general maintenance
procedures. It is important to study and
become familiar with all the maintenance
procedures before performing any
maintenance operations on the equipment.

1.1.6 Troubleshooting
This section outlines common malfunctions
and fault diagnostic procedures for the
equipment operating system. Basic
mechanical, hydraulic and electrical system
troubleshooting is included.

1.1.7 Specifications
This information provides overall required
operating parameters for the equipment you
are using. Some information may vary due to
the design of the chassis.

NOTE:Some information may vary due to the

design changes.

1.1.8 Appendix
This section provides the hydraulic basic
diagram and the electrical basic diagram.

1-5
Introduction
SYG5360THB 47

1.2 Machine Serial Number & Informa-

tion
The serial numbers and model numbers on
the components are the only numbers that
your SANY distributor will need when
ordering replacement parts or requiring
assistance for your equipment. Record the
information in this manual for future use.

Data Plate

See Fig. 1-2 for the Date Plate.

Fig.1-2

Data Plate Location

On the top of the main boom mounting turret

is the pump unit data plate (a).

Fig.1-3

1-6
 Introduction
SYG5360THB 47

1.3 Contact Information

Thank you for purchasing a SANY product. In
the event that you should need to contact us
for any reason, you can reach us as follows:

Our address:
Sany Industry Town, Changsha National
Economic & Technical Development Zone,
Hunan, China
● Service Hotline: 0086 4006098318
● Service E-mail: [email protected]
● Web site: http://www.sanygroup.com.cn

1.4 Icons and Symbols

Most accidents are usually caused by the
failure to follow fundamental safety rules for
the operation and maintenance of the
machine. To avoid accidents it is important to
read and understand all information outlined
in this manual before operating or performing
maintenance on this machine.

The following (ANSI/ISO) signal words are

used to inform you that there is a potentially
hazardous situation that may lead to damage,
personal injury or even death. In this manual
and on the machine decals, different signal
words or illustrations are used to express the
potential level of hazard.

DANGER
Indicates an imminent hazard which, if not
avoided, will result in serious injury or
death.

WARNING
Indicates a potentially hazardous situation
which, if not avoided, could result in
injury or possibly death.

1-7
Introduction
SYG5360THB 47

CAUTION
Indicates a possible potential hazardous
situation which, if not avoided, could
result in minor or major injury.

NOTICE
Indicates a situation which can cause
damage to the machine, personal property
and/or the environment, or cause the
equipment to operate improperly.

This is the general warning sign. It

is used to alert the user to potential hazards.
All safety messages that follow this sign shall
be obeyed to avoid possible harm.

This symbol indicates that the

operation is not in conformity to the safety
regulations, is prohibited or may cause
injuries or fatalities.

This symbol indicates that the operation

is in conformity to the safety regulations.

SANY cannot predict every circumstance that

might involve a potential hazard in operation
or maintenance. Some safety messages in
this manual and on the machine may not
include all possible safety precautions.

If any procedures or actions not specified,

recommended or allowed in this manual are
used, you must be sure that you and others
can perform such procedures and actions
safely and without damaging the machine,
causing injury to yourself or other personnel. If
you are unsure about the safety of some
procedures, contact your local SANY distributor.

1-8
 Introduction
SYG5360THB 47

WARNING
● All operators or maintenance personnel
involved with the use of this equipment
must read this manual thoroughly before
operating or maintaining this equipment.
● This manual must be kept on or near
t he eq u ip me n t f o r r e f er e nc e a n d
periodically reviewed by all personnel
involved with operation or
maintenance of this equipment.
● Some actions involved in the operation or
maintenance of this equipment could cause
a serious accident if they are not performed
in the manner described in this manual.
● All procedures and precautions outlined
in this manual apply only to intended
uses of this equipment. If you use your
equipment for any unintended uses that
are not specifically prohibited, you must
be sure that it is safe for you and others
to do so. In no event should you or
others engage in prohibited uses or
actions as described in this manual.
● SANY delivers equipment that complies
with all applicable regulations and
standards of the country to which the
equipment has been shipped. If this
equipment was purchased in another
country or purchased from someone
in another country, it may lack certain
safety features and specifications that
are necessary for use in your country.
If there is any question about whether
your product complies with the applicable
standards and regulations of your country,
contact your local SANY distributor before
operating this equipment.
● Improper operation or maintenance of this
equipment can be hazardous and could
result in serious injury or even death.

1-9
Introduction
SYG5360THB 47

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Safety
2 Safety
2.1 Definition of terms .............................................................................................2-4
2.2 Designated use .................................................................................................2-13
2.3 Use contrary to designated use ........................................................................2-15
2.4 Exclusion of liability ...........................................................................................2-17
2.5 Personnel ..........................................................................................................2-18
2.6 Operating Instructions, operating procedures and other regulations ................2-19
2.7 Personal protective equipment .........................................................................2-21
2.8 Before starting work ..........................................................................................2-23
2.9 Danger due to high-voltage ..............................................................................2-24
2.10 Stationary machines .........................................................................................2-27
2.11 Mobile machines ...............................................................................................2-29
2.12 Placing booms ..................................................................................................2-34
2.13 Delivery line systems ........................................................................................2-37
2.14 Pumping operations ..........................................................................................2-39
2.15 Cleaning ............................................................................................................2-42
2.16 Maintenance and special work .........................................................................2-46
2.17 Welding .............................................................................................................2-48
2.18 Working on the placing boom ...........................................................................2-49
2.19 Safety-relevant components .............................................................................2-50
2.20 Software ............................................................................................................2-50
2.21 Protective and safety ........................................................................................2-50
2.22 Electrical power ................................................................................................2-51
2.23 Hydraulic systems .............................................................................................2-53
2.24 Exhaust fumes ..................................................................................................2-55
2.25 Functional fluids ................................................................................................2-55

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Safety
SYG5360THB 47

WARNING
Always read the Safety section of this
manual before attempting to operate this
equipment. Failure to do this could result
in machine damage, personnel injury or
death.

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 Safety
SYG5360THB 47

2 SAFETY

WARNING
Make sure you fully understand the
precautions described in this manual and
the safety labels on the machine before
operating or maintaining this machine.
Read and follow all safety precautions.
Failure to do so may result in equipment
damage, serious injury or possibly death.

This section corresponds to the contents of

the VDMA brochure entitled “Safety manual
Concrete delivery and placing machines”.

Here you will find a summary of the most

important safety regulations. This section is,
therefore, particularly suitable as an initial
basic instruction for new operators. Naturally,
the various rules are also repeated once
more at the appropriate points in other
sections.

NOTE:Special safety regulations may be

necessary for some tasks. These
special safety regulations will only be
found in the description of the
particular task.
NOTE:Safety regulations referred in this
section about line pump is suitable for
our product.

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SYG5360THB 47

2.1 Definition of terms

The terms used in this safety manual are

explained below, along with descriptions of
the requirements placed on specific groups of
people.

2.1.1 Concrete pump

For the purposes of this safety manual,
concrete pumps are defined as devices which
are designed to deliver concrete to placement
sites via pipes or hoses.

2.1.2 Boom pedestal

In this safety manual, boom pedestal refers to
a device for holding and guiding an arm
assembly.

2.1.3 Arm assembly

For the purposes of this safety manual, arm
assemblies are powered slewing devices
consisting of one or more swinging or folding
sections for guiding the delivery line.

2.1.4 Placing boom

In this safety manual, placing boom refers to
a unit comprising the arm assembly and
boom pedestal.

2.1.5 Base structure

For the purposes of this safety manual, base
structures are defined as equipment which is
designed to hold a stationary placing boom to
give the latter the required stability.

2.1.6 Truck mixer

In this safety manual, truck mixers are
vehicles with mixing equipment for
transporting concrete.

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2.1.7 Delivery line systems

For the purposes of this safety manual,
delivery line systems are defined as self-
contained pipes or hoses in which concrete is
pumped from the concrete pump to the
placement site. Devices for shutting-off,
diverting or cleaning delivery lines can be
integrated into delivery line systems.

2.1.8 Machine
In this safety manual, concrete delivery and
placing machines refer to:

– Truck-mounted concrete pumps (ensemble

of truck, concrete pump with and without
placing boom). The truck manufacturer’s
safety regulations also apply to the truck.
– Truck mixer concrete pump (an ensemble
of truck mixer, concrete pump and
placing boom). The safety regulations
issued by the truck mixer manufacturer
and by the truck manufacturer also apply
to truck mixer concrete pumps.
– Stationary concrete pumps
– Stationary placing systems (an ensemble
of placing boom and base structure)

2.1.9 Operator
Authorized representative of the owner of the
concrete pumps and/or placing booms. The
operator is responsible for the use of these
machines.

2.1.10 Machine operator

Person trained in and charged with the
operation of concrete pumps and placing
booms.

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2.1.11 Hoseman
Person instructed by the site management in
how an end hose is guided. Hosemen must
be able independently to evaluate dangerous
situations which may occur in the area of the
end hose and react according to the situation.

2.1.12 Signaller and other auxiliary

personnel
Persons instructed by the site management
to help the machine operator in his work if
the latter is unable to observe all areas of
operation and danger zones. Signallers must
be able to independently evaluate all
dangerous situations which may occur when
working with a concrete pump and/or placing
boom, and to react according to the situation.
The signaller must have a suitable means of
communication with the machine operator.

2.1.13 Truck mixer driver

Person who supplies the concrete pump with
concrete from a truck mixer. Truck mixer
drivers must be instructed by the machine
operator to operate the operating elements
on the concrete pump provided for their use.
Truck mixer drivers must be able to
independently evaluate all dangerous
situations which may occur when working in
the area of the hopper of a concrete pump,
and to react according to the situation.

2.1.14 Authorized inspector

Authorized inspectors are persons
empowered by the relevant government
bodies to carry out this task of inspection.
The prerequisites for becoming an authorized
inspector are:

– To have completed a higher education

course in engineering or similar.

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SYG5360THB 47

– To have at least 5 years’ professional

experience in a relevant domain, of which
at least six months must have involved
participation in the work of an authorized
inspector.
– To possess thorough knowledge of the
relevant health and safety regulations, as
well as of directives and the generally
recognised rules of engineering.
– To have access to the necessary
equipment to carry out the inspection.
– To be able to carry out the tasks
impartially.

2.1.15 Subject expert

For the purposes of this safety manual, a
subject expert is a person who, through their
professional training, their professional
experience and their recent professional
activity, has the required specialist knowledge
to inspect the tools.

2.1.16 Qualified personnel

Persons who have completed specialist
training for a particular activity which qualifies
them to carry out their roles.

2.1.17 After Sales Service personnel

Qualified persons employed by the
manufacturer who are responsible in
particular for maintenance of the machine.

2.1.18 Maintenance
Maintenance embraces all measures required
for inspection, servicing and repair of a
machine.

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2.1.19 Place of work, working area, danger zone

Mobile machines

Fig.2-1 Example

Stationary machines

Fig.2-2 Example

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SYG5360THB 47

NO. Designation Explanation

1 Machine operator In normal operation, with the remote control

2 Place of work Hoseman At the end hose in the danger zone
(during
3 Signaller In the machine operator’s range of vision
pumping
4 operations) Auxiliary personnel As manual placing system operators
5 Truck mixer driver At the hopper in the danger zone
Area with a radius of the reach of the placing
6 Permitted
boom + end hose length
Working area
The end hose must not be moved backwards
7 Impermissible
beyond the vertical of the placing boom
Risk of injury when pumping is started,
during pumping operations, when removing
8 At the end hose a blockage and during washing out
procedures. The diameter of the danger
zone is twice the end hose length.
Beneath the placing
9 Risk of injury from falling items
boom
Area of the support
Danger of crushing when the machine is set
10 Danger zone legs and feet or area
up and when the supports are retracted
of the base structure
Any presence on or below the machine when
11 On the machine
the pump is in operation is prohibited
Risk of injury during washing out procedures
12 At the hopper and when the hopper is being filled using a
truck mixer
Area of the delivery Risk of lines bursting, risk of injury by
13
line systems crushing or shearing e. g. by gate valves
14 Structure or area being concreted Example

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Place of work
The place of work is the area in which people
must remain in order to carry out the work.

● Place of work-machine operator

The machine operator’s place of work is with
the remote control when the pump is in
operation. The place of work must be
selected so as to allow visual contact with the
site of concrete placement, and the truck
mixer driver, and so that the working area
can be observed at the same time. A
signaller must otherwise be used.

The operator’s place of work is with the

machine when this is being set up or
prepared for driving.

● Place of work-hoseman
The hoseman’s place of work is within the
danger zone of the end hose, but not
beneath the placing boom. This requires a
greater level of caution. The hoseman and
machine operator must have visual contact.

● Place of work- truck mixer driver

The truck mixer driver’s place of work is in
the danger zone of the hopper and at
operating elements for the agitator and truck
m ixe r. Th is requi r es a gr eat e r l eve l o f
caution. The truck mixer driver and machine
operator must have visual contact.

Working area
The working area is the area in which work is
carried out with or on the machine. Parts of
the working area can become danger zones
depending on the operation being carried out
and the position of the placing boom.

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SYG5360THB 47

The working area must be secured and

clearly identified. Suitable personal protective
equipment is required in the working area.
The machine operator is responsible for
safety in the working area of the machine
whilst the machine is in use.

● Impermissible working area

Because of their high manoeuvrability, some
placing booms can also be shifted into
positions for which they are not designed.
This may overload or damage the placing
boom. Placing booms must therefore only be
moved within the permitted working area.

Danger zone
The danger zone is the area surrounding the
machine, in which people may be at risk of
injury from movements required by the work.

The danger zone varies within the working

area and depends on the activity being
carried out and the position of the placing
boom. Danger zones must be secured and
clearly identified. The machine operator must
be capable of seeing the danger zone at all
times and under all circumstances. If
necessary he must appoint a signaller to
supervise the danger zone.

Depending on the working situation,

workplaces may occasionally fall within the
danger zone, especially the workplace of the
hoseman and the truck mixer driver. If a
workplace falls within the danger zone,
increased caution is required and suitable
personal protective equipment is prescribed.
Persons who are authorized to be present in
s u c h a w o r k p l a c e , m us t u s e t h e i r o w n
discretion to assess the hazards of the
situation and be able to react accordingly.

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The machine operator is responsible for

safety in the danger zone of the machine
whilst the machine is in use.

The machine operator must stop work

immediately and press the EMERGENCY
STOP button if an unauthorized person
enters the danger zone.

● Supporting legs and support feet

There is a danger of crushing in the swing-
out and extension zone for the supports.

● Placing boom
The danger zone when working with the
placing boom is the zone over which the
placing boom is slewed. In this area there is
a risk of injury from falling concrete and
delivery line components.

● Machine
All the time the vehicle is in operation, there
is a risk of injury on and below the machine
from moving parts and bursting delivery lines
or hydraulic hoses, as well as a risk of falling
on slippery surfaces or steps.

● End hose
The danger zone when pumping is started,
during pumping operations, when removing a
blockage and during washing out procedures
is the area around the end hose in which the
hose may swing out. The diameter of the
danger zone is twice the end hose length.

● Hopper
In the area of the hopper, there is a risk of
becoming trapped between the truck mixer
and the hopper and of being sprayed with
concrete. There is a risk of being crushed
and of injury by shearing from the transfer
tube. There is a risk of being entrapped by
the rotating agitator.

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SYG5360THB 47

● Delivery line systems

In the area around the delivery line systems
there is a risk of injury from the delivery line
bursting if there is an abrupt rise in pressure.
There is a risk of crushing and injury by
shearing with devices integrated in delivery
line systems.

2.2 Designated use

The machine must only be operated as

intended and in technically perfect condition.
All protective and safety-related devices, such
as removable protective devices and
EMERGENCY STOP devices, must be
available and fully functional.

The machine is constructed in accordance

with the conditions laid down in the EU
Machinery Directive (2006/42/EC) and EN
12001. Nevertheless, its use may constitute a
risk to life and limb of the user or of third
parties, or cause damage to the machine and
to other property.

The machine is designed exclusively for the

delivery and placing of concrete up to a bulk
density of 2,400 kg/m3. It must only be used
for pumping operations on construction sites.
The maximum concrete pressure must not
exceed that specified on the rating plate or in
the check book.

Designated use also includes observing the

Operating Instructions and complying with the
intervals and conditions for inspections and
maintenance work.

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2.2.1 Inspection intervals

After it is used for the first time, the
operational safety of the machine must be
checked regularly by a subject expert. The
inspection intervals depend on the age of the
machine. The older the machine, the greater
the probability of damage. This is why a
regular inspection of the machine, appropriate
to its age, is an effective means for the early
detection of damage.

In anticipation of the change to the standard

EN 12001:2003+A1:2009, inspection intervals
will be established as follows:

Machines of up to and including 5 years old:

Inspect after every 1,000 operating hours or 1
year, whichever is soonest. The interval is
repeated after every inspection.

Machines more than 5 years old:

Inspect after every 500 operating hours or 1
year, whichever is soonest.The interval is
repeated after every inspection.

Machines more than 10 years old:

Inspect after every 250 operating hours or 1
year, whichever is soonest. The interval is
repeated after every inspection.

The day of initial commissioning in

accordance with the handover report and the
machine’s operating hours meter is definitive
for the intervals. This operating hours meter
records the hours of pumping operations. The
operating hours meter must always be kept in
good working order. It must not be tampered
with. For machines without an operating
hours meter, the operating hours must be
comprehensibly recorded in writing.

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The operator is responsible for commissioning

the inspection. The outcome of the inspections
must be recorded in the check book and
confirmed by a signature. The check book
must always be kept with the machine and
must be produced upon the request of the
national supervisory bodies.

Notwithstanding national legislation, the

operator can be liable in the event of
damage, if it is proved that the damage has
arisen as a consequence of a regular repeat
inspection not being properly carried out.

2.3 Use contrary to designated use

Any use of the machine which is not
described in section 2.2, entitled "Designated
use", or which extends beyond the uses
described in this section is deemed to be
contrary to designated use. The manufacturer
accepts no liability for damage resulting from
such use. Some examples of conceivable
uses that are contrary to the designated use
are given below.

2.3.1 Transporting goods

The machine may not be used for the
transport of goods, except for carrying the
accessories used for the machine, such as
pipes, hoses, etc. The maximum permissible
gross weight may not be exceeded.

2.3.2 Lifting loads

The placing boom must never be used for
lifting loads.

2.3.3 Removing obstacles

The placing boom must not be used under
any circumstances to remove obstacles. This
would overload the placing boom, causing
damage and endangering people. Fig.2-3

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2.3.4 Extending the reach

It is prohibited to attach an extension (e.g.
freely suspended crossbeam) to the end hose
or placing boom tip in order to extend the
reach or to pump at an angle. Since the
boom and the lifting equi pment for the
extension have differing pivot points and
modes of control, it is not possible to
coordinate their movements.

2.3.5 Extensions
Extension of the placing boom and end hose
beyond the length specified on the rating
plate is forbidden.

2.3.6 Impermissible end hose Fig.2-4

The end hose must not be fitted with any

extension coupling, spout, “swan neck”, outlet
shoes or other dangerous outlet fitting or
similar device.

2.3.7 Impermissible working area

The end hose must not be moved backwards
beyond the vertical of the placing boom.

Fig.2-5

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2.3.8 Climbing the placing boom

It is prohibited to climb the placing boom, to
stand on top of it or to misuse it as a working
platform or aid to climbing.

2.3.9 High-pressure delivery

It is prohibited to deliver concrete at high-
pressure (concrete pressure greater than 85
bar) through the delivery line of the placing
boom. The delivery line and end hose are
only suitable for concrete pressures up to 85
bar in their new condition. Fig.2-6

2.3.10 Accessories and attachments

It is prohibited to fit accessories and
attachments to the machine if they have not
been expressly approved for use on this
machine by the manufacturer.

2.4 Exclusion of liability

Where the manufacturer’s delivery conditions

are agreed, liability will be as described in the
provisions there. We expressly stipulate that
the manufacturer is not liable for any damage
caused in the cases specified in these
conditions.

Unless the responsibility of the manufacturer,

the warranty will be invalidated in the
following situations in particular:
– use contrary to designated use
– incorrect operation, maintenance and repair
– use of spare parts or accessories other
than original manufacturer’s spare parts
and accessories or their equivalents
– conversions, alterations or modifications
to the machine
– fitting of accessories and attachments not
approved by the manufacturer

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– adjustment of safety pressures, speeds of

movement, power outputs, speeds of
rotation and other settings to values other
than those set in the works

2.5 Personnel

The operator must ensure that only persons

who are qualified or have received the
necessary instruction work on or with the
machine. He must clearly define who is
responsible for operation and maintenance of
the machine. He must also ensure that only
persons commissioned to work on the
machine do so.

2.5.1 Requirements
Persons operating or carrying out
maintenance work on the machine must meet
the following requirements:
– They must be aged 18 years or over.
– They must be physically and mentally
capable.
– They must be physiologically capable
(rested and not under the influence of
alcohol, drugs or medication).
– They must have been instructed in the
operation and maintenance of the
machine.
– They must have demonstrated their
competence to the operator.
– They can be expected to reliably execute
the tasks with which they are charged.
The operating personnel must not wear loose
garments or jewellery, including rings. Long
hair which is not tied back must be covered
by a hair net. Injury may result from hair
being caught up in the machinery or from
rings catching on moving parts.

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2.5.2 Qualifications
Do not allow persons who have not yet
completed training or instruction, or persons
taking a general training course, to operate
the machine unless under the constant
supervision of an experienced person.

If you do not have qualified personnel,

suitable workshop equipment etc. available,
you should commission the manufacturer’s
After Sales Department with the maintenance
of your machine.

2.5.3 Responsibility of the machine

operator
The operator must define the responsibility of
the machine operator (including in respect to
national road traffic regulations) and empower
him to reject instructions from third parties
prejudicial to safety. The machine operator
must be able to reject the site of operations if
he has doubts regarding technical safety.

2.6 Operating Instructions, operating

procedures and other regulations

2.6.1 Operating Instructions

Personnel entrusted with work on the
machine must have read the Operating
Instructions, in particular the chapter on
safety, before beginning work. Reading the
instructions after work has begun is too late.
This applies especially to persons working
only occasionally on the machine, e.g. during
setting up or maintenance.

The Operating Instructions must always be

kept to hand at the site of use of the machine
(in the tool compartment or container
provided for this purpose).

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As the operator, you must always make sure

that the Operating Instructions are available.
Have personnel working on the machine
confirm in writing their knowledge,
understanding and application of the
Operating Instructions and Safety
Regulations. At regular intervals of at least
once a year, check that personnel are
conscious of safety and the hazards involved
in their work and are taking account of the
Operating Instructions.

Personnel entrusted with work on the

machine must observe all safety notes and
hazard warnings.

Personnel entrusted with work on the

machine must be familiar with the machine
itself. You must practice all the operating
procedures described in the Operating
Instructions (extending the supports,
operating the placing boom, shifting the
pl acing boom into the drivi ng position,
preparing the vehicle for moving, etc.) under
the supervision of a subject expert until you
are certain you can execute them safely. Ask
questions if there is something you have not
understood. Begin operating the machine
only once you are familiar with the layout and
significance of all the control and monitoring
devices and the functioning of the machine in
general.

2.6.2 Operating procedures

The operator must produce operating
procedures for his personnel in accordance
with national regulations. These operating
procedures must include instructions covering
the duties involved in supervising and
notifying special operational features, e.g.
organization of work, working procedures or
the personnel entrusted with the work.

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Furthermore, reference must be made to

other generally valid legal and otherwise
mandatory regulations relating to accident
prevention and environmental protection.
Such regulations may also deal with handling
hazardous substances, the issuing and
wearing of personal protective equipment or
with national road traffic regulations. You
should familiarise yourself with the site of
operations and with how to use fire
extinguishers. Observe the fire-alarm and fire-
fighting procedures.

2.6.3 Other regulations

The current regulations for concrete delivery
and placing machines as issued by:
– the legal authorities in your country
– national supervisory bodies
– the responsible commercial liability insurance
company
are binding on the operator of the machine.

2.7 Personal protective equipment

In order to reduce risks to personnel,

personal protective equipment must be used
in so far as this is necessary or deemed to
be so by regulations. All personnel working
on or with the machine must wear safety
helmets, protective gloves and safety shoes.

Personal protective equipment must, as a

minimum, comply with the requirements of
the specified standards.

Safety helmet
A safety helmet protects your head against,
for instance, falling concrete or parts of the
delivery line in the event of a hose bursting.
(DIN EN 397; Industrial safety helmets)
Fig.2-7 Safety helmet

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Safety footwear
Safety footwear protects your feet against
falling objects and against penetration by
projecting nails.
(EN ISO 20345; Safety footwear for
professional use; Class S3)
Fig.2-8 Safety footwear
Hearing protectors
Hearing protectors protect you against the
noise generated by the machine when you
are standing close to it.
(DIN EN 352-1; Hearing protectors – General
requirements – Part 1: Earmuffs or DIN EN
352-3; Hearing protectors – General
requirements – Part 3: Earmuffs on safety Fig.2-9 Hearing protectors
helmet)

Protective gloves
Protective gloves protect your hands against
aggressive or chemical substances, as well
as against mechanical effects (e.g. impact)
and cutting injuries.
(DIN EN 388; Protective gloves against
Fig.2-10 Protective gloves
mechanical risks; Class 1111)

Protective goggles
Protective goggles protect your eyes against
injuries from concrete spatters or other
particles.
(DIN EN 166; Personal eye-protection –
Specifications) Fig.2-11 Protective goggles

Safety harness
When working at height, use the climbing
aids and working platforms provided for
reasons of safety or wear a safety harness.
The relevant national regulations must be
complied with.
(DIN EN 361; Personal Protective Equipment Fig.2-12 Safety harness
Against Falls from a Height –Full Body
Harnesses; Category III)

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Face mask and respiratory protection

A face mask and respiratory protection
protect you against particles of building
materials which could enter your body
through your respiratory passages (e.g.
concrete admixtures). Fig.2-13 Face mask and respiratory protection
(DIN EN 149; Respiratory protective devices
– Filtering half masks to protect against
particles-Requirements, testing, marking;
Class FFP1).

2.8 Before starting work

2.8.1 Checking that the machine is

ready for operation
As machine operator, it is your responsibility
to check the machine for external damage
and defects before any use of the machine.
You must immediately report any changes
(including changes in the working
characteristics) to the organization or person
responsible. If necessary, shut the machine
down and secure it against use.

2.8.2 Rendering the machine ready

for operation
As machine operator, you are responsible for
rendering the machine ready for operation.
This also includes topping up the functional
fluids. Do not fill with fuel in enclosed spaces.
Switch off the engine and the heating. Wipe
up spilt fuel immediately. Do not smoke or
use a naked flame when handling fuel.

Set all the control and monitoring devices to

the zero position before you change the
mode of control (control bl ock , c ontrol
console or remote control). Press the
EMERGENCY STOP button. otherwise the
machine might execute unintended
movements. Fig.2-14

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Never put the remote control down when the

machine is ready for operation. If this is
unavoidable in exceptional cases, you must
press the EMERGENCY STOP button,
disconnect the remote control and lock the
remote control away (see also page 40).

Never leave the machine when the engine is

running or when the engine could be started
by an unauthorized person. If you need to
leave the machine, proceed as follows:
– press the EMERGENCY STOP button,
– disconnect the remote control and lock it
away,
– switch off the ignition or the main switch,
– lock the control cabinet.

2.9 Danger due to high-voltage

2.9.1 High-voltage lines

Whenever you touch a high-voltage line,
there is a risk of death for all persons either
on the machine or in its vicinity or who are
connected to it (via the remote control, end
hose, etc.). A spark can jump across from a
high-voltage line even if you just approach it
and this will energize the machine and the
surrounding area.

2.9.2 Discharge voltage pattern

In the event of a flash over, what is known as
a “discharge voltage pattern” is formed in the
vicinity of the machine. The voltage
decreases from the inside to the outside in
this discharge voltage pattern. If you step
within this discharge voltage pattern, you will
bridge different potentials. This will cause a
vo lta ge corre s pon ding t o th e p ot ent ial
difference to flow through your body.

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2.9.3 Clearances
Maintain a minimum clearance from high-voltage
lines in accordance with the following table. The
minimum clearance is measured in the horizontal
when the placing boom is fully extended.

Rated voltage [V] Minimum clearance [m]

up to 1kV 1.0
1kV to 110kV 3.0
110kV to 220 kV 4.0
220kV to 380kV 5.0
unknown rated voltage 5.0

The specified clearances are minimum

requirements. You must observe any greater
clearances that may be specified in the
country of use.
When you set a minimum clearance, the
possibility of the high- voltage lines and the
placing boom swaying in the wind must also be
taken into consideration. You should further
note that where air humidity is high, clearances
greater than the minimum clearances shown
above are always necessary.
You must stand as close as possible to the Fig.2-15
unfolded placing boom if you wish to estimate
correctly the movements of the boom and,
above all, the clearance between the placing
boom and obstacles or high-voltage lines.
The same minimum clearances are necessary
when driving under overhead cables.
In the event that this minimum clearance
cannot be maintained under all possible
working positions, the power station
responsible must be contacted and you must
have the high-voltage line switched off.
Should you have any doubts, it is better to
forego the use of the placing boom and to lay
a separate delivery line, for instance.

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2.9.4 High-voltage warning devices

According to the current rules of engineering,
high-voltage warning devices do not meet a safety
standard which enables a safe undershooting of
the required minimum clearances to high-voltage
lines. Previous experience has shown that high-
voltage warning devices cannot make all
situations in working procedures safe. Flash overs
and fatal accidents can occur despite the use of a
high-voltage warning device. You must therefore
always maintain the minimum clearances
mentioned above.

2.9.5 Procedure in the event of a flash

over
Should a flash over occur, despite all
precautions, stay calm, do not move
(potential differential), touch nothing.
If your machine comes into contact with
heavy current lines:
– Warn those outside against approaching
and touching the machine.
– Have the power switched off.
– Only leave the machine once you are
sure that the line you have touched or
damaged has been de-energized.
Power stations are always equipped with
automatic switch-on devices. If a circuit
Fig.2-16
breaker trips, the short-circuited cable will be
switched back on again after a brief interval.
Brief intervals when the voltage is absent
give rise to a false sense of safety.

You should only move and rescue injured

persons once a representative of the power
station has notified you that the cable has
been switched off.

A radio remote control system only protects

the machine operator if he is standing outside
the discharge voltage pattern.

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2.9.6 Earthing in the event of

electrostatic charging
Faults can be caused in the radio remote
control system and dangerous electrical
charging of the machine can occur when
working in the vicinity of transmitters (radio
transmitter, etc.). Persons who bridge the
c h a rg e d p a r t s t o t he e ar t h a r e h e a v i l y
charged on contact.

Machines in use in the vicinity of transmitters

must be earthed. Secure the earthing cable
(at least 16 mm 2 ) to an extra pre-prepared,
bright metal point of the machine (e.g. not to
a piston rod) and to a conductive metal rod in
the ground (minimum insertion depth of 1.5
m). Thoroughly dampen the earth around the
metal rod to make it more conductive.

Even when the machine is earthed, the safe

clearances to high-voltage lines (see page
25) must be maintained and the instructions
regarding storms and bad weather (see page
36) must be observed.

If you have any further questions about

earthing the machine, please contact the
construction site management or the
operating company of the machine.

2.10 Stationary machines

2.10.1 Set-up site

Stationary machines are generally used on a
construction site for a lengthy period. For this
reason, site management should prepare the
set-up site carefully. The site management
must deliver the necessary documents in
good time in order to be able to prepare the
foundations, base plates or similar on time.

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When selecting the set-up site, remember

that the machine must be dismantled and
transported away again at the end of its use
on site. The ambient conditions may change
as construction work progresses.

2.10.2 Stationary booms

When stationary booms are erected on
tubular columns, lattice booms or other base
structures, the base frame of the base
structure must be secured on the foundation
horizontally in all directions. Check the
documentation provided by the manufacturer
in this regard and the corresponding notes in
the operating instructions.

2.10.3 Lifting machines and components

Machines which are transported to the set-up
site in individual parts or not under their own
power must only be lifted with suitable lifting
equipment in accordance with the
specifications in the Operating Instructions.
The lifting gear on the machine must be
capable of accepting the lifting gear and
lifting the load. No-one should stand under
suspended loads. Before work is started, a
subject expert must check that the assembled
machine is working properly.

2.10.4 Loading and transporting

Only use suitable means to load and transport
stationary machines. Ensure that no-one can be
injured by the machine tipping over or slipping.

If there are fixtures provided for transport of the

machine or its individual components, only
these should be used. The machine or
components must be properly lashed down
during transport. The transport vehicle and
machine must be marked to conform with the
road traffic regulations in the country concerned
if they are to use the public highway.

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2.11 Mobile machines

2.11.1 Set-up site

It is the machine operator who takes
responsibility for setting up the machine
safely. He must inspect the proposed set-up
site and must refuse to set the machine up at
the site of operations if he has any doubts
regarding safety.

As machine operator, you must familiarise

yourself with the working area and
surroundings before work is begun. The
working area and surroundings include
obstacles in the work and travelling areas,
the loadbearing capacity of the supporting
ground and any barriers separating the
construction site from public roads.

You must also check the approach route to

the site where the machine will be set up. If
you are unsure whether the approach route is
suitable, prepare the route before work is
started. It is especially necessary to walk the
approach route once in darkness and at dusk
or dawn. You should repeat this exercise
again before leaving the construction site.

You must always ask for a signaller if you

have to reverse into the site where the
machine will be set up. If necessary, have the
approach route closed off or secured by
signallers. Have any materials or equipment
that hinder your approach removed.

2.11.2 Supporting ground

Check the loadbearing capacity of the
supporting ground. The site management will
be able to state the permitted ground
pressure.

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The supporting ground must be level and

even. If necessary, set up a level surface on
top of the uneven ground. There must be no
voids or other ground irregularities under the
support feet. Asphalt, concrete slabs, etc. may
have been washed out underneath. Never set
the machine up on backfilled ground.

The support area must be enlarged as

required. Support blocks and timber blocks
may be used to increase the support area.
The support timbers must be undamaged and
free from ice, oil, grease, etc. The support
blocks and timber blocks must be laid under
the support plates such that the load is
distributed uniformly and the support leg
cannot slip off the side of the support.

Check the stability of the machine regularly

during operation. Interrupt the pumping
operation if the machine becomes unstable. Fig.2-17
Factors which reduce stability include, for
instance:
– modifications to the ground conditions,
e.g. caused by rain water or the thawing
of frozen ground
– the support sinking on one side
– fluid losses through leaks in the support
hydraulics

2.11.3 Corner bearing loads

The corner bearing load is stated on each
support leg. This value must always be legible.

The force transferred to the ground by each

support leg diffuses through the soil in a
conical pattern at an angle of 45°. Safe
clearance to the pits and slopes must be
maintained, and such clearance must be
determined in accordance with the nature of
the ground. The safe clearance is measured
from the foot of the pit. Fig.2-18

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However, for undisturbed, compacted ground,

the safe clearance corresponds to pit depth,
but must be a minimum of 2 m.

For loose or back-filled ground, the safe

clearance is twice the pit depth, but a
minimum of 2 m.

2.11.4 Supports
The placing boom must not be raised until
the machine has been supported in
accordance with the Operating Instructions.
There is otherwise a risk of the machine
toppling over.

Swing out and telescope the support legs to

their end positions in sequence. Intermediate
positions are prohibited to guarantee stability.
Exceptions are machines which have been
equipped by the manufacturer with a device
which allows secure erection with a reduction
in support. Check the corresponding notes in
this regard in the operating instructions.

Lock all supports mechanically, if this is

provided for in the design. Close all shut-off
valves in the support hydraulics. Leaks can
cause the supports to sink on one side.

The machine must be made level in all

directions. The maximum permitted deviation
from the horizontal is 3°. Greater deviations
from the horizontal overload the slewing gear
for the placing boom and jeopardize the
stability of the machine.

Check stability regularly during operation. The

elastic distortions to the machine frame
occasionally occurring under extreme positions
of the placing boom (one support foot lifts from
the ground) must be compensated for by
resetting the support cylinders until all support Fig.2-19
feet are firmly placed on the ground.

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2.11.5 Driving
When preparing the machine for driving, you
must perform the following tasks in particular:
– The placing boom must be folded in fully
and positioned on the placing boom
support provided.
– The support legs and support feet must
be fully retracted and secured.
– Raised or locked axles must be lowered
and released.
– Accessories belonging to the machine must
be safely stowed away and secured.
– The maximum permissible gross weight
may not be exceeded.
While the vehicle is being driven, the delivery
line, pump and hopper must be empty. If
there are concrete leavings in the hopper, it
must not be possible for the leavings to be
thrown out while the vehicle is in motion,
thereby creating a risk of injury. You must
adapt your driving style to the altered centre
of gravity of the machine. You must not
exceed the maximum permissible gross
weight of the machine. Observe the road
traffic regulations and specifications of the
machine manufacturer.

Maintain a clearance of at least 1 m from the

secured edges of construction pits and at
least 2 m from slopes.

Always make sure that there is sufficient

clearance when driving under underpasses,
over bridges and through tunnels or when
passing under overhead cables. The same
minimum clearances apply when driving
under high-voltage lines as when working
with the placing boom. Be aware of the
Fig.2-20
height of the truck. Only drive over arches,
bridges or other supporting structures if the
loadbearing capacity is adequate.

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Do not drive across uphill or downhill

gradients. Be aware of the elevated position
of the truck’s centre of gravity when travelling
on a slope and on ascending or descending
routes. Always adapt your travelling speed to
the prevailing conditions on sloping terrain.
Never change to a lower gear on a slope but
always before reaching it.

Observe national road traffic regulations. If

necessary, clean the tyres, lights and number
plate. Before travelling with the machine,
check that the braking, steering, signalling
and lighting systems are fully functional.

Persons accompanying the driver must be

seated on the passenger seats provided for
this purpose.

Whilst the truck is in motion, the mixer drum

on truck mixer concrete pumps must only be
rotated at the maximum speed of rotation
specified in the Operating Instructions. The
truck is at risk of tipping over, particularly
when travelling round corners.

2.11.6 Towing
The machine must only be towed, loaded and
transported in accordance with the Operating
Instructions. Only use existing towing hitches
for towing and observe the truck
manufacturer’s regulations.

You must comply with the prescribed driving

position, permitted speed and itinerary when
towing.

2.11.7 Loading
The lifting points fitted to the machine as
standard are provided for assembly purposes
only. They are not suitable for lifting the
complete machine. The lifting points for lifting
the entire machine are specially marked. Fig.2-21

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Use only appropriate means of transport and

lifting equipment of adequate loadbearing
capacity. Lifting equipment, lifting tackle,
support trestles and other auxiliary equipment
must be reliable and safe in operation.

Use only stable loading ramps of adequate

loadbearing capacity for loading. Ensure that
no-one is at risk from the machine tipping
over or slipping.

Secure the machine against rolling, slipping

and toppling over on the transport vehicle.

2.12 Placing booms

2.12.1 Unfolding the placing boom

Only raise a mobile placing boom from the
driving position once the machine has been
supported in accordance with the Operating
Instructions. Stationary booms may only be
raised after the proper set-up has been
checked by a subject expert.

Only raise the placing boom in the sequence

described in the Operating Instructions. The
correct sequence depends on the folding
system (roll-and-fold system, Z-fold system,
etc.).

Always ask the site management to supply

you with an assistant to act as a signaller.
Agree clear hand signals or other signals with
the signaller so that you can communicate
with each other. You should position the
signaller such that he can always observe the
whole of the placing boom. Your primary duty
as the machine operator is to observe the
site of concrete placement.

Only slew the placing boom over persons

when the end hose is empty. There is a risk
of concrete falling out of the end hose.

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Press the EMERGENCY STOP button

immediately if the placing boom moves
unexpectedly. If this should occur, you must
cease working and have the cause of the
fault rectified by your qualified personnel or
our After Sales Department.

Placing booms with placing boom hinges

which allow considerable flex angles have a
very large potential working area. Because of
this high manoeuvrability, various placing
booms can, however, also be shifted into
positions that are of no interest for the
pumping operation. Under certain
circumstances it is even possible to overload
or cause damage to the placing boom. We Fig.2-22
have indicated such impermissible working
areas by the use of warning signs and
information plates on the machine and
appropriate notes in the Operating Instructions.

2.12.2 End hose

The end hose must hang freely each time you
start pumping, when you start pumping again
after blockages, and during washing out
procedures. No-one should stand within the
danger zone of the end hose. The diameter of
the danger zone is twice the end hose length.
Do not guide the end hose when pumping is
started. There is a risk of injury from the end
hose swinging out or stones being ejected.

There is a risk of injury to the hoseman if the

end hose becomes caught in the Fig.2-23
reinforcement and suddenly jumps out on
further movement of the placing boom.

Never bend the end hose over. Never

attempt to straighten a bent end hose by
increasing the pressure. The end hose must
not be submerged below the surface of the
concrete being delivered, otherwise the
concrete may spray upwards.

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The concrete may also spray from the end

hose d ue to t he presence of air in the
delivery line. To prevent this from occurring,
the hopper must always be filled with
concrete as far as the agitator shaft so that
no air can be sucked in.

The end hose must be secured against falling.

2.12.3 Procedure in storms

Return the placing boom to the driving
position in the event of storms or bad
weather.
– Placing booms with a vertical reach of 42 m
or more may only be operated in wind forces
up to 7 (wind speed 61 km/h = 17 m/s).
– Placing booms with a vertical reach of less
than 42 m may only be operated in wind
forces up to 8 (wind speed 74 km/h = 20 m/s).
Wind speeds in accordance with the Beaufort
scale are average wind speeds measured
over a period of 10 minutes. Higher speed
gusts of wind may occur briefly during the
measuring period. Higher wind speeds
jeopardize stability and safety of the structural
elements. There is a risk of lightning strike in
a thunderstorm.

A lightning strike poses a lethal danger to

persons. The machine and the surrounding
area will be charged with electricity. Earthing
the machine does not reduce this risk. For
this reason, you should fold in the placing
boom if there is a risk of lightning strike.

Tower cranes on construction sites generally have

wind speed measuring equipment, so that you
can ask about the wind speed at any time. If no
wind speed measuring equipment is available,
you can ask the nearest meteorological office
what the wind speed is, or estimate the wind
speed using the following rule of thumb.

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– In winds of force 7 and greater, green

leaves break from the trees and there is
perceptible resistance when walking
against the wind.
– In winds of force 8 and greater, small
branches break from trees and walking
outside is significantly impeded.

2.12.4 Concreting in cold weather

The boom must not be used in temperatures
below minus 15°C (+5°F) unless the
manufacturer has given express approval.
There is a danger of damage to the steel
(brittle fracture) and the seals throughout the
system at such extreme minus temperatures.

In addition, such minus temperatures should

be considered the realistic lower limit for
con c re te pl aceme nt, as it is no lo nge r
possible to prepare concrete such that it can
achieve its strength without the use of special
additives.

2.13 Delivery line systems

2.13.1 Suitable delivery lines

Use only perfect delivery lines, end hoses,
couplings, etc. suitable for the delivery job
and manufactured by the machine
manufacturer. Delivery lines are subject to
wear which varies according to the pressure
and composition of the concrete, the material
from which the delivery line is made, etc.

2.13.2 Securing delivery

Delivery lines, delivery hoses, end hoses and
couplings must be securely fastened and
secured against spontaneous opening.

Fig.2-24

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2.13.3 Tightness and blockages

Regularly force water through the delivery
line under operating pressure to check that
the system is watertight.

A properly-cleaned delivery line is the best

insurance against the formation of blockages.
Blockages increase the risk of accidents.
Never attempt to push through a blockage
(e.g. by increasing the delivery pressure,
using compressed air, etc.). There is a risk of
fatal injury from the delivery line bursting or
from concrete being ejected from the end of
the delivery line. Always try to remove the
blockage by reverse pumping and then
restarting forward pumping. If the blockage is Fig.2-25
not removed, relieve the pressure on the
delivery line before removing the section of
delivery line concerned.

2.13.4 Opening delivery lines

You must not open or tap delivery lines while
these are pressurized. Concrete exiting under
pressure can cause injury. The concrete
column must be depressurized by reverse
pumping before the delivery line is opened.
Never work bending directly over the coupling.

2.13.5 Clearance to delivery lines

No-one should remain in the vicinity of
separate delivery lines during pumping
operations. Cordon off the danger zone. If it
is not possible to place a large enough
cordon around the danger zone, the delivery
line must be covered by suitable means.

Fig.2-26

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2.13.6 Fastening delivery lines

Delivery lines, in particular riser lines which are
not laid along placing booms, must be securely
fastened in order to transfer the forces
generated in them into the structure or other
structural members. The lines must be laid so
as to avoid kinks, sharp bends, stresses and
damage during pumping operations.

2.13.7 Continuation delivery lines

A continuation delivery line connected to the
placing boom must not exert a load on the boom.

Devices for shutting- off, diverting or cleaning

delivery lines

During operation there is a risk of being

crushed and of injury by shearing.
Hydraulically driven devices are generally
supplied with power by a machine’s hydraulic
system. It must therefore be possible to see
from the devices and the machine with
control unit and vice versa. Observe the
safety regulations for the machine and the
device when connecting and operating a
device. Make sure that no-one is in the
danger zone before operating devices.

Use only suitable, perfectly functioning

devices to shut-off, divert and clean the
delivery l ine. Defective and unsui table
devices may cause damage to the whole
delivery system and injure persons in the
surrounding area due to a malfunction.

2.14 Pumping operations

2.14.1 Place of work
The machine operator’s place of work is with
the remote control when the pump is in
operation. If you operate the machine using
the remote control, all operating and control
devices on the machine must be closed to
prevent unauthorized interventions.

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In the case of stationary placing booms,

platforms or similar equipment are only
provided for assembly and maintenance
work. Use of these platforms as a workplace
during operation is prohibited.

It is forbidden to climb onto the machine

during operation. In the case of stationary
placing booms, it is forbidden to climb ladders
during operation.

2.14.2 Safety
Before switching on the machine, you must
make sure that nobody can be injured by the
running machine.

Refrain from any procedures that may impair

the stability of the machine or are prejudicial
to safety in any other way.

2.14.3 Remote control

You must always carry the remote control on
your person when the machine is ready for
operation. Only in this way can it be
guaranteed that you can press the
EMERGENCY STOP button in the event of
an emergency situation. The EMERGENCY
STOP button may only be unlocked once the
cause/emergency has been remedied (see
also page 23).

You must carry the remote control in such a

way that no control element is actuated
unintentionally.

During breaks in pumping, interruptions,

maintenance work or your absence from the
machine, you must secure the machine
against inadvertently rolling away and to
prevent unauthorized use. Press the
EMERGENCY STOP button on the remote
control and lock the remote control away.

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2.14.4 Moving machine components

and hot surfaces
Keep all access covers, maintenance flaps,
guards, etc. closed and locked during
operation. This also applies to the grille,
water box cover, and covers on cylinders, for
example. There is otherwise a risk of injury
from moving parts of the machine and a risk
of burning on hot surfaces. In particular, there
is a risk of burns from the engine, attached
parts and the exhaust.

Never start work unless the grille is closed

and bolted down or otherwise secured.

Do not touch moving parts of the machine,

whether the machine is running or switched
off. Always switch off the engine first, and
dump the accumulator pressure where an
accumulator is fitted.

Never poke any objects (e.g. a shovel

handle, trowel or similar) into moving
machine components. Such objects could
become trapped and dragged into the
machine. They might then hit you or be torn
from your hands and cause you injury.

2.14.5 Constant observation of the

machine
You should be constantly observing the
machine for any damage or faults while it is
in use. In the event of faults or malfunctions
that impair safety at work, shut the machine
down immediately and secure it. Have the
faults rectified im medi atel y. If i t is not
possible to rectify faults which jeopardize the
safe operation of the machine, you must
suspend operations until the defects are
rectified.

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2.14.6 Truck mixer

As the machine operator, it is your role to
instruct the truck mixer drivers delivering the
concrete to you. Only allow the truck mixer
drivers to work alone once you are certain
that they have understood your instructions.

Make sure that no-one stands between the

approaching truck mixer and the machine.
There is a danger of being crushed between
the truck mixer and the machine.

2.15 Cleaning
2.15.1 General
You must drain the delivery line, pump and
hopper completely. Concrete leavings in the
hopper, in particular, may be thrown out
whilst the truck is moving.

The machine must not be driven with the

placing boom unfolded or the support legs
extended, even over short distances. This
rule also applies when you have to drive the
machine to a different site for cleaning. The
placing boom and support legs must be fully
retracted and secured.

The preferred methods for cleaning the

delivery line are reverse pumping or forced
cleaning with water. The agitator must be
switched on during reverse pumping.
Otherwise, the concrete flowing back into the
hopper can bend the agitator shaft. Use a
catch basket, pipe cleaning head and wash- Fig.2-27
out ball for forced cleaning to prevent any
water from flowing into the formwork.

Never spray remote controls or control

cabinets with barrier agents (mould oil or
similar) to protect them against
contamination. This causes significant
corrosion damage to the electrical system.

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2.15.2 Cleaning agents

Take care when using aggressive cleaning
agents. Aggressive cleaning agents may
attack materials (e.g. rubber) and painted
surfaces. You can use commercially available
paint cleaning and care agents, as long as
these have a pH value of between 4 and 9.
Ask the manufacturer of the cleaning agent to
confirm its suitability. Observe the
manufacturer’s instructions regarding use and
safe handling. Wear protective clothing.
Always rinse off cleaning agent thoroughly with
clean water; do not allow puddles to form.

Do not use sea water or other water

containing salt for cleaning purposes.
Fig.2-28
Do not use any highly flammable agent for
cleaning; there is a danger of fire.

2.15.3 Hazards
There is a risk of injury at all points on the
machine from slipping, tripping, bumping into
things, etc. Use the handles and steps to climb
into and out of the machine. It is forbidden to
stand on the grille. Do not jump from the machine.

Do not reach into the hopper or any other moving

machine components. This rule must also be
followed when you are opening the outlet on the
bottom of the hopper. Do not remove the grille.

Only point the water jet into the hopper or

other moving machine components. Do not
insert the hose. It could become entangled
with moving machine components.

2.15.4 Cleaning with compressed air

When the delivery line is being cleaned with
compressed air, there is an increased risk of
accident from explosively escaping compressed
air, spurting concrete and flapping delivery or
end hoses if they have not been removed.

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Safety
SYG5360THB 47

Compressed air should only be used for

cleaning purposes under the supervision of a
subject expert. All persons participating in the
cleaning procedure must be instructed in the
safety regulations.

The manufacturer accepts no liability for

damage caused by incorrectly performed
compressed air cleaning. If you blow out the
delivery line with compressed air, you must
observe the following rules without fail:
– Individual pipes and short pipe runs up to
10 m in length must not be blown through
with compressed air. There is a risk of
accident from rebound.
– Only blow out delivery lines which have
the same nominal diameter throughout
their length. Reducer pipes must be
drained and flushed out by hand.
– No bends, delivery or end hoses may be
fitted at the end of the delivery line.
– A catch basket must be fastened at the
end of the delivery line and a wash-out
adaptor must be fitted on the head of the
delivery line. Catch basket and wash-out
adaptor must fit the delivery line system.
– The concrete must be able to flow freely
from the end of the delivery line.
– No persons may be present in an area of
3 m around the delivery line, at the end
of the delivery line and especially in front
of the opening in the catch basket.
– Care must be taken to ensure that any
concrete that might be expelled from the
catch basket cannot injure anybody or
cause any damage.
– The wash-out adaptor must be fitted with
a separate, large dump cock and a
pressure gauge.

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 Safety
SYG5360THB 47

– The pressure gauge must be kept under

constant observation during the cleaning
process. The pressure in the delivery line
must be rapidly dumped via the dump
cock in the event of a sudden drop in
pressure (concrete column exiting from
the end of the line) or increase in
pressure (risk of blockage).
– The sponge ball or the plug used to push
the concrete out must be sufficiently
dense that the air does not pass through
it into the concrete. In addition, the
delivery line must be sealed to the rear
when the sponge ball or plug is caught in
the catch basket.
– Only work on the delivery line (e.g. open
the delivery line) once this has been
depressurized. Make sure that the
compressed air has been dumped
completely.
– The dump cock must be opened in such
a way that no-one can be injured by
concrete residue that might be expelled
from the dump cock.

2.15.5 Protection against water

Water spraying on the machine from random
directions has no damaging effect. The
electrical system is protected against spray
water, but is not waterproof.

You must close/seal all openings into which

water/steam/cleaning agent must not
penetrate for safety or functional reasons
before cleaning the machine with water or a
steam jet (high-pressure cleaner) or other
cleaning agents. Electric motors and control
cabinets are particularly at risk.

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SYG5360THB 47

2.15.6 Post-cleaning procedure

After the machine is cleaned, the covers/
tapes must be completely removed and the
machine must be checked to ensure that it is
ready for operation (see also page 23).

Look out for leaks, loose connections, chafe

marks and damage during the cleaning
procedure. Any identified defects must be
rectified immediately. The machine must be
greased after it has been cleaned using a
high-pressure cleaner.

2.16 Maintenance and special work

2.16.1 Requirements for special work

In the capacity of operator, it is your
responsibility to provide all the necessary
information to the personnel concerned
before special work or maintenance work is
carried out. Someone should be nominated
as the person responsible for this.

Carry out the maintenance and inspection

operations and comply with intervals specified
in the Operating Instructions, including
specifications for the replacement of parts
and equipment. These activities must be
carried out by qualified personnel only.

Workshop equipment appropriate to the task

in hand is absolutely necessary for the
execution of maintenance work.

Secure a wide area around the maintenance

area as far as is necessary.

A machine completely shut down for

maintenance and repair work must be
secured against being restarted inadvertently:
– Lock the main control devices and
remove the key.

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 Safety
SYG5360THB 47

– Fix a warning plate to the main switch.

Only carry out maintenance work if the
machine is parked on level and sufficiently
supporting ground and is secured against
rolling away.

Use specially designed or otherwise safety-

oriented climbing aids and working platforms
when carrying out assembly work above head
height. Never use machine parts as climbing aids.
Keep all handgrips, steps, railings, platforms and
ladders free from dirt, snow and ice.

Carefully secure individual parts and large

assemblies to lifting gear when carrying out a
replacement operation. Use only suitable and
technically perfect lifting gear and suspension
systems with adequate lifting capacity. Never
stand under suspended loads.

The fastening of loads and instruction of

crane operators should be entrusted to
experienced persons only. The signaller must
be within visual range of or in voice contact
with the crane operator.

Observe national regulations when working

with lifting gear.

Work on chassis, braking and steering

systems must only be carried out by qualified
personnel trained for such work.

Clean the machine, especially connections

and threaded unions, of any traces of oil, fuel
or preservatives before carrying out
maintenance or repair work. Do not use
aggressive cleaning agents.Use lint-free
cleaning rags.

Bolted connections that you have loosened

for carrying out maintenance and repair work
must always be retightened to the specified
torque.

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Safety
SYG5360THB 47

Do not open gas-filled spring elements, as

used on maintenance flaps, for instance. The
spring elements are filled with gas under high
pressure which can escape explosively if you
attempt to open them. Relieve the tension on
systems under mechanical stress.

Be aware of hot functional fluids and surfaces

(hydraulic fluid, hydraulic fluid radiator, etc.).

Ensure that all functional fluids, consumables

and replaced parts are disposed of safely and
with minimum environmental impact.

2.17 Welding

Only qualified personnel commissioned by

the manufacturer may carry out welding work
on the placing boom, on the supports or on
other components which are important for
safe operation. The work must be inspected
by an authorized inspector.

Always attach the earth cable of the welding

unit directly to the component which is being
welded. The welding current must not flow
through hinges, cylinders, etc. Significant
damage may be caused by current bridging
gaps.

Electronic components can be destroyed by

stray voltage during arc welding processes.
For this reason:
– Disconnect the remote control cable from
the control console.
– Disconnect all cables leading to the
receiver of the radio remote control
system.
– Close connector sockets with caps.
– Disconnect the positive and negative
leads from the battery.

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 Safety
SYG5360THB 47

Only carry out welding, flame cutting and

grinding operations on the machine if this is
expressly approved by the manufacturer.

Clean the machine and its surroundings of

dust and flammable substances and make
sure that the premises are adequately
ventilated before carrying out welding, flame-
cutting and grinding operations (danger of
explosion).

Only qualified personnel should carry out welding

work on the fuel and oil reservoirs in accordance
with the manufacturer’s specifications.

2.18 Working on the placing boom

Only carry out maintenance and repair work

on the placing boom if the placing boom is
folded or properly supported, the engine is
switched off and the support legs are
secured.

Support the plac ing boom arms before

starting work on the valves, cylinders or
hydraulic lines on the boom.

The delivery line was installed without tension

with the placing boom in the driving position
and can only be replaced without difficulty in
this condition. Stresses may be generated on
folding if the delivery line is replaced when
the placing boom is unfolded.

Do not remove the whole delivery line but

exchange the delivery arm, e.g boom arm by
boom arm. Otherwise, the pivot points of the
new delivery line will have to be redetermined
using special equipment.

Following substantial changes, placing booms

must be inspected by an authorized inspector
before recommissioning.

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SYG5360THB 47

2.19 Safety-relevant components

Some of the manufacturer’s spare parts, such

as pumps, valves and controller cards are
supplied from the works with a basic setting.
These must be adjusted (set) in accordance
with the information on the circuit diagram or
machine card after installation in the
machine.

Parts relevant to safety and adjustable

devices (pressure limiting valve,
potentiometer, fluid flow limiter, hydraulic
cylinders, etc.) must only be repaired,
replaced or adjusted by After Sales Service
personnel. Seals must only be removed by
the manufacturer’s After Sales Service
personnel. Modifications to the machine
ratings (for example, increasing pressures,
modifying speeds, etc.) are not permitted.

2.20 Software

If a machine is equipped with software, the

software may only be used as is provided for
in the manufacturer’s Operating Instructions.

Only persons authorized by the machine

manufacturer may intervene in the machine’s
software. This also applies to updates.

Unauthorized interventions in the machine’s

software may lead to severe damage and
accidents.

2.21 Protective and safety

Any safety devices removed for maintenance

purposes must be refitted and checked
immediately upon completion of this work.

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 Safety
SYG5360THB 47

All equipment required for safety and

accident prevention (warning signs and
information plates, grilles, guards, etc.) must
be in place. Such equipment must not be
removed, modified or damaged.

Keep all warning signs and information plates

on the machine complete and in a perfectly
legible condition.

It is your responsibility as operator to ensure

that any warning signs and information plates
that have been damaged or rendered illegible
are replaced without delay.

2.22 Electrical power

2.22.1 General
Work on electrical systems or operating
equipment must only be carried out by
qualified personnel. For further information on
machines operated on the site power supply,
see also section 2.22.3, entitled "Power at
the construction site".

The power supply to machine components on

which maintenance work is to be carried out
must be isolated, if provided for in the
regulations.Before starting any work, you
must check the de-energized parts for the
presence of power and earth or short-circuit
them in addition to insulating adjacent live
parts and elements. Disconnect the negative
lead from the battery before starting any work
on the electrical system. When reconnecting,
connect the positive terminal first, and then
the negative terminal.

Before starting work on high-voltage

assemblies and after cutting the power
supply, you must connect the supply cable to
earth and short-circuit the components such
as capacitors with a rod-type earth electrode.

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SYG5360THB 47

If work is to be carried out on live parts, the

presence of a second person is required who
can switch off the power supply to the machine
in the event of an emergency. Secure the
working area with a red-and-white safety chain
and a warning plate. Use insulated tools only.

2.22.2 Electrical components

Control cabinet, motor and control elements
are protected as standard at least to degree
of protection IP 54. IP 54 means:
– Complete protection against contact with
live components or internal moving parts.
Protection against damaging dust deposits.
– Water spraying on the equipment from
random directions shall not have a
damaging effect.
Use only original fuses with the specified
current rating. The electrical system can be
destroyed by overrated fuses or bridging. You
must switch off the machine immediately if a
fault occurs in the power supply.

2.22.3 Power at the construction site

The power on the construction site must be
supplied from a special feed point
(construction site power distribution point).
Machines with an electric motor must not be
connected to the mains power supply.

Only qualified personnel may work on

electrical systems with an operating voltage
in excess of 25 volts alternating voltage or 60
volts direct current. Only such qualified
personnel may install, connect, disconnect
and open electrical control cabinets.

An electric shock (possibly with fatal

consequences) may be the result of touching
machines with electric motors or contact with
o t h e r e l e c t r i c a l c a b l e s i f t h e e l e c t ri c a l
connection has not been made properly or
the supply cable is damaged.

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SYG5360THB 47

2.23 Hydraulic systems

2.23.1 General
Work on hydraulic systems must only be
carried out by qualified personnel.

Always wear your personal protective

equipment when carrying out work on the
hydraulic system. Escaping fluid is toxic and
can penetrate the skin.

Injection through the skin is a major medical

emergency situation. In the event of injuries
caused by pressurised oil, inform the company
medical officer and call a medical specialist
immediately. This also applies for injuries
which may seem only slight. Hydraulic fluid
which has penetrated underneath the skin
must be removed immediately. Otherwise,
there is a risk of life-endangering impairment
to blood circulation and infections.

Parts of the system and pressure lines which

are to be opened (hydraulic, pneumatic, and
delivery lines) must be depressurized
according to assembly descriptions before
repair work is started.

Work only on depressurized systems. Switch

the hydraulic pump drive and the engine off,
otherwise there is a risk of injury caused by
functional fluids escaping under pressure.
Where a hydraulic accumulator is fitted, open
the accumulator dump valve to prevent any
movements of the machine as a result of the
residual pressure. Modifications to the
hydraulic accumulator are prohibited.

Be aware that enclosed hydraulic fluid can

remain under pressure for a certain length of
time. Do not open any hydraulic systems if
they are under pressure from an external
force (e.g. from a raised placing boom).

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Safety
SYG5360THB 47

Route and install hydraulic lines in accordance

with current engineering standards. Ensure
that connections are not interchanged. The
fittings, lengths and quality of the hoses must
comply with technical requirements.

You must carefully bleed the hydraulic

system after any maintenance work,
otherwise there is a risk of injury caused by
swinging and telescopic support legs
extending rapidly, the placing boom lowering,
etc. Open vent valves very carefully until
hydraulic fluid starts to escape. You should
on no account open vent valves further than
necessary or go so far as to remove them.

Damaged hydraulic lines must be replaced

rather than repaired. You must replace
damaged or saturated hy draulic hoses
immediately. Spurting hydraulic fluid may
cause injury and fire.
2.23.2 Replacing hydraulic hoses
During the repeat inspections, a subject
expert must check the hydraulic hoses for
external damage. The inspection must be
recorded in the check book. The operator
must have hydraulic hoses replaced if they
show signs of external damage.
2.23.3 Noise emissions
The place of work in normal operation is with
the remote control. For this reason, it is not
possible to specify a particular place of work
for the machine operator. Take the values for
the sound pressure level and sound power
level from the machine Operating Instructions.

Wear suitable personal protective equipment

in the vicinity of the machine.

As the operator, you must instruct your

personnel to always wear their personal ear
protection. You are responsible for ensuring
that your personnel comply with this regulation.

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 Safety
SYG5360THB 47

All soundproofing equipment must be fitted

and in perfect condition. All soundproofing
equipment must be closed during operation.
A high sound level can cause permanent
hearing damage.

2.24 Exhaust fumes

Vehicle exhaust gases contain constituents

which can be lethal or carcinogenic. Operate
internal combustion engines and fuel-
operated heating systems only in adequately
ventilated premises. Before starting up the
engine in enclosed spaces, make sure that
there is adequate ventilation and direct the
exhaust gases away from the place of work.

We a r pers on al pr o tect i ve cl ot hi n g a n d
equipment for all work in which exhaust
gases or particles of building material can
enter the body through the respiratory
passages. Comply with the information issued
by the manufacturer of the building material.

2.25 Functional fluids

When handling oils, greases and other

functional fluids, observe the safety
regulations applicable to the product
concerned (see the safety data sheet).

Oils, fuel and other functional fluids may be

hazardous to health upon contact with the
skin, etc. You must, therefore, always wear
personal protective clothing and equipment
when you are handling toxic, caustic or other
functional fluids that are hazardous to health
and always take note of the manufacturer’s
information.

Fig.2-29

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SYG5360THB 47

Take care when handling toxic and caustic

functional fluids (brake fluid, battery acid,
water glass, concrete set accelerating
admixtures, cement, etc.). Building materials
containing cement have a highly alkaline
effect when they react with water (and also
with perspiration). Admixtures are toxic and
caustic.

Cleaning agents, concrete release agents,

preserving agents etc. propelled by
compressed air can cause very serious
damage to the respiratory tract if a respiratory
protection mask is not worn. Spray mist
enters the lungs very easily.

Frequent injuries are eye injuries caused by

concrete spatter, water glass or other
chemical substances.

Take care when handling hot functional fluids

and consumables (risk of burning or
scalding).

Have used operating equipment and

functional fluids such as filters, batteries, oil,
brake fluid, etc. disposed of properly. Used
cleaning rags should also be disposed of
properly. Fig.2-30

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System Functions
3 System Functions
3.1 General Overview .............................................................................................3-3
3.2 Boom System ...................................................................................................3-6
3.3 Outrigger System ..............................................................................................3-9
3.4 Truck Chassis ...................................................................................................3-12
3.5 Pumping System ...............................................................................................3-14
3.6 Hydraulic System ..............................................................................................3-17
3.7 Electric Control System ....................................................................................3-24
3.8 Remote Control System ....................................................................................3-48

3-1
System Functions
SYG5360THB 47

WARNING
Always read the Safety section of this
manual before attempting to operate this
equipment. Failure to do this could result
in machine damage, personnel injury or
death.

3-2
 System Functions
SYG5360THB 47

3 SYSTEM FUNCTIONS

3.1 General Overview

This section of the manual provides detailed
information regarding the basic description
and overview of all the controls, alerts and
operating systems on your equipment. It is
important to study and become familiar with
all systems before proceeding with any
pumping operations. (Some truck chassis
information may be included here.)

3.1.1 Main component locations

The SANY truck-mounted concrete pump
consists of the following main components,
see Fig. 3-1.

Left side

4
8 1 2 3 5 6 7
[1] Chassis
[2] Boom
[3] Outrigger system
[4] Hydraulic system
[5] Electrical system
[6] Body understructure
[7]Pumping mechanism
[8] Remote control
system (in cab)
[9] Boom & outrigger
Right side backup hydraulics
12 11 10 9 (in cabinet)
[10] Outrigger control
[11] Maintenance
operation box
[12] Small operation box

Fig.3-1 General Figure of Truck-mounted Concrete Pump

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SYG5360THB 47

3.1.2 Main characteristics

(1) Stability function with one button
The booms can keep stabilization just
with one button after action, and the
ending-hose can also achieve the
position quickly.

(2) Automatic stabilization technology

The technology mixed with putzmeister,
shaking of the booms decrease by 50%.

(3) Automatic pumping technology

The technology mixed with putzmeister,
the changing speed of main cylinder can
reach 29~30/min when the pressure of
system is 12MPa, the efficiency can
increase 25%, and the cost of diesel is
10% lower than before.
(4) Function of preventing swing
The swinging range of revolving tower
can decrease by 60% with this
technology, and the precision of the
acting also increases a lot.

(5) Automatic diagnosing function

The system can making diagnosis itself
including 150 kinds of malfunction, the
driver can repair complex malfunction
with the suggesting.
(6) Automatic boom system

a. Flexing function with one

switch:spreading/retracting the booms by
pushing/pulling only one switch

b. Limiting function of acting area?you will

never be worried about the safety when
you working in a complex environment if
you confirm the area of booms before
acting with this function.

c. Locking function: the first and the second

booms can be locked, and then you can

3-4
 System Functions
SYG5360THB 47

move the other ones, the locking booms

will keep their position during the whole
process until you unlock them.

(7) New technology in damageable structure

The life of the damageable structures
increases a lot with this new technology
and new technics.
(8) Safety technology

a. Overload safeguard of booms:adding

safety valve in balance valve of boom
cylinder, it will release the pressure when
the booms is over-lord in order to
protecting the boom system.

b. Safety equipment in Hopper:the

equipment in the hopper will stop working
(pumping mixing) if the Grille is opened,
this function will protect the repairer when
the equipment in the hopper are broken
and needing repair.

c. Safeguard of hydraulic oil: with this

function, the system will release the flow
of the pumps if the hydraulic oil is lower
than one position, Then SYCD show that
the equipment need more oil. And the
system will stop working if the hydraulic
oil is lower than the limiting line until
adding enough oil or forcing it.

3-5
System Functions
SYG5360THB 47

3.2 Boom System

3.2.1 Boom overview

The boom system is used for concrete output
and placing.
By the extension/retraction of boom cylinder
and the rotation of turntable, the concrete can
be directly conveyed to the position ( paving
site) at the end of boom, via the delivery pipe
attached on the boom.
The boom of R type is applied, which has
compacted structure, can be rapidly folded Fig.3-2
and unfolded, and requires for small space
for folding, see Fig. 3-2.

3.2.2 Boom components

The boom system is principally made up of
the foldable plane four-connecting rod
mechanism formed by articulating the four-
arm boom, connecting rod, oil cylinder and
connecting piece, see Fig. 3-3.

Fig.3-3 Boom of Truck-mounted Concrete Pump

[1] Oil cylinder of arm (1) [7] Oil cylinder of arm (3) [13] Connecting rod (6)
[2] Arm 1 [8] Connecting rod (3) [14] Arm 4
[3] Oil cylinder of arm(2) [9] Connecting rod (4) [15] Oil cylinder of arm 5
[4][Connecting rod (1) [10] Arm 3 [16] Connecting rod (7)
[5] Connecting rod (2) [11] Oil cylinder of arm (4) [17] Connecting rod (8)
[6] Arm 2 [12] Connecting rod (5) [18] Arm 5

3-6
 System Functions
SYG5360THB 47

3.2.3 Boom control

There are three methods of boom control:

(1) A remote controller that is physically

carried by the equipment operator and
used during normal pumping operation.
See “Remote Control System” on page
page 3-47 for details.

NOTE:The specific model of remote controller

is subject to the real products.

The seven-rocker remote controller(Fig. 3-4):

● Rocker (a) controls boom rotation.

● Other rockers controls up/down Fig.3-4
movement of articulating boom arm 1-5.
NOTE:See “Boom components” on page 3-7
to identify articulating boom arm 1-5.

● The Boom Speed Switch (b) is used to

selected the boom movement speed.

The remote controller of intelligent boom (Fig.

3-5):

● In the manual mode, the five linear

rockers a, b, c, d and e are respectively
corresponded to arms 1~5.
● In the intelligent mode, the five rockers
a, b, c, d and e are used to control the
vertical movement of the end of boom.
● Under the intelligent mode, the switch f
is used to automatically extend/retract
the boom.
NOTE:See “Boom components” on page 3-8
to identify articulating boom arms
1,2,3,4 and 5.
f
(2) A hard-wire connection for direct
communication with the in-cab receiver. Fig.3-5

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System Functions
SYG5360THB 47

NOTE:See page 3-53 for the hard-wire

connector port of double-rocker
remote controller;

NOTE:See page 3-57 for the hard-wire

connector port of intelligent boom
remote controller.

(3) Back-up hydraulics (located in a cabinet

on the right side of the chassis) that can
be used to manually lower the boom if
the system electronics fail, see Fig. 3-6.

No. Function
a Control handle for slewing
b Control handle for arm 1
f
c Control handle for arm 2
d Control handle for arm 3 Fig.3-6
e Control handle for arm 4
f Control handle for arm 5

NOTE:Refer to Charter 4 “Operation” for

complete details on boom control.

3-8
 System Functions
SYG5360THB 47

3.3 Outrigger System

3.3.1 Outrigger overview

The outrigger system is a part of the
r e v o l v i n g t o w e r . T h e o u t r i gg e r s y s t e m
supports, stabilizes and levels the entire
concrete pumping system during pumping
operations.

The X-shaped outrigger configuration

includes rear outriggers that unfold outwards
a w a y f r om t h e t r u c k c h a s s i s a n d f r o n t
outriggers that extend (telescope) out from
the truck chassis.

3.3.2 Outrigger components

5
1
8 9
2 6 4

Fig.3-7 Components of Outrigger

[1] Turntable [6]Telescope cylinder of front
[2] Slewing mechanism outrigger
[3]Fix revolving tower [7]Right rear outrigger
[4] Right front outrigger [8]Left rear outrigger
[5]Left front outrigger [9]Spread cylinder of rear outrigger

3-9
System Functions
SYG5360THB 47

3.3.3 Outrigger control

There are three methods of outrigger control:

(1) A set of four levers (a) and a momentary

safety toggle switch (b) located on the left
side of the machine controls all four
outriggers, see Fig. 3-8.

NOTE:Holding the toggle switch (b) down

activates the levers. The levers (a) will
not function if the toggle switch is
released.

Left side (driver side) outriggers control

Fig.3-8
The levers for the left side of the machine
control the outriggers as indicated in the table
below:

Lever Direction Action

Up Lift the left front outrigger
a
Down Descend left front outrigger
Up Retract left front outrigger
b
Down Extend left front outrigger
Up Fold left rear outrigger
c
Down Unfold left rear outrigger
Up Lift left rear outrigger
d
Down Descend left rear outrigger
Fig.3-9

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 System Functions
SYG5360THB 47

Right side (nondriver side) outriggers control

The levers for the right side of the machine

control the outriggers as indicated in the table
below:

Lever Direction Action

Up Lift the right rear outrigger
a
Down Descend right rear outrigger
Up Fold right rear outrigger
b
Down Unfold right rear outrigger
Retract right front Fig.3-10
Up
c outrigger
Down Extend right front outrigger
Up Lift right front outrigger
d
Down Descend right front outrigger

(2) Back-up hydraulics (located inside a

cabinet on the right side of the chassis)
that can be used to manually retract all
four outriggers if the system electronics
fail, see Fig. 3-11.

With lever (e) in the down position, hydraulic

oil flows to the outrigger controls.

NOTE:Refer to Charter 4 “Operation” for Fig.3-11

complete details on outrigger control.

3.3.4 Outrigger pads

Outrigger pads (a) are used to support the
outriggers after they are in their extended
positions.

The outrigger pads (a) are stowed on each

side of the truck when not in use.

Fig.3-12

3-11
System Functions
SYG5360THB 47

3.4 Truck Chassis

Always keep the truck chassis operator's
m a nu a l w i t h t h e t r u c k . A l s o , y o u m u s t
become familiar with all of the truck chassis
operating systems.

Damage to or unauthorized modifications to

the truck chassis may compromise the ability
of the truck chassis to function as originally
designed.

3.4.1 Truck chassis overview

(1) The chassis of truck-mounted concrete
pump is mainly used to provide power for
traveling and working of the truck-
mounted concrete pump.

(2) The shift fork in transfer case, driven by

the pneumatic device, can drive the
clutch sleeve, so that the power in
vehicle's engine can be switched by
transfer case. The truck-mounted pump
can run if the power is switched to the
rear axle of vehicle, and can convey and
distribute the concrete if the power is
switched to the hydraulic pump.

(3) The chassis is composed of the chassis

of car, transfer case, oil pump assembly,
platform and accessories, etc. The
chassis adopted in the truck-mounted
concrete pump should conform to the
requirements of the local traffic rules and
relevant regulations (see Fig. 3-13).

3-12
 System Functions
SYG5360THB 47

3.4.2 Truck chassis components

Fig.3-13
[1] Vehicle's chassis
[2] Transfer case and oil pump assembly
[3] Platform and accessories

3-13
System Functions
SYG5360THB 47

3.5 Pumping System

3.5.1 Pumping system overview

The pumping system conveys the concrete
from the hopper at the rear of the truck
chassis through the conveying piping of the
boom and to the point of application.

3.5.2 Pumping system & related components

Pumping system is composed of pumping
system (including main oil cylinder, water
tank, delivery cylinder, concrete piston, etc.),
swing mechanism, S-valve, mixing
mechanism, hopper, lubrication system,
piping, etc. (see Fig. 3-14).

8 11
3
4 7

1
2

10
9
12

Fig.3-14 Schematic Diagram of Pumping System

[1]Main oil cylinder A [5]Left conveying tube [9]S-valve

[2]Main oil cylinder B [6]Concrete piston A [10]Agitator
[3]Water tank [7]Concrete piston B [11]Hopper
[4]Right conveying tube [8]Swing mechanism [12]Discharge outlet

3-14
 System Functions
SYG5360THB 47

3.5.3 Pumping system operation

The following occurs when the pump is energized.

NOTE:The item numbers used here are the

same as used in Fig. 3-14 on page
3-14.

(1) Hydraulic fluid enters the main oil cylinder

(1), forcing that concrete piston (6)
forward (towards the hopper) while the
other concrete piston (7) retracts (away
from the hopper).
(2) The swing mechanism (8) positions the
S-valve (9) to align with concrete piston (6).
(3) Suction created by the retracting
concrete piston (7) pulls concrete from
the hopper (11) to fill that piston’s
conveying tube (4).
(4) When the two pump pistons have
reached the limit of their travel, the swing
mechanism (8) aligns the S-valve (9) with
concrete piston (7). 12
13
(5) Hydraulic fluid enters the other main oil
cylinder (2) forcing the concrete piston (7) Fig.3-15
forward, thus forcing the concrete from
the conveying tube into the S-valve, out
through the discharge outlet (12) and up
through the boom-mounted conveying
piping (13) (the number 12 and 13
see Fig. 3-15).
(6) At the same time, the other pump piston
(6) retracts to pull concrete from the
hopper into its conveying tube.
(7) When the two pump pistons have
reached the limit of their travel, the swing
mechanism (8) repositions the S-valve (9)
and the process repeats to align with
concrete piston (7).

Fig.3-16

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System Functions
SYG5360THB 47

The wash tank (3) helps keep the piston

rods clean as the piston rods travel within
their pumping cylinders.
The agitator (10) keeps the concrete mix
in the hopper (11) stable, thus ensuring
smooth flow from the hopper and into the
conveying tubes (4) and (5).

3.5.4 Pumping controls

9
.IThere are two methods of pumping control,
Fig.3-17-1
see Fig. 3-17.

(1) Using the remote controller.

● If you use the seven-rocker remote

controller, the toggle switch (9) is used to
control the pumping direction and the
dial (10) is used to control the pumping
flow speed.
NOTE:The item numbers here are the same
as used in Fig.3-92 on page 3-49 and
Table 3-2 on pabe 3-50.

● If you use the intelligent boom remote Fig 3-17-2

controller, the toggle switch (4) is used to
control the pumping direction and and
the dial (5) is used to control the
pumping flow speed.
NOTE:The item numbers here are the same
as used in Fig.3-93 on page 3-51.

(2) The pump pressure high / low switch (3), 6

the pumping direction toggle switch (4) 3
and the pumping flow speed switch (6)
4
on the rear chassis switch panel (see Fig.
3-18).

NOTE:The item numbers here are the same

as used in Fig.3-25 on page 3-24.

NOTE:Refer to Charter 4 “Operation” for

complete details on pumping control.
Fig.3-18

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 System Functions
SYG5360THB 47

3.6 Hydraulic System

3.6.1 Outrigger controls

There are two banks of levers and toggle
switches for controlling all four outriggers.

● A set of four levers and toggle switches

on the left side of the machine.
NOTE:Holding the toggle switch(6) down
activates the levers(1), (2), (3) and
(4). The levers will not function if the 1 2 3 4 5 6
toggle switch is released.
Fig.3-19

No. Name Function

Lifting/descending It is used to control the lifting and descending of left front
1 handle for left front outrigger. By pushing the handle upward, the outrigger is lifted.
outrigger By pushing downward, the outrigger is descended.
Extension/retraction It is used to control the extension and retraction of left front
2 handle for left front outrigger. By pushing the handle upward, the outrigger is
outrigger retracted. By pushing downward, the outrigger is extended.
Folding/unfolding It is used to control the folding and unfolding of left rear outrigger.
3 handle for left rear By pushing the handle upward, the outrigger is folded. By
outrigger pushing downward, the outrigger is unfolded.
Lifting/descending It is used to control the lifting and descending of left rear
4 handle for left rear outrigger. By pushing the handle upward, the outrigger is lifted.
outrigger By pushing downward, the outrigger is descended.
When the button is pressed, the concrete pump will stop working
and all operations become ineffective. When the button returns
5 E-STOP button
to its initial position clockwise, the concrete pump will work
normally.
Cooperate with control handles for outrigger to control the
Control switch for
6 extension and retraction of outrigger. Only when the control
outrigger
switch is pressed, can the control handles work.

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System Functions
SYG5360THB 47

● A set of handles and toggle switches on

the right side of the machine.
NOTE:Holding the toggle switch (1) down
activates the handles (3), (4), (5) and
(6). The handles will not function if the
toggle switch (1) is released.

Fig.3-20

No. Name Function

Cooperate with control handles for outrigger to control the
Control switch for
1 extension and retraction of outrigger. Only when the control switch
outrigger
is pressed, can the control handles work.
When the button is pressed, the concrete pump will stop working
and all operations become ineffective. When the button returns to
2 E-STOP button
its initial position clockwise, the concrete
pump will work normally.
Lifting/descending It is used to control the lifting and descending of right rear
3 handle for right rear outrigger. By pushing the handle upward, the outrigger is lifted. By
outrigger pushing downward, the outrigger is descended.
Folding/unfolding It is used to control the folding and unfolding of right rear
4 handle for right rear outrigger. By pushing the handle upward, the outrigger is folded.
outrigger By pushing downward, the outrigger is unfolded.
Extension/
It is used to control the extension and retraction of right front
retraction handle
5 outrigger. By pushing the handle upward, the outrigger is
for right front
retracted. By pushing downward, the outrigger is extended.
outrigger
Lifting/descending It is used to control the lifting and descending of right front
6 handle for right outrigger. By pushing the handle upward, the outrigger is lifted. By
front outrigger pushing downward, the outrigger is descended.

3-18
 System Functions
SYG5360THB 47

3.6.2 Outrigger and boom backup hydraulics

The hydraulic valve body is located in the
fixed revolving tower of truck-mounted
concrete pump and used for local control of
boom as well as manual control in case that
the remote control system is not applied.

NOTE:If the system electronics fail, however, 5 6 7

1 2 3 4
this valve can be manually operated
to lower the boom and operate the Fig.3-21
outriggers.

The various levers operate as listed below:

No. Name Function

It is used to switch between outrigger and air cooling system. By
pushing it upward, the oil circuit of outrigger multi-way valve is put
Switch handle for
through (can be controlled by the control switch beside the valve),
1 outrigger and air
and by pushing downward, the boom pump cooperate with pinion
cooling system
pump to actuate the air-cooling motor, mixing motor or water pump
motor.
It is used to control the actions of turntable. By pushing it upward,
Control handle for
2 the turntable moves clockwise, and by pushing downward, the
slewing
turntable moves anti-clockwise.
It is used to control the movement of arm 1. By pushing the handle
Control handle for
3 upward, the boom is unfolded, and by pushing downward, it is
arm 1
folded.
It is used to control the actions of arm 2. By pushing the handle
Control handle for
4 upward, the boom is unfolded, and by pushing downward, it is
arm 2
folded.
It is used to control the actions of arm 3. By pushing the handle
Control handle for
5 upward, the boom is unfolded, and by pushing downward, it is
arm 3
folded.
It is used to control the actions of arm 4. By pushing the handle
Control handle for
6 upward, the boom is unfolded, and by pushing downward, it is
arm 4
folded.
It is used to control the actions of arm 5. By pushing the handle
Control handle for
7 upward, the boom is unfolded, and by pushing downward, it is
arm 5
folded.

NOTE:Hydraulic valve configurations may

vary, depending on the boom system
on your machine.

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System Functions
SYG5360THB 47

3.6.3 Pump hydraulics

The heart of the concrete pumping system is
Main valve block bracket
the main control valve located on a protective
bracket (see Fig. 3-22) on the chassis and
beneath the boom system.

The main control valve is ported to actuate

and control the two pumping cylinders. See
“Pumping System & Related Components” on
page 3-14. The result is a steady supply of
concrete from the hopper at any chosen Fig.3-22
flowrate through the boom-mounted
conveying pipes and to the end hose at the
point of delivery. See “Main component
locations” on page 3-3 for locations of
components.

3.6.4 Mixing control valve and mixing

cutoff valve
The auxiliary valve block with mixing and
water pump control valve block is mounted at
the left of hopper (see Fig. 3-23).

By controlling the reverse mixing

electromagnetic valve (single-electromagnetic
change valve), the mixer switches over the
two rotary directions: When rotating clockwise
(the electromagnet is not electrified), the
mixer feeds concrete to the delivery cylinder;
when rotating anti-clockwise (the
electromagnet is electrified), the mixer
pushes concrete off the delivery cylinder.

Fig.3-23

[1]Auxiliary valve block

[2]Mixing cutoff valve
[3]Mixing motor

3-20
 System Functions
SYG5360THB 47

NOTE:The bi-directional electromagnetic

change valve mounted on the
auxiliary valve block which is shielded
by the cover plate as in the figure can
change between the oil circuit and
water pump system or mixing system
over the two directions. Thus, the
water pump system can not work with
mixing system at the same time, that
is, when the water pump is working,
the mixing system is not working, or
when the mixing system is working,
the water pump is not working.

3.6.5 Accumulator and Unloading Ball

Valve of Accumulator

The accumulator installed at the left rear side

of truck-mounted concrete pump is used to
provide auxiliary energy for the change circuit
and reduce the impact over system. The
unloading ball valve of accumulator of truck-
mounted concrete pump is installed at the
position of tank oil return outlet. When the
unloading ball valve is open, the pressure oil
of accumulator will be unloaded, so as to
make maintenance convenient (see Fig. 3-
24).

NOTE:When the load of accumulator relieves

but the host still runs, the S-valve and
delivery pipe may continue to run,
which may lead to danger of crushing
or cutting figures when checking the
hopper, S-valve and delivery pipe. So,
the machine must be stopped before
Fig.3-24
check.If the machine is still running,
do not access to the hopper from the
[1]Accumulator
discharge port at the lower of hopper
[2]Auxiliary valve block
or the screen at the upper of hopper [3]Main valve block
and do not throw sundries into the [4]Unloading ball valve of accumulator
hopper either.

3-21
System Functions
SYG5360THB 47

3.6.6 Self-sealing Device of Main Oil

Pump Oil Inlet and Gear Pump Oil
Suction Cut-off Valve
T h e o i l s u c t i on pi p el i n e of o i l p u m p i s
equipped with oil circuit sealing devices which
are mainly used to seal the oil suction
pipeline of pump when checking the hydraulic
system so as to prevent the hydraulic oil of
oil tank from leaking.

The oil tank inlet self-sealing device is used

for the main oil pump as the oil suction
sealing device; the cut-off valves are used for
gear pump and boom pump as the oil suction
sealing devices.

The self-sealing device of oil tank inlet is

installed on the oil tank wall. When the
adjusting threaded rod is tightened, the oil
suction of main pump is smooth; when the
Adjusting
threaded rod is released, the oil suction is threaded rod
blocked up, and it is not allowed the main 1 2 3 4 5
pump to work now to avoid to be
damaged(see Fig. 3-25). Fig.3-25

NOTE:The oil tank inlet self-sealing device

[1]Oil tank inlet self-sealing device
and cut-off valve must be open so as [2]Oil suction pipe of main pump
to keep the oil suction smooth. [3]Oil suction cut-off valve of gear pump
Otherwise, the pump might be [4]Oil suction pipe of gear pump
[5]Hydraulic oil tank
damaged due to air suction.

Do remember to open the cut-off

valve of gear pump, and screw down
the adjusting threaded rod of the oil
tank inlet self-sealing device (the
method is pressing and screwing
down the threaded rod with hands at
the same time) after checking the
system.

3-22
 System Functions
SYG5360THB 47

3.6.7 Water pump

The water pump is under the platform of
truck-mounted concrete pump (see Fig. 3-26).

NOTE:The bi-directional electromagnetic

change valve mounted on the
auxiliary valve block which is shielded
by the cover plate as in the figure can
change between the oil circuit and
water pump system or mixing system
over the two directions. Thus, the 1 2 3 4
water pump system can not work with
Fig.3-26
mixing system at the same time, that
is, when the water pump is working, [1]Water pump motor
the mixing system is not working, or [2]Mouthpiece of water gun and water pipe
[3]Water pump
when the mixing system is working,
[4]Pressure gauge of water pump
the water pump is not working.

3.6.8 Filter
Cleanliness is a key factor in maintenance of
hydr aulic system.If t he hydrauli c oil is
polluted, the hydraulic system will not work
normally. The impurity in oil tank can be Oil intake filter
filtrated by passing through oil intake filter
and oil return filter element GP.(see Fig. 3-27
)

For new vehicle, oil return filter element GP

must be replaced when running 500h.After
that, oil intake filter and oil return filter
element GP must be replaced every 1000h.

When replacing hydraulic oil, oil intake filter Oil return filter
element GP
and oil return filter element GP should be
changed, either.
Fig.3-27
You should obey local effective regulation
when dealing with old filter core

3-23
System Functions
SYG5360THB 47

3.7 Electric Control System

3.7.1 Electric Control Cabinet

The electric control cabinet of the truck-
Power

mounted concrete pump is installed in the

SY series truck mounted concrete pump
Info

Lang
uage

Output: STROKE: 0 times/min

Run Oil TEMP:

right side of revolving tower and mainly

Start

E-stop
FOR
Press: CE
Rotary: PUMP

Bug PAR
SET

consists of operating panel, components &

elements and electric control cabinet body
(see Fig. 3-28, Fig. 3-29 and Fig. 3-30).

Table 3-1
Fig.3-28
No. Name Function
1 S Y CD The display serves to show the
Display various parameters concerning
operation of the concrete pump,
such as the rotation speeds of
engine, pumping time, pumping
output, malfunction data, etc.

2 Functional The buttons F1-F6 can be applied

Buttons according to the specific prompt on
the SYLC display.

11 2

Fig.3-29

NOTICE 1 2 3 4 5 6

It is prohibited to wash the electric control

cabinet body and elements with water or
make them sprinkled.

7/8

Fig.3-30

[1]Electric control cabinet body

[2]Circuit board assembly SYEB
[3]Central distribution box
[4]SYMC special controller
[5]Emergency stop
[6]SYCD display
[7]SANY Truck pump electric plate SYMCEB
[8]SANY Truck pump electric plate SYEB

3-24
 System Functions
SYG5360THB 47

SYCD

Th e SYCD i s p r o v i d e d w i t h f un c t i o n o f
indicating various working conditions.

Homepage

This page contains the following information:

Strokes frequency, flux, rotation angle,

pumping press, temperature of oil, force
pump, force fan, force eddy, rotation speed of
motor and so on(see Fig. 3-31).

Functions of the buttons are as follows: Fig.3-31

● F1: go to the system function page.

● F2: choose the language.
● F3: no function in this page.
● F4: press this button to start counting the
time and the cubic yard, press again to
stop.
● F5: force pump
● F6: to set the parameters.

Control system function menu

On the homepage, press F1 to go to the
system function page(see Fig. 3-32), this
page contains the following information:

● Realtime Working Info

● Working Statistic Info
● Fuel Consume
● Device Information Query
● I/O State and Feedback Current Fig.3-32

● Intelligent Boom Test

● Current Faults
● History Faults
Functions of the buttons are as follows:

3-25
System Functions
SYG5360THB 47

● F1: return to home page.

● F2 F3: no function in this page.
● F4: choose the up item.
● F5: choose the down item.
● F6: to confirm the item which you
chosen.
(1) Realtime Working Info.
This screen displays the realtime working
information about currently flux, stroke times,
Fig.3-33
engine RPM, pump time, pump cube, pump
count and so on.

Functions of the buttons are as follows:

● F1: return to home page.

● F2: go to the pre-page.
● F3~F6: no function in this page.
(2)Device Information Query
This page contains the following information
(see Fig. 3-34): Scan the information about
the device configuration, such as: SYMC
program version, SYCD program version,
Fig.3-34
chassis, delivery volume, hydraulic system
etc.

Functions of the buttons are as follows:

● F1: return to home page.

● F2: go to the pre-page.
● F4~F6: no function in this page.
(3)I/O State and Feedback Current
This page displays all of the input and output
port information for the device(SYMC). Show
as onFig. 3-35 and Fig. 3-36.

Press button F1 to return to the home page .

Fig.3-35
F2 and F3 have no function in this page.

Press F4 to go to the next page.

3-26
 System Functions
SYG5360THB 47

Press F5 to go to IO-OUT/IN menu.

NOTE:This display is mainly used for service

engineers when eliminating the fault
codes.

Fig.3-36

(4)Current Faults
This display will display current fault codes
which have occurred. If there is no fault
currently, it will display the contents as Fig. 3-
37

Fig.3-37

(5)History Faults
This display shows a record for the
preveninet faul t for the device,and the
engineers just need to follow the prompts to Fig.3-38
carry out the appropriate troubleshooting

3-27
System Functions
SYG5360THB 47

Fig.3-39

Force pump
Press F5 button on the home page to go to
the page shown as Fig. 3-40. On this page
the display has some notices that pertain to
force pump, force fan and force rotate.

Fig.3-40

PAR SET
This page contains the following information
(see Fig. 3-41):
● Pump Parameter Set
● Boom Damping Parameter Set
● Boom Parameter Set
● Assistant Function
● Device Info Configure
● Turn on Confirm
Fig.3-41
● Intelligent Diagnose System

3-28
 System Functions
SYG5360THB 47

● Black Casket
Functions of the buttons are as follows:
● F1: return to home page.
● F2: go to the pre-page.
● F3: no function in this page.
● F4: choose the up item.
● F5: choose the down item.
● F6: to confirm the item which you
chosen.
NOTE:Accessing this item requires a
password.

(1) Boom Damping Parameter Set

Modify the parameters in this page to start
the function of boom shock-absorbing.
Functions of the buttons are as follows:
● F1: return to home page.
● F2: go to the pre-page.
● F3: no function in this page.
● F4: perform.
Fig.3-42
● F5: no function in this page.
● F6: to confirm the item which you chosen.
NOTE:When you need to modify it, please
contact the After-sales Service
Engineer

3.7.2 Small operation box

The small operation box is on the right side
of the chassis frame and in front of the steps
beside the hopper. The functions of the
switches on the panel are listed below.

(1) E-STOP

(2) Remote or Local Operation

(3) Pump Pressure High / Low Fig.3-43

3-29
System Functions
SYG5360THB 47

(4) Pumping Forward / Backward

(5) Flush Water On / Hopper Agitator On

(6) Pump Delivery - Increase / Decrease

(7) Horn & Vibrate Hopper Grate

(1) E-STOP (see Fig. 3-44)

● Press the button to apply emergency

stop, and then the concrete pump stops
working and all operations become
ineffective.
● Turn the button clockwise to make it
return to the initial position, and then the
concrete pump works normally.
Fig.3-44
● Sound the horn before resuming normal
operations.

CAUTION
Failure to sound the horn before resuming
normal operations could result in minor or
major injury.

(2) REMOTE & LOCAL — Two-position

toggle switch (see Fig. 3-45).
Fig.3-45
● Turn the button leftward to apply remote
control mode, actuate the remote
controller and make the operating panel
and control handle for boom fail to work.
● Turn the button rightward to apply local
control mode, actuate the operating
panel and control handle for boom and
make the remote controller fail to work.

(3) PRESSURE HIGH-LOW — Three-

position momentary toggle switch (see
Fig.3-46
Fig. 3-46).

3-30
 System Functions
SYG5360THB 47

● Turn the button leftward to apply high-

pressure mode and actuate the concrete
pump for high-pressure pumping.
● Turn the button rightward to apply low-
pressure mode and actuate the concrete
pump for low-pressure pumping.

CAUTION
Always check the pipe pressure rating
before operating. If the piping does not
indicate it is designed to handle high
pumping pressure, do NOT position the
switch to the “HIGH” pressure position.
Failure to do so will result in equipment
damage and could result in personal
injury.

(4) PUMPING FORWARD & BACKWARD —

Three-position toggle switch (see Fig. 3-
47).
● Turn the button leftward to apply forward Fig.3-47
pumping mode and actuate the concrete
pump to convey concrete from hopper to
boom end.
● Set the button at middle position to make
the pump stopping working.
● Turn the button rightward to apply
reverse pumping mode and actuate the
concrete pump to suck concrete from
boom end to hopper.

(5) FLUSH & AGITATE─ Three-position

toggle switch (see Fig. 3-48).
● Turn the button leftward to actuate the
water pump, and then washing of
concrete pump can be carried out.
● Turn the button rightward to actuate the
mixing shaft, and then mixing of concrete
in the hopper can be carried out. Fig.3-48

3-31
System Functions
SYG5360THB 47

● Set the button at middle position to apply

standby mode, and then the water pump
or mixing system will stop working.
NOTE :Always start the agitator before
beginning any pumping operations to
keep concrete in the hopper over the
material cylinder openings.

(6) DELIVERY INC & DEC (see Fig. 3-49).

● Turn the button leftward to increase Fig.3-49
pumping output steplessly, while
releasing the button, it returns to neutral
position automatically.
● Turn the button rightward to decrease
pumping output steplessly, while
releasing the button, it returns to neutral
position automatically.

(7) HORN & VIBRATE — Three-position

momentary switch (see Fig. 3-50). Fig.3-50
Turn the button rightward to make the
horn sound once, while releasing the
button, it returns to neutral position
automatically.
4
3.7.3 Maintenance and operation box
The maintenance and operation box is on the
rear boom support pedestal. The functions of
1 5
the switches are listed below:
(1) Piston exit /keep/reset 2 6
(2) Agitate reverse
(3) Main cylinder forward/backward
3 7
(4) E-STOP
(5) Preheat 8

(6) Speed up/down

(7) Swing cylinder forward/backward
(8) 24V-3A electrical outlet Fig.3-51

3-32
 System Functions
SYG5360THB 47

(1) PISTON EXIT/KEEP/RESET (see Fig. 3-

60)
PISTON
● It is a three-position toggle switch to
access the pump pistons during
maintenance procedures.
● KEEP position - Used for normal
operation.
● EXIT position - To draw the pump
pistons into the wash box for service. Fig.3-60

● RESET position - For installing pump

pistons.

(2) AGITATE REVERSE (see Fig. 3-53)

AGITATE REVERSE
After applying the switch, the mixing
blade begins to rotate reversely, and then
stops reverse rotation after several
seconds of delay.

CAUTION
Never reach into the hopper while the Fig.3-53
paddles are rotating. Be sure all hydraulic
functions are shut down completely and
all movement has stopped before reaching
into the hopper. Failure to do so may
MAIN CYLINDER
result in serious injury.

(3) MAIN CYLINDER FORWARD& BACKWARD

(see Fig. 3-54)

Two-position toggle switch controls the

direction of the pumping cylinders in case
the pumping cylinders require service.

Leaving the switch in one position results Fig.3-54

in the cylinders moving in this direction.

3-33
System Functions
SYG5360THB 47

(4)E-STOP (see Fig. 3-56)

It is used for emergency situations only,
pressing this large, red, round button
immediately shuts down all pumping and
hydraulic operations, except for the truck
engine.
When pressed, the button locks in the
STOP position until it is released by
simply rotating it clockwise as indicated
by the arrows on the button. All functions
will resume normal operation after the E-
STOP button is released.
Sound the horn before resuming normal
operations.

CAUTION Fig.3-56

Failure to sound the horn before resuming

normal operations could result in minor or
major injury.

(5)PREHEAT (see Fig. 3-57)

Apply the switch at low temperature or PREHEAT
before operating the machine, so as to
preheat the hydraulic oil.

NOTICE
Switch to the STOP position when the oil
has reached operating temperature. Do
not leave the switch in the START
position. Doing so could cause the Fig.3-57
hydraulic oil to overheat.

3-34
 System Functions
SYG5360THB 47

(6) SPEED UP & DOWN (see Fig. 3-58)

It is used to adjust the rotation speed of SPEED

diesel engine and drive the loads through
controlling the diesel engine, namely
turning it upward for acceleration and
turning it downward for deceleration.

Fig.3-58
(7) SWING CYLINDER FORWARD/BACKWARD
(see Fig. 3-59)
SWING CYLINDER
● It is used to adjust the position of swing
cylinder in case of jamming or check.
● Turning it upward for moving forward;
● Turning it downward for moving backward.

Fig.3-59

(8)24-volt Outlet (see Fig. 3-61)

24V 3A
It is located on the switch panel shown
on. This outlet is always energized and
cannot be switched off.

Fig.3-61

3-35
System Functions
SYG5360THB 47

3.7.4 Electromagnetic valves for mixing

The electromagnetic valve of mixing valve is
installed in the auxiliary valve block (see Fig.
3-62).

NOTE:Control the electromagnetic valve for

reverse mixing to switch the mixer
over the two rotary directions: during
forward rotating (the electromagnet is
1 2 3 4
not electrified), the mixer feeds  
concrete to the delivery cylinder; while
reverse rotating, (the electromagnet is
electrified), the mixer pushes concrete
Fig.3-62
off the delivery cylinder.
[1]Stamping electromagnetic valve of
accumulator
[2]Mixing electromagnetic valve
[3]Electromagnetic valve for reverse mixing
[4]Electromagnetic valve for water pump

3-36
 System Functions
SYG5360THB 47

3.7.5 Electromagnetic valve of boom

Th is e lect ro ma g ne t i c v a l ve of b o o m is
installed in the fixed revolving tower of the
truck-mounted concrete pump (see Fig. 3-63).

NOTE:The electromagnetic valve of boom is

electrohydraulic proportion control
valve, which is featured by speed
control in accordance with current and
1 2 3 4 5 6 7
stable starting.

The normal operations are of remote Fig.3-63

control mode while the handle only [1]Electromagnetic valve for switchover
serves for emergent operation. of outrigger and air cooling system
[2]Rotary electromagnetic valve
[3]Electromagnetic valve of arm 1
[4]Electromagnetic valve of arm 2
3.7.6 System gauges & indicators [5]Electromagnetic valve of arm 3
[6]Electromagnetic valve of arm 4
The system gauges enable the equipment
[7]Electromagnetic valve of arm 5
operator to monitor the hydraulic system
performance, temperature and fluid level.

In addition to these system gauges, a water

4
level gauge is located on each outrigger to
provide a visual indication of the water level 1

remaining in the water supply system built 2 5

into each rear outrigger (see Fig. 3-64).
3

NOTICE
Know the location and function of these
monitoring systems before beginning
Fig.3-64
operation. Failure to do so may result in
damage to the machine or a system [1]Main system pressure
malfunction. [2]Changeover pressure
[3]Agitator pressure
[4]Hydraulic fluid levels
[5]Cleaning water levels

3-37
System Functions
SYG5360THB 47

(1) Main System (Pump) Pressure (see Fig.

3-65) Oil Pressure of main system

It activates for 2 minutes each time the Oil

20
Pressure toggle switch (see item 1, on
3000 30

page 3-33 Fig.3-52) on the quick-check 10 2000 S

1000
4000

5000

panel on the rear boom support pedestal MPs 6000

 40

is used and the concrete pump is running.

NOTE:Main system (pump) hydraulic pressure
is set to relieve at approximately 34 Fig.3-65
MPa (4,931.3 psi).

(2) Change-over Pressure (see Fig. 3-66)

Change-over pressure
It displays the S-tube shift cylinder hydraulic
operating pressure during operation. 20

3000
10 2000 4000 30
S
The change-over pressure is the accumulator 1000
5000

pressure and it is always active. 0

MPs
6000

40

NOTE:This gauge will pulsate between 152-

117 bar (2,200-1,700 psi) each time Fig.3-66
the accumulator fires.

(3) Agitator Pressure (see Fig. 3-67)

Agitating oil pressure
It displays the agitator circuit hydraulic
pressure.
1500 2000
S 2500
NOTE:Agitator hydraulic pressure is set to 1000

500
3000
3500

relieve at approximately 12 MPa MPs

(1,741 psi).

Fig.3-67

3-38
 System Functions
SYG5360THB 47

(5) Hydraulic Fluid Levels & Temps (a) and

(b) (see Fig. 3-68)
a
It indicates the hydraulic oil level and its
temperature in the main hydraulic tank.
● (a) is used when the outriggers and
boom are in their travel (storage)
positions (outriggers folded/retracted into b
chassis, boom fully collapsed).
● (b) is used when the outriggers are fully
extended and in the operating mode, but
the boom is still fully collapsed.

NOTICE Fig.3-68
Always check the hydraulic oil levels
before you travel to the job site and after
the outriggers have been extended. Use
(AW46) hydraulic oil. Failure to do so
could result in equipment damage if there
is a leak in the hydraulic oil circuit.

(6) Cleaning Water Level & Temp (c) (see

Fig. 3-69)
It indicates level of water and its
temperature in the built-in water-wash
system for cleaning the machine after
pumping operations are completed. Use
tap water for refilling.

WARNING
Never use toxic or flammable fluids in the
wash system; use only fresh, clean tap
water. Using toxic or flammable fluids in
Fig.3-69
this system could cause injury or an
explosion resulting in death.

NOTE:For operation in cold climate conditions,

mixing a nontoxic antifreeze with the
water keeps it from freezing.

3-39
 System Functions
SYG5360THB 47

(7) Main System (Boom & outrigger)

Hydraulic Pressure (see Fig. 3-70)

It is behind the right valve body boom

control door, this gauge is normally off 7
but activates for 2 minutes each time the
Oil Pressure toggle switch (see item 1,
on page 3-33 Fig.3-52) on the quick-
check panel on the rear boom support
pedestal is used.

NOTE:Boom system hydraulic pressure is set

to relieve at approximately 34 MPa
(4,931.3 psi). Fig.3-70

(8) Filter Flow Indicator (see Fig. 3-71)

8
It is on the left side of the deck and in
front of the hydraulic cooler on top of the
filter near the valve body, this device
monitors the hydraulic flow within the
filter.

● GREEN indicator in window – Normal

● RED indicator in window –Blocked filter
(replacement required)

Fig.3-71

(9 ) Auto-Grease Pressure Gauge (see Fig.

3-72) 10

It is located on the auto-grease unit near

the hopper, this gauge displays the
grease pumping system pressure. This 10

gauge pulsates between 0.035 and 0.103 0

MPa (5 and 15 psi) during normal

40

pumping operations.

NOTE:It is normal to see fresh grease around

the hopper during pumping operations.
Fig.3-72

3-40
 System Functions
SYG5360THB 47

3.7.7 Light
The lamps and switches of truck-mounted
concrete pump:

(1) The side marker lamp is at side of

platform (see Fig. 3-73).

Fig.3-73

(2) The number plate lamp is at the hopper

of truck-mounted concrete pump (See
Fig. 3-74).

Fig.3-74
(3) The operation lamp is on the operation
valve of outriggers at both sides of truck-
mounted concrete pump (see Fig. 3-75).

Fig.3-75

3-41
System Functions
SYG5360THB 47

(4) The width lamp is behind the rear

outrigger of truck-mounted concrete
pump (see Fig. 3-76).

(5) The working lamp is at the platform at the Fig.3-76

rear of truck-mounted concrete pump
(see Fig. 3-77).

Fig.3-77

3-42
 System Functions
SYG5360THB 47

(6) The rear fog lamp is at the hopper at the

rear of truck-mounted concrete pump
with ISUZU chassis and HINO chassis.
(see Fig. 3-78).

Fig.3-78

(7) The side response reflector is at front

Side Response reflector
outrigger of the truck-mounted concrete
pump (see Fig. 3-79).

Fig.3-79

(8) The tail lamp is at rear outrigger of the

truck-mounted concrete pump (see Fig.
3-80).

Fig.3-80

3-43
System Functions
SYG5360THB 47

(9) The working lamp switch is behind the

working lamp (see Fig. 3-81).

Fig.3-81

(10) From left to right, they are master switch

of power supply, pumping position
indicator lamp, driving position indicator
lamp, which located on the operating
panel in the cab (see Fig. 3-82).

Fig.3-82

(11) The common switch of lamps is at the

side of steering wheel (see Fig. 3-83).

Fig.3-83

3-44
 System Functions
SYG5360THB 47

3.7.8 E-STOP buttons

There are E-STOP buttons at various
locations on the SANY concrete pumping
equipment, plus one more on the portable
remote controller. Use any of these E-STOP
buttons to immediately stop all concrete
pump systems (except for the truck engine).
Production changes may result in additional
E-STOP locations on your machine not Power SY series truck mounted concrete pump

shown here. When pressed, the E-STOP

Info

Lang
uage

Output: STROKE: 0 times/min

Run Oil TEMP:

Start

button locks in the pressed position until it is E-stop

FOR
Press: CE
Rotary: PUMP

Bug PAR
SET

rotated clockwise and allowed to spring back

to its normal position.

WARNING
All personnel involved with the job — no Fig.3-84
matter what their duties — must be aware
of all E-STOP button locations before any
concrete pumping operations are begun.
Failure to do so may result in damage,
injury or possibly loss of life.

(1) E-stop button on electrical control

cabinet.

(2) E-STOP button on maintenance and

operation box.

Fig.3-85

3-45
System Functions
SYG5360THB 47

(3) E-STOP button on small operation box.

Fig.3-86

(4) E-STOP button nearby the operating rod

of left outrigger.

Fig.3-87

(5) E-STOP button nearby the operating rod

of right outrigger.

Fig.3-88

3-46
 System Functions
SYG5360THB 47

(6) E-STOP button on the bottom of right

side of the remote controller.

3.8 Remote Control System

The remote control system is consisted of in-
Fig.3-89
cab receiver and remote controller.

3.8.1 In-Cab receiver

The in-cab receiver (see Fig. 3-90) assembly
consists of the following components: 2

(1) Antenna (mounted on cab exterior during

normal operation) 3
1
(2) Receiver (remains inside cab during
normal operation)

(3) Main electrical connector

Fig.3-90

NOTE:Equipped with a magnetic base so that

it can be conveniently placed on metal
surfaces where desired. For maximum
recepti on, it is best to place the
antenna on the roof of the truck cab.

Fig.3-91

3-47
System Functions
SYG5360THB 47

3.8.2 Remote controller

The remote controller is carried by the
equipment operator.

Below are descriptions of the control

functions on the remote controller (see Fig. 3-
92) and Table. 3-2. Study and become
familiar with all functions on this unit before
operating the controller.

12 11 10

Fig.3-92
[1]Main swcitch [6]Double-way handle 4# [12]Boom speed switch
[2]Operation Rod for boom [7]Double-way handle 5#
rotation [8]Cut off switch
[3]Double-way handle 1# [9]Boom speed switch
[4]Double-way handle 2# [10]Horn control switch
[5]Double-way handle 3# [11]Output adjustment switch

3-48
 System Functions
SYG5360THB 47

CAUTION
Never set the remote controller transmitter
down when the equipment is ready for
operation. If this must occur, you are
required to press the E-STOP pushbutton,
disconnect the controller hard wire cable
(if used), and lock the remote controller
away. Failure to observe and follow this
directive could result in personal injury
and / or machine damage.

Table 3-2

No Name Functions

1 Main swcitch Control the power of remote controller

Control the boom rotation.
Operation Rod for boom
2 Up:clocwise rotation;
rotation
Down:inverted hour rotation
3 Double-way handle 1# Control boom 1.Up:unfold;Down:fold
4 Double-way handle 2# Control boom 2.Up:unfold;Down:fold
5 Double-way handle 3# Control boom 3.Up:unfold;Down:fold
6 Double-way handle 4# Control boom 4.Up:unfold;Down:fold
7 Double-way handle 5# Control boom 5.Up:unfold;Down:fold
8 Cut off switch Cut off the chasis
9 Horn control switch Control the horn
Control pumping direction.
Forward/reverse pumping
10 Up:forward pumping;
switch
Down:reverse pumping
Adjust the output of pumping.
11 Output adjustment switch Inverted hour:reduce output;
Clocwise:add output
Out:fast step;
12 Boom speed switch
In:slow step

3-49
System Functions
SYG5360THB 47

Fig.3-93 Remote Controller of Intelligent Boom

[1]Undervoltage indicator lamp of battery [15]Double-way handle 4#

[2]LCD [16]Double-way handle 5#
[3]Page/OK knob (button) [17]Cut-off button of remote controller
[4]Forward/reverse pumpimg switch [18]Sound button
[5]Output adjustment switch [19]Emergency stop switch
[6]Automatic extension/retraction switch [20]Starting switch
[7]Orientation/reset toggle switch [21]Inching button for swing cylinder
[8]Fast/slow selector switch [22]Standby
[9]Boom lock switch [23]Hard-Wire connector port
[10]Mode selector switch [24]Intelligent key of remote controller
[11]Double-way handle of turntable [25]Flameout button of engine
[12]Double-way handle 1# [26]Remote controller display program
[13]Double-way handle 2# download interface
[14]Double-way handle 3# [27]Battery of remote controller

3-50
 System Functions
SYG5360THB 47

Intelligent boom remote

controller functions
(1) Undervoltage indicator lamp of battery

It is used to indicate the battery quantity of

remote transmitter.

● “Green” meaning normal.

● “Red” meaning insufficient and
replacement required.
(2) LCD

It is used to display the working conditions of

pump and query the malfunction.

NOTICE
The LCD on the remote controller is easy
to be damaged, please wear the straps of
remote controller well around the neck of
the operator when operating.

(3) Page/OK knob (button)

● Rotate it to page the display;

● Press it to increase the lighteness of
LCD.
(4) Forward/reverse pumping switch

This is a three-position toggle switch used to

Fig.3-94
control the concrete flow direction.

● Up position - carry out forward pumping

● Down position - carry out reverse
pumping
● Center position - No pumping action.
(5) Output adjustment switch

Calibrated in increments from 1 through 10 to

set pump output.

Fig.3-95

3-51
System Functions
SYG5360THB 47

(6) (Automatic extension/retraction switch

Under the intelligent mode, it is used to

automatically extend/retract the boom.

● Push the switch up and keep for at least

2 seconds to start the function of
automatic extension;
● Push the switch down and keep for at
least 2 seconds to start the function of
automatic retraction.
NOTE:When the boom is extended or
retracted automatically, if it may be
blocked by any barrier, please switch Fig.3-96
to the manual mode to continue to
extend or retract the boom fully.

(7) Orientation/reset toggle switch

It is temporarily unavailable.

Fig.3-97

(8) Fast/slow selector switch

Three-position toggle switch used to select

the boom movement speed.

● “Rabbit” position - Fast boom speed

● “Snail” position - Slow boom speed
● F3- Unavailable temporarily.

Fig.3-98

3-52
 System Functions
SYG5360THB 47

(9) Boom lock switch

● Up position - lock the arm 1;

● Down position - lock the arm 1 and arm
2;
● Center position - unlock the arm 1 and 2.

Fig.3-99

(10)Mode selector switch

It is used to switch the Manual/Column Plane/

Right Angle modes of boom action.

NOTE:Till now the column plane and right

angle modes are now opened.

Fig.3-100

(11)Double-way handle of turntable

It is used to rotate the turntable.

● Push the handle upward to make the

turntable move clockwise;
● Push it downward to make the it move
anti-clockwise.
NOTE:When under the automatic extension
mode, only the arm 1 is lifted can the Fig.3-101
handle be operat ed to make the
turntable move. When the turntable is
moving, the boom will stop to act.

3-53
System Functions
SYG5360THB 47

(12)Double-way handle 1#

● Under the manual mode, it is used to

control the unfolding/folding of arm 1;
● Under the intelligent mode, it is used to
control the vertical movement of the end
of boom.

Fig.3-102

(13)Double-way handle 2#

● Under the manual mode, it is used to

control the unfolding/folding of arm 2;
● Under the intelligent mode, it is used to
control the vertical movement of the end
of boom.

Fig.3-103

(14)Double-way handle 3#

● Under the manual mode, it is used to

control the unfolding/folding of arm 3;
● Under the intelligent mode, it is used to
control the vertical movement of the end
of boom.

Fig.3-104

3-54
 System Functions
SYG5360THB 47

(15)Double-way handle 4#

● Under the manual mode, it is used to

control the unfolding/folding of arm 4
● Under the intelligent mode, it is used to
control the vertical movement of the end
of boom.

(16)Double-way handle 5# Fig.3-105

● IUnder the manual mode, it is used to

control the unfolding/folding of arm 5
● Under the intelligent mode, it is used to
control the vertical movement of the end
of boom.

Fig.3-106

(17)Cut-off button of remote controller

It is used to cut off the remote transmitter.

Fig.3-107

NOTE:Press the button for 2~3 seconds to

turn off the remote controller.

3-55
System Functions
SYG5360THB 47

(18)Sound button

It is used to control the horn of chassis.

Always sound the horn to alert others in the

area before starting any operation or
operating changes.

Fig.3-108

(19)Emergency stop switch

It is used to stop the pumping at any

condition.

NOTE:If the Emergency stop switch on the

remote controller is pressed, rotate it
up clockwise and then press the start
button to unlock the Emergency stop
switch.

Fig.3-109

(20)Starting switch

Press the switch, so that the truck-mounted

concrete pump operates and each switch on
the remote controller is available.

Fig.3-110

3-56
 System Functions
SYG5360THB 47

(21) Page up button

It is used to control the movement of swing

cylinder.

Fig.3-111

(22) Page down button

Unavailable temporarily..

Fig.3-112

(23)Hard-Wire connector port

It is used for direct line hook-up to the

receiver.

NOTE:It is best to use the direct hard- wire

hook-up feature if in an area where
radio frequency between the controller
and receiver could be hampered.

Remove the battery (27) from the battery

pack before using the remote controller if a
hard-wire hook-up is to be used
Fig.3-113

3-57
System Functions
SYG5360THB 47

(24)Intelligent key of remote controller.

It is used to lock and unlock the remote

transmitter; unscrew it to deactivate the
remote controller and screw it down to
activate the remote controller.

It is used to turn off the engine of chassis.

Fig.3-114

(25)Flameout button of engine

It is used to turn off the engine of chassis.

Fig.3-115

(26)Remote controller display program

download interface

It is used to download the display program for

R&D engineer

Fig.3-116

3-58
 System Functions
SYG5360THB 47

(27)Battery of remote controller

Power supply of remote controller.

(28)Control handle of damping

It is used to control boom damping.

Fig.3-117

3-59
System Functions
SYG5360THB 47

E
G
PA
K
AN
BL

3-60
 Operations
SYG5360THB 47

Operations
4 Operation
4.1 Pre-operational Checks ....................................................................................4-3
4.2 Set-up Site ........................................................................................................4-5
4.3 Starting Up ........................................................................................................4-7
4.4 Outrigger Set-Up ...............................................................................................4-10
4.5 Function Checks ...............................................................................................4-18
4.6 Boom Movements .............................................................................................4-23
4.7 Hand Signals for Boom and Pump Operations .................................................4-28
4.8 Extending the Boom .........................................................................................4-34
4.9 Pumping Operations .........................................................................................4-39
4.10 Equipment Clean-up ........................................................................................4-53
4.11 Retracting the Boom & Outriggers ...................................................................4-61
4.12 Driving, Towing and Loading ...........................................................................4-62
4.13 Machine Decals ...............................................................................................4-67

4-1
Operations
SYG5360THB 47

WARNING
Always read the Safety section of this
manual before attempting to operate this
equipment. Failure to do this could result
in machine damage, personnel injury or
death.

4-2
 Operation
SYG5360THB 47

4 OPERATION

4.1 Pre-operational Checks

Before starting your work operations, it is

important to perform a pre-operational check
to be sure your equipment is in safe
operating condition. If any problems are
found during your pre-operational check,
have them repaired immediately. Never
operate a machine that is unsafe, damaged
or in need of repair.

WARNING Fig.4-1
Never operate a machine that is unsafe,
damaged or in need of repair. Using
inappropriate equipment can cause
accidents or possibly death. Always check
the maintenance record for this equipment
before operating.

Before operating this equipment read and

understand the following:

● Look for any obviously missing or

damaged marks.

● Inspect the outrigger system for damage

or missing components. Be sure the
outrigger locks are functional and that
the outriggers are properly retracted and
locked in place before you travel.

● Inspect the hopper area for loose,

missing or damaged items. Be sure this
area is clean and functional.

● Be sure all safety and work-related

equipment necessary for the job is in
place and properly secured for travel.

4-3
Operation
SYG5360THB 47

● Check the condition of all visible

hydraulic hoses. Look for worn or leaking
fittings and cuts, scuffed or cracked hose
surfaces. Have worn, cracked or leaking
hoses repaired or replaced immediately.

● Inspect the boom system for damage,

loose or missing parts. Immediately
replace any missing or damaged parts
and repair or replace loose components
that could fall or break during operations.

● Inspect the conveying piping for damage,

excessive wear, dents, loose clamps or
mountings. Inspect gaskets and hoses,
blow-out adapter, sponge (clean-out) ball
catchers and any related items. Never
use a worn hose or damaged piping.

● Inspect the hydraulic cylinders for

damage or leaks. Have damaged or
leaking hydraulic cylinders repaired
immediately.

● Be sure all safety decals are in place

and are not damaged. Be sure they are
clean and visible for all personnel to see.

● Be sure the steps, walkways and other

areas are clean and not covered with
mud, concrete or debris.

● Check the hydraulic tank and cooler. Be

sure they are not damaged, loose,
leaking or blocked with debris.

NOTE: When at the first time to start the new

machine, check the piston rod of
swing cylinder and oil cylinder of
boom (4). If protective sleeves are
applied, take off the protective sleeves
to prevent the protective sleeves
being entangled into oil cylinder
during cylinder working. Failure to do
so may causing faults.

4-4
 Operation
SYG5360THB 47

4.2 Set-up Site

Awareness of these three basic items

displayed in Fig. 4-9 are critical to safe
operation when performing concrete
thoroughly to be sure it will accommodate
your equipment and work operations. Review
all set up, pumping and safety rules with the
crew before starting.

WARNING
Failure to observe and follow these
directives may result in equipment
damage, property damage, personal injury
or even death.

Overhead power lines

Working clearances

Slab to be poured

Working clearances

Surface conditions Building

Fig.4-2

4-5
Operation
SYG5360THB 47

Surface conditions

Always check in with the contractor and talk

with the superintendant or foreman regarding
where to set up safely. The contractor needs
to supply a safe set-up area where the soil
and surface are capable of supporting your
equipment.

Always check for hidden dangers such as

voids, pipes or any underground conditions
that could cause your machine to tip. Never Fig.4-3
set up in an area where recent excavations
have taken place.

Working clearances

It is essential to maintain a safe distance

between the boom and obstructions such as
cranes, scaffolding, buildings or any objects.

CAUTION
Always study the area thoroughly before
unfolding the boom. Never allow yourself
to get into a situation where equipment or
property could be damaged or personnel
could be injured.
Fig.4-4

Overhead power lines

Always assume that all power lines are live.

Never take the word of someone on the job
site that it has been de-energized.

DANGER
Only a qualified representative of the
responsible power company can verify
that all electrical systems have been de-
energized. Failure to follow this alert will
result in serious injury or death. Fig.4-5

4-6
 Operation
SYG5360THB 47

4.3 Starting Up

CAUTION
Never use starting aids to start the engine.
Starting aids are explosive and will
damage the engine or possible injury may
result.

When you take over the machine, you must

become so familiar with the equipment that
damage and accidents cannot occur.

Every time you use the machine, you take on

full responsibility for the safety of anyone
located in the machine's danger zone. You
are therefore under an obligation to ensure
that the mac hine is c om pletely s afe i n
operation.

4.3.1 Test run

You must have a test run and function

checks before starting work on the
construction site.

The test run should be made before operation.

(1) After the handle brake is applied with the
light on, do not move the pump truck
(see Fig. 4-6).

(2) Put the chassis at the neutral position

and turn off the engine. Confirm there is
no foreign material in the hopper and
clean off. Then, start the engine.

Releasing position
of hand brake
Indicator lamp is on when
P the hand brake is pulled on

Fig.4-6

4-7
Operation
SYG5360THB 47

(3) Check the air pressure for more than

700kPa (see Fig. 4-7).

H
10
5 15

0 20 5

F
Barometer

Fig.4-7

(4) Press down the power button and wait for

10sec, to finish SYMC programme
initialization (see Fig. 4-8).

Fig.4-8

(5) Put the chassis at the neutral position

and turn off the engine.Press down the oil
pump position button to exchange the
driving to pumping position of the transfer
case, with the indicator on (see Fig. 4-9).

NOTE: Press down the oil pump button and

remain until the indicator beeping.

Fig.4-9

4-8
 Operation
SYG5360THB 47

(6) Start the engine. Step down the clutch to

swift the gear per the instructions of the
sign in the cab.
(7) After stepping down the clutch (at 1:1
gear position with the transfer case),
release the clutch slowly, and the pump is
in pumping.
NOTE: In normal operation of the generator
and oil pump, the pumping is made
with the hopper screen closed. If the
hydraulic fluid temperature is below
15°C, preheating should be made for
the system.
(8) After pumping, shift empty gear, turn off
the engine, press the traveling button,
check if the lamp of traveling position is
light, if not press the traveling button
again till it is light, and then start the
engine again and drive with shifting gear
(see Fig. 4-10).

Fig.4-10
4.3.2 Start the machine and engaging
the transfer gearbox power take- off

CAUTION
Be sure the truck chassis is sitting on a
firm and level surface. Failure to follow
this alert could result in loss of control or
possible injury.

(1) Set the parking brake on the truck

A
chassis to the park Position. TO P
PL
LL Y
PU

PARKING
BRAKE
Bendin
P E
U
SH AS
E
TO EL
R

Fig.4-11

4-9
Operation
SYG5360THB 47

(2) Chock all wheels on the truck. The wheel

chocks are stored below the chassis
toward the front of the truck.

(3) The transfer gearbox is installed after the

truck gearbox in the Cardan shaft line.

NOTE: The following notes must be abided in

order to prevent damage when using
the transfer gearbox:

● When the transfer gearbox is engaged

and disengaged, the engine must be Fig.4-12
stopped and the Cardan shaft should
not be turned. Furthermore, no gear
may be selected.

● The engine may only be restarted

after it has been shut down during
pumping operations if the concrete
pump is switched off and the pumping
rate has been turned down to 0".

NOTE: Refer to truck chassis operator’s

manual for details on starting the
engine.

4.4 Outrigger Set-Up

You must have read the safety section and
have completed the operations for starting up
the machine before you begin setting out the
machine supports.

4.4.1 Working area

See Fig. 4-2 on page 4-5 for the working area.

4-10
 Operation
SYG5360THB 47

WARNING
People who remain in the working range
without authorization can be injured. You
should therefore secure the working
range. Keep the working range under
constant observation. You must cease
working immediately and press the E-
STOP button if unauthorized person enter
the working range.

4.4.2 Danger zone

WARNING
There is a danger of crushing in the area
through which the supports may be
swung out or extended. You should
secure the danger zone. Keep the danger
zone under observation. If anyone enters
the danger zone, you must halt work
immediately and press the E-STOP button.

When the rear outrigger is unfolded or folded,

the whole revolving area of the outrigger is
dangerous for people may be hurt by
clamping (see Fig. 4-13).

Fig.4-13

4-11
Operation
SYG5360THB 47

When the outrigger is put down, check if

there is anything under it to avoid being
pressed by the outrigger. The foreign
substances under the outrigger must be
cleared away (see Fig. 4-14).

Fig.4-14

4.4.3 Operation of outriggers

(1) Unlock the rear outriggers (see Fig. 4-

15).

NOTICE
Failure to unlock the rear outriggers as
directed here may result in machine
damage as the control system attempts to
unfold the rear outriggers as described
later in this procedure.

Fig.4-15

(2) Unlock the front outriggers (see Fig. 4-

16).

NOTICE
Failure to unlock the front outriggers as
directed here may result in machine
damage as the control system attempts to
extend the front outriggers as described
later in this procedure.

Fig.4-16

4-12
 Operation
SYG5360THB 47

(3) Set the switch (a) on small operation box

to the local position to activate the
electrical system for the outriggers. See
“Main component locations” on page 3-3
for the location of the small operation box.

a
Turn the
switch right
O

(4) Operation of left outriggers: Fig.4-17

There is a group of (four) outrigger control

handles on both sides of the truck-mounted
concrete pump, and the left ones are in
charge of the actions of outrigger as follows:
1. lifting/descending of left front outrigger; 2.
extension/retraction of left front outrigger; 3.
Folding/unfolding of left rear outrigger; 4.
lifting/descending of left rear outrigger
(see Fig. 4-18).

During the operation, turn on the control

switch of outrigger 5 (see Fig. 4-18), and then
pull the corresponding control handle to 1 2 3 4 5
operate the outrigger. The order for unfolding
outrigger is: 2-3-1-4;The order for folding Fig.4-18
outrigger is: 4-1-3-2.

For supporting, it is necessary to support to

the proper positions by two times: the first
supporting distance is about 30cm; for the
second time it has not supported to the
proper position until the tyre of truck-mounted
concrete pump is lifted above the ground
(see Fig. 4-19).
30cm

Fig.4-19

4-13
Operation
SYG5360THB 47

(5) Operation of the right outriggers

The control handles at the right side are in

charge of the actions of outrigger as follows:
1. lifting/descending of right rear outrigger; 2.
folding/unfolding of right rear outrigger; 3.
extension/retraction of right front outrigger; 4.
lifting/descending of right front outrigger. The
order for unfolding right outriggers is: 3-2-4-1;
the order for folding right outriggers is: 1-4-2-
3.
1 2 3 4

Fig.4-20

(6) Ensure that outriggers are fully extended

or unfolded; the arrow decals markings on
both front and rear outrigger mountings
must align, indicating they are fully
extended and in the proper operating
position. See Fig.4-21.

WARNING
Never operate the equipment with the
outriggers partially extended or partially
The arrows of outrigger and lug well aligned
unfolded. Loss of control, serious injury
or death may result.

The arrows of outrigger extended boom well aligned

Fig.4-21

4-14
 Operation
SYG5360THB 47

4.4.4 OSS

NOTE: OSS is the abbreviation of One-Side-

Support which is a type of support for
supporting the machine in narrow
spaces.

(1) This truck-mounted concrete pump is

provided with OSS function.

(2) When the OSS function is used, the

placing scope of boom should be strictly
controlled to prevent the truck-mounted
concrete pump from overturning.

NOTE: The machine can be set up for safe

use with outrigger placement on the
right or left side only if necessary.
Once the boom is elevated and
extended, it can then be positioned
above the placing area. This operation
requires careful planning and
continued monitoring of the outriggers.

WARNING
Never retract the outriggers until the
boom is folded into the transport position,
even if you will be moving the truck only a
short distance. If the truck must be moved
for any reason, always retract the boom
back to the travel position and lock it
securely before retracting the outriggers.
Failure to do so may result in loss of
control, rollover, personal injury or death.

(3) When the OSS function is used, the

operation area is as follows:

a. With left outriggers retracted and right

outriggers fully extended, and taking the
central axial line as the origin, rotate the
boom rightward from 0° to 120°(see Fig.
4-22); Fig.4-22

4-15
Operation
SYG5360THB 47

b. With right outriggers retracted and left

outriggers fully extended, and taking the
central axial line as the origin, rotate the
boom leftward from 0° to 120° (see Fig.
4-23).

(4) The working area of the truck-concrete

pump depends on the length and rotation
angle of boom. Anyone is forbidden to
enlarge the working scope by means of
addition of spare parts.

4.4.5 Levelling the machine

Fig.4-23
Once the outriggers are unfolded and
extended in the proper operating position, it is
important to level the chassis.

(1) Be sure there is solid, stable ground

beneath where the outrigger levelling
cylinders will sit. See table 2-2 on page 2-
32 for details on surface conditions.

Fig.4-24

(2) Place the approved factory-approved

cribbing pads (1) that came with the
pumping unit beneath where the outrigger
1
leveling cylinders will sit.

Fig.4-25

4-16
 Operation
SYG5360THB 47

(3) Hold switch (6) in the down position to

operate the outriggers hydraulic control
levers (1 and 4).

NOTE: Switch (6) is a safety feature to

prevent accidental activation once the
outriggers are in place during the
pumping or boom movement
operations. If switch (6) is not held
down, the control levers (b and c) will
not function (see Fig. 4-26).
NOTE: See “Outrigger controls” on page 3-16
1 4 6
for the functions of control levers(1)
and (4). Fig.4-26

(4) Use the levelling gauges to determine

when the machine is level (see Fig. 4-27).

NOTE: All truck chassis wheels must be

slightly off the ground with full weight
of the machine resting on the
outriggers.

Fig.4-27

CAUTION
Always stand clear from the outrigger
levelling cylinders during set-up. Failure
to do so could result in serious injury.

Monitor the cribbing support under the

outrigger cylinder foot to be sure it remains
central in place and will support the weight of
the pump truck chassis.

Fig.4-28

4-17
Operation
SYG5360THB 47

(5) Extend each outrigger levelling cylinder

the same amount. Never exceed the 3°
range indicated on the levelling gauge
(see Fig. 4-29).

CAUTION
Operation outside the 3° operating range
may cause loss of control, a rollover and
serious injury.
Fig.4-29

WARNING
Never allow any personnel to crawl under
any part of the pump truck unit while
raising the truck chassis. Serious injury or
even death will result if the truck moves
or shifts.

4.5 Function Checks

You should check the following functions

before you begin using the machine on the
construction site.

4.5.1 Pump functions

The fundamental prerequisite for problem-

free use is a fully functional pump.

Switch over
Check for an unimpeded switch over function
of the delivery pistons and the S-valve at
various engine speeds.

Magnetic switches
Check that the drive cylinders switch over
automatically once the hydraulic pistons are
close to the magnetic switches. When the
piston approaches the magnetic switch to
change direction, the mark colour of changing
direction in the page of SYCD will change for
one time.

4-18
 Operation
SYG5360THB 47

Stroke time
Measure the machine stroke time under no
load, i.e. without concrete.
● Set the engine to maximum speed.
● Set the maximum pumping rate.
● Start the measurement at the first switch
over of the S-valve.
● The first single stroke is complete with
the next S-valve switch over.
● Measure the stroke time in a minute for
three times, get the average. The value
must match the data of maximal
pumping times in the test reading.
NOTE: Due to differences in reaction times
when using the stopwatch, the value
determined may vary from the value
stated by approximately 5%. You may
have to take the measurement several
times and calculate the mean of the
values measured.

4.5.2 Filter functions

The hydraulic system of truck-mounted

concrete pump has one high pressure oil
filters. (see Fig. 4-30)

The checking processes of the filter is as

following:

● Bring the hydraulic fluid up to operating

temperature (122 F (50° C)).

● Set the maximum pumping rate.

● Press in the red button on the filter if it is

sticking out.

NOTE: If the indicator at the top of oil filter

Fig.4-30
turns green, it indicates that the oil
filter is in good condition, without any
blockage; if it turns red, in indicates

4-19
Operation
SYG5360THB 47

that the filter core is seriously blocked

and the operation is stopped, and the
filter core must be replaced.

Environmental protection
Comply with the waste disposal regulations in
force for your area when changing the fluid
filter.

4.5.3 E-STOP function

It is only possible to intervene rapidly in the

event of danger if all the E-STOP buttons are
functioning.

The machine is no longer safe in operation if

one of the E-STOP buttons is defective, as
you will no longer be able to switch the
machine off quickly enough if danger
threatens. You must therefore inspect the
function of the E-STOP buttons and the lever
position for the boom valves before starting
work each time.

The machine is only switched off electrically

when one of the E-STOP buttons is pressed.
Although this causes all the electrically
actuated hydraulic valves to be switched off,
an uncontrolled sinking of the boom caused
by leakages in the hydraulic system, for
instance, cannot be prevented in this way.

In no event should you first press the E-

STOP button if the boom starts uncontrolled
movements. Should you do this you will have
no ability to counteract the movement.

Furthermore, the E-STOP circuit has no

influence on the accumulator pump and the
agitator pump, i.e. the accumulator is filled
and the agitator continues to rotate, despite
the E-STOP button having been pressed.

The way of checking the function of E-STOP

buttons is as following:

4-20
 Operation
SYG5360THB 47

● Switch the pump on.

● Operate a boom function.
● Press one of the E-STOP buttons. The
pump and the boom must come to a halt
immediately.
● Check all E-STOP buttons on the
machine and on the remote control in the
same way.

4.5.4 Function check on the boom

control block

You may only operate the machine if the

boom control block is fully functional.

● Switch on remote control.

● Operate the boom control levers briefly
several times while observing the levers
on the boom control block.
● The lever for the boom valve operated
and the lever for the operating mode
selector valve must move each time.
NOTE: As soon as you release the boom
control levers on the remote control
unit, the levers for the boom arm
valves previously actuated and for the
operating mode selector valve must
return to the central position (zero
position). The reactions of the
operating mode selector valve on the
boom control block are delayed by
some 3 seconds if you use the cable
remote control.

4.5.5 Function check on the agitator

safety cutout

This machine is fitted with an agitator safety

cutout. A pressure roller switch is acted on as
soon as you open the grille. This causes the
agitator to halt and the pressure to be
dumped from the accumulator, ie the S-valve
will no longer be able to switch over. In

4-21
Operation
SYG5360THB 47

addition, the delivery pistons return to the end

position and the concrete pump halts.

WARNING
A defective agitator safety cutout can
cause you to believe that the machine is
safe, even though this is not really the
case. This can lead to the agitator
continuing to run or the S-valve switching
over when the grille is open. You must
therefore check the function of the
agitator safety cutout before you start
each pumping job. Failure to do this could
result in damage to the agitator or serious
injury to persons.

● Open the grille with the concrete pump

running.

● The switching cam acts on the pressure

roller switch.

● The agitator must come to a halt

immediately.
● The S-valve must no longer switch over.

● The concrete pump must run to the end

position and halt.

WARNING
You must stop work if you open the grille,
but
●the agitator continues to run,
●the S-valve continues to switch,
●the concrete pump does not run to its
end position.
Failure to do this could result in serious
injury to persons.

NOTE: You must switch the concrete pump

off and back on again to restart it.

4-22
 Operation
SYG5360THB 47

4.6 Boom Movements

Prohibited activities
You must have read the safety section and
completed the operations to set up the
machine before you unfold the placing boom.
Only unfolding the placing boom once you
have set the machine up properly.

WARNING
Avoid the following actions. They overload
the placing boom and may lead to damage
or endanger persons: Fig.4-31
● Allowing the placing boom to strike an
obstacle, see Fig. 4-31;
● Pushing with the placing boom, in order
to move an obstacle out of the way,
see Fig. 4-32;
● Tearing away a trapped end hose by
force.

Fig.4-32
4.6.1 Restrictions on use

Extreme weather conditions, such as gales,

storms or low temperatures restrict the use of
the boom, or can even make its use
impossible.

Bad weather and storms

Shift the placing boom to the rest position in
the event of storms and bad weather,
see Fig. 4-33.
● Booms with a vertical reach of 42 m or
more (M 42 and larger) may only be
Fig.4-33

4-23
Operation
SYG5360THB 47

operated in wind forces up to 7 (wind

speed 61 km/h = 17 m/s).
● Booms with a vertical reach of less than
42 m (< M 42) may only be operated in
wind forces up to 8 (wind speed 74 km/h
= 20 m/s).
Wind speeds in accordance with the
Beaufort scale are average wind speeds
measured over a period of 10 minutes.
Higher speed gusts of wind may occur
briefly during the measuring period.
Higher wind speeds jeopardize stability
and safety of the structural elements.
There is a risk of lightning strike in a
thunderstorm. Tower cranes on
construction sites generally have wind
speed measuring equipment, so that you
can ask about the wind speed at any
time. If no wind speed measuring
equipment is available, you can ask the
nearest meteorological office what the
wind speed is, or estimate the wind
speed using the following rule of thumb.
● In winds of force 7 and greater, green
leaves break from trees and
inconvenience is felt when walking
against the wind.
● In winds of force 8 and greater, small
branches break from trees and progress
is impeded.

Cold weather
The boom must not be used in temperatures
below minus 15°C. There is a danger of
damage to the steel (brittle fracture) and the
seals throughout the system at such extreme
minus temperatures. In addition, such minus
temperatures should be considered the
realistic lower limit for concrete placement, as
it is no longer possible to prepare concrete
such that it can achieve its strength without
the use of special additives.

4-24
 Operation
SYG5360THB 47

4.6.2 Danger zone

CAUTION
There is a risk of injury from parts of the
delivery line falling beneath the slewing
circle of the placing boom. There is a risk
of injury from falling concrete beneath the
end hose. You should therefore secure the
danger zone. Keep the danger zone under
constant observation. You must halt work
immediately and press the E-STOP button
if anyone enters the danger zone.

High-voltage lines
A spark can jump across from high-voltage
lines even if you just approach them and this Fig.4-34
will energize the machine and the
surrounding area. You must therefore always
maintain the specified safe clearance.

Minimum Safety Distance Between the

Boom and Electric Wire
Voltage (KV) Minimum Distance (m)
0~1 1.5
1~100 3.5
100~200 4.5
200~300 5.5
>300 0.01(U-50)+3

Fig.4-35

4-25
Operation
SYG5360THB 47

Overlapping working ranges

Take note of the working ranges of other
construction plant (e.g. cranes, other concrete
placing booms, etc.).

Signal boom movements

Move the placing boom with cautious
operation of the controls. Maintain visual
c on ta c t w i th t he pl ac i n g s i t e. W ar n by
sounding the horn before you move the
boom.

Hand signals
Fig.4-36
Move the placing boom only if you can see
all of the working range. If this is not the
case, you must only move the placing boom
in response to signals from a signaller. Agree
unambiguous hand signals with the signallers
giving directions.

4.6.3 Spontaneous retraction of the

boom and support cylinders

The hydraulic fluid heats up to an average Fig.4-37

temperature of 60°-70°C during operation
because of the friction in the lines. When the
hydraulic fluid cools, its volume reduces as
cold hydraulic fluid has a smaller volume than
does hot hydraulic fluid. This causes the
cylinders on the boom, swing-out legs and
supports to retract a little and the boom and
the outrigger to sink.

NOTE: The boom can sink during lengthy

pauses in work due to cooling of the
hydraulic fluid. For this reason you
should never leave the boom in the
unfolded position during breaks in
working. In addition, you must keep
the supports under constant
observation whilst the machine is in
operation. You may have to readjust
the swing-out cylinders and support
cylinders.

4-26
 Operation
SYG5360THB 47

Loss of volume
The extent to which the boom and the truck
sink depends on the extent to which the
various boom and support cylinders have
been extended and the magnitude of the
temperature difference in the hydraulic fluid.

4.6.4 Uncontrolled boom movements

The following defects may be the cause of
uncontrolled boom movements:
● Malfunction in the remote control circuit
● Malfunctions on the boom control block
● Lines, threaded unions or boom cylinders
leaking
● Defective mono-isolator on the boom
cylinder
● Hydraulic system not carefully bled
● Insufficient hydraulic fluid in the reservoir
● Cooling of the hydraulic fluid

In this case, the boom may move as soon as

the remote control is switched on. Halt work
immediately. You can continue working only
after the causes have been remedied and
perfect functioning of the machine is ensured.
NOTE: Whatever the reason for the
uncontrolled movements of the boom,
you must halt the work on site and
have the cause for the breakdown
determined and rectified by qualified
personnel.

DANGER
In no event should you first press the E-
STOP button if the boom starts
uncontrolled movements. Should you do
this you will have no ability to counteract
the movement.

4-27
Operation
SYG5360THB 47

Countermeasures
You must proceed as follows if the boom
starts uncontrolled movement:
● under the uncontrolled movement
immediately and attempt to steer the
boom out of the danger zone and bring it
to rest under control. If the uncontrolled
boom movement continues, despite
counter-measures:
● Press the E-STOP button.

NOTE: Repeated practice is required to

ensure that it will be possible to
implement the measures described
above in an emergency.

4.7 Hand Signals for Boom and

Pump Operations
4.7.1 Standard boom hand signals

Clear communications are a means for

avoiding accidents. In addition to voice
communication systems, hand signals are an
excellent method for communications
between the signal person and the operator
(who will be controlling boom extension and
boom positioning).

A set of one-hand and two-hand signals is

presented by the CPMA (Concrete Pumping
Manufactures Association). Never begin
o p er a t i o n s u nt i l a l l s i g n al s a r e c l e a r l y
understood. If nonstandard signals are used,
be sure the operator and signal person agree
on them before operations are to begin.

The operator shall respond to operating

signals from the proper signal person only,
but shall obey a stop signal at any time from
anybody. The signal person shall be in a
clearly visible or lighted location. If signal
communications are interrupted at any time,
the operator will stop all movement of the
equipment immediately.

4-28
 Operation
SYG5360THB 47

CAUTION
Always operate the boom slowly and
cautiously. Rapid, jerky movements could
result in loss of control and possible
injury to nearby personnel.

OPEN OR EXTEND THE BOOM:

Use both right and left hands with the thumbs
pointing away from each other.

This is the standard signal used by the signal

person to indicate to the operator to open or
extend the boom system (see Fig. 4-38).

Fig.4-38

MOVE BOOM UP:

Use the right or left hand with a thumb-up
signal.

This is the standard signal used by the signal

person to indicate to the operator to raise the
boom (see Fig. 4-39).

Fig.4-39

4-29
Operation
SYG5360THB 47

MOVE BOOM DOWN:

Use the right or left hand with a thumb-down
signal.

This is the standard signal used by the signal

person to indicate to the operator to lower the
boom (see Fig. 4-40).

Fig.4-40

MOVE BOOM TO LEFT:

Use the right hand with a thumb pointing in
the direction as viewed by the operator you
are trying to signal.

This is the standard signal used by the signal

person to indicate to the operator to move the
boom to the left (see Fig. 4-41).

Fig.4-41

MOVE BOOM TO RIGHT:

Use the right hand with a thumb pointing in
the direction as viewed by the operator.

This is the standard signal used by the signal

person to indicate to the operator to move the
boom to the right (see Fig. 4-42).

Fig.4-42

4-30
 Operation
SYG5360THB 47

MOVE THE BOOM A LITTLE BIT:

Using the right or left hand and opening and
closing the thumb and index finger indicates
to the operator to move the boom in short or
slight movements.

This is the standard signal used by the signal

person to indicate to the operator to move the
boom slightly (see Fig. 4-43).

Fig.4-43

STOP BOOM MOVEMENT:

Use the right or left hand with a closed fist to
indicate to the operator to stop all boom
movements.

This is the standard signal used by the signal

person to indicate to the operator to stop all
boom movements immediately (see Fig. 4-
44).

Fig.4-44

RETRACT OR CLOSE THE BOOM:

Use both right and left hands with the thumbs
pointing inward towards each other.

This is the standard signal used by the signal

person to indicate to the operator to retract or
close the boom system (see Fig. 4-45).

Fig.4-45
4.7.2 Pump operation hand signals
These one- and two-hand signals presented
by the CPMA (Concrete Pumping
Manufactures Association) are required
during pumping operations by OSHA
(Occupational Safety and Health Association).

4-31
Operation
SYG5360THB 47

Never begin operations until all signals are

clearly understood. If nonstandard signals are
used, be sure the operator and signal person
agree on them before operations are to
begin. The operator shall respond to
operating signals from the proper signal
person only, but shall obey a stop signal at
any time from anybody. The signal person
shall be in a clearly visible or lighted location.

If signal communications are interrupted at

any time, the operator will stop all movement
of the equipment immediately.

START OR SPEED UP PUMPING:

Using the right or left hand at waist level,
make a fist and move the forearm in and out
to indicate to the operator to start pumping
operations.

Move the forearm in and out at a faster pace

to indicate an increase in pumping speed.

This is the standard signal used by the signal

person to indicate to the operator to start or
speed up the pumping speed (see Fig. 4-46). Fig.4-46

SLOW DOWN PUMPING:

Using both hands with the palms facing down
at waist level, move the forearms up and
down to indicate to the operator to slow
pumping operations down.

This is the standard signal used by the signal

person to indicate to the operator to slow
pumping operations down (see Fig. 4-47).

Fig.4-47

4-32
 Operation
SYG5360THB 47

CHANGE PUMPING SPEED SLIGHTLY:

Using the right or left hand and opening and
closing the thumb and index finger, indicates
to the operator to increase or decrease
pumping speed (flow).

This is the standard signal used by the signal

person to increase or decrease pumping
speed (flow) by a small amount (see Fig. 4-
48).

Fig.4-48

RELIEVE PRESSURE IN PUMP SYSTEM:

Use the right hand or left hand to tap twice
on your hard hat to indi cate to put the
pumping system in the reverse mode to
relieve pressure on the piping system.
This is the standard signal used by the signal
person to put the pumping system in the
reverse mode (see Fig. 4-49).

CAUTION
Stop pumping in the forward mode and Fig.4-49
place the system in the reverse mode
immediately if the signal person uses this
signal during operations. Failure to do so
may result in a sudden rupture in the
piping system or hose end-swing and
personal injury.

ADD WATER TO HOPPER:

Using the right hand and thumb pointing
toward your mouth, lift the right hand and tilt
the head as to indicate drinking. At the same
time, hold up the left hand and use your
fingers to indicate the amount in gallons
(liters) of water to be added to the mix.

This is the standard signal used by the signal

person to indicate the concrete mix is too
thick and needs to be thinned out for better
flow (see Fig. 4-50). Fig.4-50

4-33
Operation
SYG5360THB 47

STOP THE PUMP:

Use the right or left hand with a closed fist
and extended index finger moving the hand
across the base of the throat (slashing
motion) to signal the operator to stop all
pumping operations.
This is the standard signal used by the signal
person to indicate to the operator to stop all
pumping operations immediately (see Fig. 4-
51).
Fig.4-51
NOTICE
This signal may be used by other
personnel in an emergency. The operator
shall obey a STOP signal at any time from
anybody.

DONE, CLEAN UP:

Using both hands with thumbs up motion
indicates to the operator that all pumping
operations are done and it is time to clean
up.
This is the standard signal used by the signal
person to indicate to the operator that all
pumping operations are completed (see Fig.
4-52).

Fig.4-52
4.8 Extending the Boom

Before extending the boom:

● See “Outrigger Set-Up” on page 4-10.
● Be sure your working radius, danger
zones and clearances are clear to raise
the boom. See “Set-up Site” on page 4-
5.
● Be sure all personnel involved in
pumping operations understand all boom
hand signals. See “Pump operation hand
signals” on page 4-31.

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 Operation
SYG5360THB 47

● Be sure all unauthorized personnel are

clear of the work area.

4.8.1 Preparing the Remote Controller

(1) Be sure the receiver antenna (a) is

positioned on the cab roof of the truck for
clear communication between the remote
controller and in-cab receiver.

NOTE: The remote controller system

equipment is found inside the truck
cab. Fig.4-53
NOTE: If signal interference will be a
problem, you may want to use the
hard-wire connector.

(2) Set switch (a) on small operation box to

the REMOTE position to activate the in-
cab receiver. See “Main component
locations” on page 3-3 item 12.
a
Turn leftward

Fig.4-54

(3) The controller unit (a) is equipped with

straps (b) that must be worn around the
neck of the operator during normal
operating procedures. See “Remote
control system” on page 3-47.

Fig.4-55

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Operation
SYG5360THB 47

4.8.2 Unfolding the boom

For details on remote controller joystick
functions, see “Remote Control System” on
page 3-47.
NOTE: See “Outrigger and boom backup
hydraulics” on page 3-19 if the
electronic control system fails while
unfolding the boom.

NOTICE
Lowering the boom with the hopper in the
open position will result in damage to the
boom, hopper and hopper cover. Fig.4-56

(1) Firstly unfold the boom 1 to about 90°

position (see Fig. 4-56), or when
unfolding the boom 2, it may cause the
boom, end base structure and other
components to bump.

(2) After unfolding the boom 2 to over 70°

position, the boom 3 can be unfolded Fig.4-57
(see Fig. 4-57).

(3) After unfolding the boom 3 to over 45°

position, the boom 4 can be unfolded
(see Fig. 4-58).

Fig.4-58

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 Operation
SYG5360THB 47

(4) Firstly unfold the boom 5 to over 15°

position, and the boom 4 can be unfolded.
which avoid arm5 head and tie rods (tie
rod 5,6) between arm3 and arm4 to bump
(see Fig. 4-59).

(5) Unfold the boom 4 and boom 5(see Fig.

4-60).

The sequence of folding the boom is the

opposition sequence of unfolding the boom.

Fig.4-59
NOTICE
When unfolding or folding each boom, it
must provide enough height and space for
boom movement in order to avoid
b um p . Wh e n tu r n i n g b o o m o p er at i o n
handle, don't turn to the dead position
once and move slowly to the maximal
opposition.

WARNING
When concrete putting in boom delivery
pipe, the total weight of boom increase
Fig.4-60
sharply, and the weight distortion of boom
increase, and the the distortion is most at
the whole boom horizontal placing state,
a nd t h e bo o m en d d es c en d s h ar p l y ,
which may cause personnel and
equipment damage.Therefore, the
minimum distance is over 3 meter from
boom and end hose to ground or obstacle
before placing.

Fig.4-61

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Operation
SYG5360THB 47

4.8.3 Unlocking the end hose

Hold the end hose upward and pull the

locking bar (a) downward to release the hose
for operation. See Fig. 4-62.

NOTE: Don’t unlock the end hose until the

boom is in place and ready for
pumping operation. a
Fig.4-62
4.8.4 Checking outrigger stability

Stability of the unit is very important and must

be ensured after the boom is fully extended.

Follow the steps below before beginning any

pumping operations.

NOTICE
Lowering the boom with the hopper in the
Fig.4-63
open position will result in damage to the
boom, hopper and hopper cover.

(1) Slowly slew the extended boom over

each outrigger.

(2) If you see an outrigger jack sinking or

unstable, immediately slew the boom back
to its original transport position.

(3) Adjust the amount of dunnage under the

cribbing pads until you have enough soil
contact to hold the unit without sinking.

(4) Repeat the procedure for each outrigger.

CAUTION
Failure to observe and follow these
directives could result in machine tipover,
equipment damage or personal injury.

4-38
 Operation
SYG5360THB 47

4.9 Pumping Operations

Normal pumping operation can begin only

after the boom is positioned in the desired
location.

4.9.1 Safety precautions

NOTICE
The pumping system can be started, only
after making sure that the change valve of
the auxiliary valve group is set at the
mixing position, the mixing shaft runs
properly, the engine, transfer case and oil
pump run normally, the outriggers are
supported well and the boom is unfolded
as required, and all the examinations are
carried out. Failure to do so may result in
serious damage to the pumping system,
or personal injury.

(1) Once the forward/reverse pumping switch

is turned to the forward position, the
piston will begin to work. Carefully
observe whether the main oil cylinder and
the swing valve oil cylinder change
direction normally, whether the tube
clamps are loose, and whether adaptors
are leaky.

(2) Press reverse pumping button in case of

jamming in tube. However, never conduct
reverse pumping excessively. Or else, the
jamming in tube will become aggravated.

(3) In case of emergency, directly press E-

STOP button to stop the machine, so that
each part of truck-mounted concrete
pump stops.

4-39
Operation
SYG5360THB 47

(4) When starting the truck-mounted

concrete pump, accident may be caused
by sudden swing of end hose, thus people
should be away from the dangerous area
of end hose (that may be covered by end
hose) during the starting course. The
diameter of this area is two times of the
length of end hose. If the maximum length
of end hose (1) is 4m, the diameter of this
area(2) is 8m (see Fig. 4-64).

Fig.4-64

(5) During the operation, you should choose

a safe place to stand, and use the
appropriate support tools to guide the end
hose. Standing on the edge of the
building and holding the end hose is
forbidden, otherwise, the swing of hose or
boom may lead to the fall of operator
(see Fig. 4-65).

Fig.4-65

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 Operation
SYG5360THB 47

(6) Never allow the rubber hose from

bending or jamming, and the end hose
cannot be immersed into the concrete.
Otherwise, it is easy to cause burst and
personnel injury due to the increase of
pipeline pressure (see Fig. 4-66).

Fig.4-66

(7) The end hose should be hanged down

safely and reliably (see Fig. 4-67).

Fig.4-67

(8) The hopper screen should be closed

when the pumping system is running, and
it is strictly prohibited to stretch the hands
into the hopper or water tank and touch
the swing mechanism (see Fig. 4-68, Fig.
4-69 and Fig. 4-70).

Fig.4-68

4-41
Operation
SYG5360THB 47

Fig.4-69

Fig.4-70

(9) When the pressure is applied, it is

prohibited to open or remove the delivery
pipes, and it is necessary to decompress
the concrete inside the pipe by the
reverse pumping. Beware of the wounding
by the instant ejection of concrete
(see Fig. 4-71).

Fig.4-71

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 Operation
SYG5360THB 47

CAUTION
Do not to use the concrete pump at high
pressure (concrete pressure greater than
85 bar) when connected to a pipe suitable
only for lower pressure (concrete pressure
less than 85 bar). The operator has to
make sure that he is using a suitable pipe
before switching on the high pressure.
SANY does not take any liability for wrong
use.

(10) Always check weather conditions. Wind

speeds in excess of CPMA (Concrete
Pump Manufacturers Assn.) and ACPA
(American Concrete Pumping Assn.)
standard ratings and electrical storms
could cause injury or even death.

Lower the boom system immediately and

take shelter if high winds or an electrical
storm should occur during pumping
operations.

Fig.4-72

(11) Never allow personnel to stand between

the mix truck and pumping equipment
when positioning the mix truck with the
hopper. Always stand at a safe distance
when positioning the equipment.

Fig.4-73

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Operation
SYG5360THB 47

(12) Be sure all pumping material has

stopped discharging from the end hose
before moving or retracting the boom.

Be sure there is no material residue that

could fall from the end hose onto the
equipment, work site or personnel below.
Stop or reverse pumping operations
before moving or retracting the boom.

4.9.2 Notes on correct pumping

Bouncing boom
If the boom bounces very heavily in pumping Fig.4-74
operations, check the support and correct it
as required. If the support is correct, reduce
the pump speed or change the boom
position.

The boom can also bounce if air is taken in

and compressed in the delivery line. You
should therefore always make sure that the
agitator hopper is always filled with concrete
to the mixer shaft and that no air is sucked
in.

Favourable boom position

A horizontal position of the last arm is
favourable for pumping (see Fig. 4-75). Last arm horizontal

If the last arm is lower than the horizontal,

the concrete in this part of the delivery line
will flow more quickly as a result of its self-
weight. The flow velocity is lower if the arm
position is horizontal, and thus the wear on
the delivery pipes and the end hose is less.

When the pump is stopped, only the content

of the end hose flows out if the arm position
is horizontal; the content of the delivery line
Fig.4-75
can flow out if the arm position is below the
horizontal.

4-44
 Operation
SYG5360THB 47

The strokes of the pump cause forces to act

along the delivery line and thus along the
boom. If the last arm is vertical, the forces
also act vertically on the boom end and move
the boom up and down. If the arm position is
horizontal, the boom is moved forwards and
backwards, which causes a light rocking
motion.

Damping valve
You must close the damping valve when you
are pumping soft consistence concrete (snail
symbol) as otherwise the S-valve switches
over too harshly. You must open the damping
valve (hare symbol) when you are pumping
stiff consistence concrete as the concrete has
a damping effect.

4.9.3 Pre-operational checks

Before starting any pumping operations,

confirm that:

● All personnel involved are ready for the

concrete placing process and that they
understand all rules and procedures and
know where all E-STOP buttons are
located. See “E-STOP buttons” on page
3-45.

● All personnel have an unobstructed view

and are able to communicate with the
boom operator.

● All hand signals are understood.

● The end hose safety chain (a) is in place

and will support the end hose during
operations (see Fig. 4-76). Fig.4-76

NOTE: Never remove this safety chain during

pumping operations.

4-45
Operation
SYG5360THB 47

CAUTION
Do not use the safety chain to position the
end hose. Do not hang onto the end hose
or boom during pumping operations.
Failure to observe and follow this directive
may result in equipment damage or
possible injury.

● The auto-grease system is full and

operating. It is important that the
operator monitor this system during
operation.

NOTE: Grease build-up under the hopper

indicates the system is operating
normally.

NOTICE
Failure to monitor this system may result
in component damage or lock-up.

4.9.4 Pumping

Priming the system

(1) Open the hopper (a) and lock the cover a

b
in a safe position using both locks (b) to
secure it on both ends (see Fig. 4-77).

NOTE: If the boom must be lowered for any

reason, be sure to close the hopper
cover first.

NOTICE
Lowering the boom with the hopper in the
open position will result in damage to the Fig.4-77
boom, hopper and hopper cover.

4-46
 Operation
SYG5360THB 47

(2) Fill the hopper with fresh water and add

either a pump priming agent or grout to
lubricate the conveying piping.

NOTE: Follow the instructions on the priming

agent/grout packaging for the amount
and mix time.

(3) Set switch (a) on the rear chassis switch

panel to the AGITATE position to mix the
material with the water (see Fig. 4-78).

(4) Once the priming agent/grout and water

are mixed, signal the personnel at the end a
hose before engaging the pump. See
“Pump operation hand signals” on page 4-
31 for details. b

Using the remote controller

(1) Set switch (b) on the rear chassis switch

panel to the REMOTE position and
prepare the remote controller for operation
(see Fig. 4-78).
Fig.4-78
(2) Move switch (a) to the discharge position
while regulating the flow with dial (b)
(see Fig. 4-79).

Fig.4-79

4-47
Operation
SYG5360THB 47

Using the rear chassis switch panel

(1) Set switch (a) to the LOCAL position

(turn rightward), see Fig. 4-80.
a
(2) Move switch (b) to the FORWARD
position while regulating the flow with
switch (c). c

NOTE: Always sound the horn with switch (d) b d

before you start the pump.

The pumping cylinders will begin

operation and the mixed priming agent will
start moving through the conveying piping.

Fig.4-80

4-48
 Operation
SYG5360THB 47

Pumping concrete
Fill the hopper with concrete when the last of
the priming agent is near the bottom of the
hopper.
a
NOTE: To avoid concrete build-up on the
hopper grate, occasionally use the
Switch (a) on either the rear chassis
switch panel or the remote controller
to shake concrete residue from the
grate into the hopper (see Fig. 4-81).

NOTICE
Always keep more than enough concrete
in the hopper during pumping operations Fig.4-81
t o a vo i d tra p p in g air in the mater i a l
cylinder openings.

4.9.5 Possible faults

Faults may occur even if you have observed

all the notes on correct pumping. This section
lists the faults occurring most frequently, and
indicates how to rectify them.

4-49
Operation
SYG5360THB 47

Blockages
1 2
The following faults can lead to blockages:
● delivery line insufficiently wetted;
● S-tube leaking;
● lines leaking;
● concrete leavings in the S-tube and 3
delivery pipes;
Fig.4-82
● unfavourable concrete composition;
● segregated concrete;
● set concrete.
NOTE: In the event of blockages, pump the
concrete immediately back into the
agitator hopper and mix it up. You
can switch over to forwards pumping
when the delivery cylinders and the S-
valve are switching over automatically
again without problem. Begin pumping
again with care.

Overheating
Continuous operation under high loading can
lead to overheating of the hydraulic fluid. All
pumps have a thermo-electrical cut-out. The
pump is automatically shut down if the fluid
heats up to over 90 ℃ . Proceed as follows to
prevent this: Check that the hydraulic fluid
radiator is operating correctly. If not, you can
switch it on using the toggle switch on the
control cabinet.
● Reduce the output.
● Fill the water box with fresh water as
soon as the fluid temperature rises
above 80 ℃ .

Cooling
● Change the water continuously if the
temperature continues to rise.
● Look for the cause of fluid overheating
and rectify it.

Fig.4-83

4-50
 Operation
SYG5360THB 47

Additional cooling
● If you absolutely must supply additional
cooling, direct the water jet onto the
drive cylinders and the piston rods of the
drive cylinders.

NOTICE
Never spray water on the hydraulic fluid
reservoir. Damage may be caused to the
hydraulic pump.
Never use sea water or water containing
salt for cooling. Otherwise the chrome Fig.4-84
layer on the delivery piston rods and
delivery cylinders will be destroyed.

Restarting after overheating

Should the pump have, nevertheless, been
switched off because of overheating, you
should proceed as follows:

● Switch the pump off.

● Never switch the engine off, as the
hydraulic fluid radiator must remain in
operation.
● Refresh the water in the water box.
● Wait until the hydraulic fluid has cooled if
you are not able to find the fault
immediately.
● Once the red indicator lamp has
extinguished, switch the pump back on
and continue pumping slowly at reduced
output.
● Determine the cause of the fluid
overheating once pumping operations
have been completed and rectify the
fault.

4-51
Operation
SYG5360THB 47

4.9.6 Special cases

On some construction sites, it may be the

case that the net reach of the boom is not
adequate. You then have the option of
connecting a continuation delivery line to the
boom tip or, if your machine is equipped with
a lateral outlet, connecting a delivery line
there.

Continuation delivery line

No forces must be transferred from the fixed
delivery line to the boom or vice versa.

The stationary delivery line may not place

additional loading on the boom. This will
prejudice the stability of the machine. The
delivery hose may not be bend, nor may be it
be stretched. Blockages can occur if it is
bent. If it is stretched out, forces may be
transmitted which can lead to damage to the
structure, delivery hose or boom. The boom
can sink during pumping operations and
place the delivery hose under tension as a
consequence of cooling of the hydraulic fluid
in the boom cylinders. This can cause forces
to be transferred or the delivery hose to tear.
You should therefore keep the delivery hose
under constant observation.

● Extend the boom to bring the last arm

approximately 1.5-2 m from the
stationary delivery line.

● Dismantle the end hose.

● Mount a 3 m long delivery hose in place

of the end hose.

● Connect the delivery hose and the fixed

delivery line using a SKH attachment
coupling. Use an A seal as the seal.

● Fasten the SKH attachment coupling

securely to the structure.

4-52
 Operation
SYG5360THB 47

4.10 Equipment Clean-up

After all pumping operations are completed, it

is important to remove and clean all concrete
material residue from the machine before
folding the boom.

NOTICE
Failure to thoroughly clean the pumping
system at the completion of pumping
operations will result in equipment
damage.

4.10.1Cleaning the Boom Piping

Clean the conveying piping before cleaning
any other parts of the concrete pump unit.

Timing is very important during this operation

because concrete can set up and harden
very quickly.

(1) Fully extend the boom vertically using the

joystick controls on the remote controller.
This position will aid in the extraction of
any concrete within the boom piping
(seeFig. 4-85).

Fig.4-85

4-53
Operation
SYG5360THB 47

(2) Set the Remote/Local switch (a) on the

rear chassis switch panel to the LOCAL
position (turn rightward) and Pumping
Forward/Backward switch (b) to the
a
BACKWARD position to empty the
conveying piping as much as possible
(see Fig. 4-86 ). See “Main component
locations” on page 3-3.
b
NOTICE
Use only the rear chassis switch panel
when performing cleaning operations to
avoid damage to the remote controller.

Fig.4-86
When no additional concrete exits the
boom piping, move the Pumping Forward
/ Backward switch (b) to the central
position to stop the reverse pumping
operation.

(3) Lower the boom to access the end hose.

Then soak the sponge ball in water and
insert it into the end hose (see Fig. 4-87 ).

Fig.4-87

4-54
 Operation
SYG5360THB 47

(4) With the saturated sponge ball inserted

into the end hose, fully extend the boom
vertically once more to extract any
residual concrete from the boom
conveying piping.

Fig.4-8 8

(5) Set the Pumping Forward / Backward

switch (b) to the BACKWARD position
once more to begin reverse pumping flow,
draw the sponge ball through the
conveying piping and extract any residual
concrete from the boom conveying piping.

Residual concrete will empty into the

hopper and the sponge ball will follow
b
(see Fig. 4-8 9).

NOTE: As the sponge ball gets closer to the

hopper, use a wooden mallet to gently
tap on the piping to determine the
location of the sponge ball. A dull
sound indicates the conveying piping
is still full. A hollow, ringing sound Fig.4-89
indicates the piping is clear of
concrete and the ball is closer to the
end.

4-55
Operation
SYG5360THB 47

(6) When the sponge ball is close to the

a b a
elbow near the hopper, set the Pumping
Forward / Backward switch to the center
position to stop pumping action; then
remove the lock pins (a) and the elbow
(b) (seeFig. 4-90).

Fig.4-90

(7) Move the lever (a) at the bottom of the

hopper to open the hopper bottom door
and allow the hopper to drain (see Fig. 4-
91).

When the hopper is empty, retract the

boom for additional cleaning if necessary.
a
Retrieve the sponge ball and wash out the
remaining conveying piping by hand, then
reinstall the elbow and lock pins that
Fig.4-91
secure the elbow to the hopper.

NOTE: It may be necessary to repeat steps 4

for 10 several times to ensure that all
concrete residue is removed from the
boom piping.

NOTICE
Be sure all conveying piping sections are
clean and clear of any concrete residue
before performing the final wash of the
pump and exterior. Failure to do so may
result in equipment damage when the
pump is next used.

4-56
 Operation
SYG5360THB 47

(8) Move the lever (a) at the bottom of the

hopper to close the hopper bottom door
after all residual concrete has been
cleaned from the boom conveying piping,
then retract and lower the boom into place
for travel (see Fig. 4-92 ).

CAUTION a
If required, using compressed air to clean
the boom piping or a separate pipeline
should be done only under the Fig.4-92
supervision of a trained expert. All hoses
must be removed and a ball catcher must
be attached to the discharge end. Failure
to follow these procedures could result in
serious injury.

4.10.2 Hopper, delivery cylinder and S-tube

One possible method of cleaning the hopper,
the delivery cylinder and the S-valve is
described below.
NOTE: This machine is equipped with an
agitator safety cutout. As soon as you
open the grille, the agitator is halted
and the pressure is dumped from the
accumulator. This means that the S-
valve will no longer be able to switch
over. In addition, the delivery pistons
return to the end position and the
concrete pump halts. You must switch
the concrete pump off and back on
again to restart it.

WARNING
In no event should you insert the water
hose, the spray gun or other objects
through the grille into the hopper to spray
out the delivery cylinders. Such objects may
be trapped by the S-valve as it switches
over and become damaged. The objects
may be caused to fly about, thereby causing
an injury to you or other persons.

4-57
Operation
SYG5360THB 47

Drain off the leavings

● Place a sheet beneath the hopper.

● Open the hopper flap beneath the

hopper and let the leavings flow out of
the hopper.

● Switch the pump over to reverse

pumping.

● This pumps the leavings out of the

delivery cylinders into the hopper and
thus out of the hopper opening.
Fig.4-93

Spray out delivery cylinder

● Open the two cross pins on the hinged
elbow to take out the sponge ball, open
the hinged elbow.

● Allow the concrete pump to run slowly in

reverse.

● Spray the S-valve out carefully

downwards from the hinged elbow.
Slowly insert the hose up to the marking
as you do this. Fig.4-94

● Hold the water hose in this position,

introduced as far as the marking, for
several minutes, until only clean water
runs out.

This will flush out the two delivery

cylinders alternately.

● Carefully spray out the hopper using a

hose.

● Hose down all components that have

come into contact with concrete. Fig.4-95

4-58
 Operation
SYG5360THB 47

4.10.3Truck superstructure and post-

cleaning procedure

Once the delivery line, hopper, delivery

cylinders and S-tube have been washed out,
you must then rinse down thoroughly all parts
of the machine that have come into contact
with concrete. Concrete that is not washed off
immediately can attack the paint, especially if
aggressive concrete additives have been
used.

Use the built-in pressure washing system to

remove residual concrete from the exterior of
the boom parts, hopper and other areas after
the boom conveying piping is clear. Water for
the pressure-washing system is located in the
rear outriggers.

(1) Connect the water pump and water gun

with flush hose at the left side rear of the
truck below the chassis.

(2) Set switch (a) on the rear chassis switch

panel to the FLUSH position (turn
leftward), see Fig. 4-96 and the water will
spurt out from the water gun(see Fig.4-97 ). a

Fig.4-96

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Operation
SYG5360THB 47

NOTICE a b
Be careful not to let the pressure washing
system go dry during washing operations.
Damage to the pump may result.

(3) Use valve (a) to adjust the water

pressure making sure the pressure
reading remains within the green zone on
the gauge (b) (see Fig. 4-97).

NOTICE
Fig.4-97
Failure to remove all concrete residue may
result in damage to the machine,
especially during later operation.

a
(4) Set switch (a) on the rear chassis switch
panel to the STOP position (turn
middle ) in 30s after close the ball valve of
water gun ( see Fig. 4-98), or it will effect
the lifetime of the water pump.

(5) Use either of the following two methods

to prevent the possibility of freeze-up Fig.4-98
during cold weather:

● Drain any water residue from the rear a

outrigger tanks after all pressure-washing
operations are complete. Each rear
outrigger has a drain cock (a) on the
bottom center of the frame (see Fig.4-
99 ).

● Add non-toxic antifreeze to the water to

prevent freezing and reduce cold climate
freeze-up.

Fig.4-99

4-60
 Operation
SYG5360THB 47

4.11 Retracting the Boom &

Outriggers

WARNING
Clear the work area of all personnel and
equipment before proceeding. Never
retract the outriggers with the boom
raised. Always be sure the boom is fully
collapsed and secured in place before
retracting the outriggers. Loss of control
or a rollover may occur, resulting in
equipment damage, personal injury or
death.

(1) Ensure that all clean-up operations are

complete.
(2) Confirm that the parking brake on the
truck chassis is set to the PARK position
and that all wheels are chocked.
(3) Retract the boom to its fully collapsed
position and secure it in place. See
“Extending the Boom” on page 4-34 for
details.
(4) Standing clear of the outriggers, retract
each outrigger jack the same amount until
each outrigger is fully lowered, never
exceeding the 3° range shown on the
level indicator during the process. If
necessary, use a spotter to help guide
you.
(5) With all personnel still clear of the work
area, retract the front outriggers into the
truck chassis, then fold the rear outriggers
in place against the exterior of the truck
chassis. Fig.4-100

(6) Ensure that all outriggers are properly

locked and secured in place before you
travel.

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SYG5360THB 47

4.12 Driving, Towing and Loading

4.12.1Driving

General travel precautions

Before traveling, be sure the boom is properly
seated in its cradle, resting in the approved
location and locked in place.
Never travel with an incorrectly placed boom.
Loss of control may result (see Fig. 4-101).

Fig.4-101

Before traveling, ensure that all outriggers

and other equipment are secured in place
and all road safety devices are present and
secured (see Fig. 4-102 ).

Double-check these items before you travel

each time.

Fig.4-102

Always be aware of your travel height.

Bridges, power lines and overhanging objects
pose a hazard when traveling with your
equipment (see Fig. 4-103).

Check your equipment dimensions in the

specifications section of this manual and be
sure your route will accommodate the
equipment.
Fig.4-103

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 Operation
SYG5360THB 47

Always travel at a safe, controllable speed.

Avoid sudden stops or high speed turns
which could cause loss of control or a
possible rollover (see Fig. 4-104).

Keep in mind, the larger the equipment on

the truck body, the higher the center of
gravity.

Driving on slopes
Driving on slopes may pose a hazard. In Fig.4-104
order to prevent tipping or losing control of
the machine, it is important to follow some
basic simple rules.

Always drive straight up or straight down the

slope (see Fig. 4-105).

Keep the boom equipment fully retracted and

properly locked down.

You may have to back the machine up the

slope if the slope grade is too steep.

Never turn the ignition switch OFF when

driving on a slope.

Drive in low gear at a slow, controllable Fig.4-105

speed.

Never turn or maneuver the truck on a slope.

Due to the high center of gravity in the
concrete pumping equipment, loss of control,
tipping or a rollover may result (see Fig. 4-
106).

Fig.4-106

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SYG5360THB 47

Driving in reverse

Driving in reverse may pose several hazards.

Below is a list of some basic rules to follow
when driving in reverse:
● Be sure the area behind you is clear of
people or objects that might be in the
way.
● Sound the horn before moving your
machine to warn others in your area you
are moving.
● Designate a person to direct your
movements when backing in areas that
may pose a hazard or where there is
poor visibility.
● Do not rely totally on your truck's mirrors;
keep in mind there are blind spots when
using mirrors.
● Always use a spotter or guide when
backing this machine.

Parking and securing the equipment

When parking or securing your equipment, it

is important to follow several basic safety
rules. Keep in mind, you are responsible for
the security of your equipment when it is
parked or shut down. Below is a list of some
basic rules to follow when parking your
equipment:
● Never leave a machine running and
unattended, even for a moment.
● Always park the machine in a flat, stable
level location away from moving
equipment, pedestrians or traffic.
● Retract all boom work equipment down
onto its supports, neutralize all controls
and secure boom equipment in place.
Retract all outriggers and secure them in
place.
● Chock the wheels.
● Remove the ignition key and lock all
areas on the machine equipped with a
locking security feature.

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 Operation
SYG5360THB 47

● Be sure the parking brake is set to the

PARK position.
● Lock and secure access panels, truck
driver's cab, fuel and oil tanks to prevent
tampering while the equipment is
unattended.
● If necessary, cordon off the area with
security alerts to warn others of the
equipment's presence.

4.12.2Towing
● Observe the stipulations of manufacturer
of chassis when towing the Pump Truck
with other towing machines
● Do not use the pumping parts (for example,
hopper) to tow the Pump Truck, but only
the towing eye can be used to. The
towing eye is at the forepart of the Pump
Truck, and it is used to tow the Pump
Truck when the later is broken down.
● In addition, you may also use the
outrigger drag loop to tow the Pump
Truck. But the outriggers shall be
retracted and put at the axle of towing
direction. When you tow the Pump
Truck, if the outrigger swings out or is at
an angle to the towing direction, it may
cause a serious consequence (see Fig.
4-107).

Fig.4-107

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Operation
SYG5360THB 47

4.12.3Loading

● Only use the special lifting holes on the

outriggers and on the securing turret can
you lift the Pump Truck.

● Strictly perform operation specifications

and safety regulations of lifting rigs, tools
and other devices when lifting.

● Confirm the nameplate of the Pump

Truck to make sure the lifting capacity of
the lifting rig is more than 1.2 times of
weight of the Pump Truck.

● You may use traveling crane, hoist, front-

face lifter etc. to lift the Pump Truck. The
lifting tool may be the anti-cut nylon
sling, D-type shackle or arc-type shackle.
You may use shackles to connect the
lifting hole and the nylon sling, and lock
the lifting tool and adjust the length of
sling to guarantee the leveling of the
Pump Truck (see Fig. 4-108).

● Do not use sling to lift the Pump Truck

Fig.4-108
● Do not use at discretion a lifting point to
lift the Pump Truck (see Fig. 4-109).

Fig.4-109

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 Operation
SYG5360THB 47

4.13 Machine Decals

It is important that all safety, alert and
warning decals are in place, not damaged,
covered or removed. It is also important for
the operator and all personnel involved to be
aware of the decal content and locations on
the equipment.

NOTE:Our SANY dealer can supply you with

new replacement decals if the ones
o n the m achi ne ar e dama ge d or
missing. Never modify or change
existing decal information unless
authorized by your SANY distributor.

When replacing damaged or missing

decals, be sure they are placed in the
proper locations.

NOTE:Additional safety or warning decals

may be added to your machine if
necessary.

NOTE:The following images are typical

representations and will differ from
your machine, dependi ng on the
model in exact locations of placement,
etc.

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Operation
SYG5360THB 47

4.13.1 Locations of safety marks on

the complete vehicle

注意

WARNING

注意

1 2 3 4 5 6 7 8 9 12 13 14 10 11 17271920 2122 23 24 26 18

Fig.4-110

注意

WARNI NG

28 29 32 33 34 35 31 36 37 38 39 40 41 42 43 44 45

Fig.4-111

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 Operation
SYG5360THB 47

Cab and Fixed revolving tower viewed from the roof

警告
警告

53 54 55 56 57 58 16

Front of revolving tower revolving tower

49 50 51 52

48

One side of outrigger Mudguard of rear wheel

15 47

Rear outrigger
Cover plate of water tank
viewed from the roof

46
59 30 25

Fig.4-112

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Operation
SYG5360THB 47

4.13.2 Mark descriptions

Table 4-1

NO. Mark Callout NO. Mark Callout

1 Warning Mark for Hand Scald 23 Caution mark for safety helmet

2 Information Mark about Outrigger 24 Warning Mark for Outrigger Activation

Pressure

3 Mark on Outrigger Lock 25 Mark for Concrete Piston Operation

4 Mark for Warning of Anti-falling 26 Prohibition for Hopper

27 Warning Mark for Preventing Boom
5 Directive Mark 1 against Electric Shock
Mark for Caution to Splashing
6 Smoking Prohibition 28
Concrete
7 Warning mark for water pump usage 29 Protective Mark on Swing Mechanism
8 Identification Mark on Water Pump 30 Piston Protection Mark
Mark for Water Pump Drainage 31 Caution Mark for Delivery Pipe
9 Procedure Breakage

10 Mark for lubrication points 32 Warning Mark on Stair

11 Mark for left One-sided support 33 Mark about Agitating Oil Pressure

12 Mark for Warning of Electrical injury 34 Mark about Swing Valve System Oil
Pressure
13 Mark for Safety Guards 35 Mark about Main-system Oil Pressure

14 Mark for working on equipment 36 Caution scutcheon for protective the

pump pipe
15 Mark for Arrow 37 Instruction Mark for Outriggers
16 Mark for CCC Authentication 38 Mark for right One-sided support
17 Warning Mark for Accumulator 39 Information Mark about Placing Range

Instruction Mark for Boom Supporting 40 Instructions Mark for Use

18
Rack
19 Cautions Mark for boom usage 41 Mark for Warning of Breakage of Oil Tube

20 Warning Mark for Delivery tube 42 Directive Mark 2

43 Name Mark of Truck-mounted Concrete

21 Mark for Emission Pump

22 Mark of Grease Cup 44 Marks for Boom Operation

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 Operation
SYG5360THB 47

Table 4-1

NO. Mark Callout NO. Mark Callout

45 Mark for Greasing 55 Warning Mark for Stepping on the Covering Parts

46 Mark at Water Inlet 56 Mark for Benz Cigarette Lighter

47 Warning Mark for Hand Injury Due to 57 Mark for Speed Set and Brake
Tyre Pressing

48 Mark for Gear Oil Draining Outlet 58 Mark for Switchover of Driving and
Pumping
49 Mark 1 on Oil Tank 59 Mark for Checking Piston Head
50 Mark 2 on Oil Tank

51 Instruction Mark for Sealing Oil Tank

52 Mark of Exhaust Valve of Main Oil

Pump
53 Identification Mark of Hydraulic Oil Tank
54 Mark at Gear Oil Filler

4.13.3 Detailed explanation to safety

marks

(1) Warning Mark for Hand Scald (see Fig.

4-113)

● It warns personnel to beware of scald

caused by engine, oil tank or others.

Fig.4-113

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Operation
SYG5360THB 47

(2) Information Mark about Outrigger

Pressure (see Fig. 4-114)

● It gives the information about the loads

imposed by the working truck-mounted
concrete pump with the outriggers laid.

Fig.4-114

(3) Mark on Outrigger Lock (see Fig. 4-115)

● It indicates that the outrigger must be

unlocked before telescoping or extending
outriggers.

● It indicates that the outrigger must be

locked before moving vehicle.

Fig.4-115

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 Operation
SYG5360THB 47

(4) Mark for Warning of Anti-falling (see Fig.

4-116)

● It prohibits climbing the revolving tower

during pumping, or the person may slide
and fall off.

Fig.4-116

(5) Directive Mark 1 (see Fig. 4-118)

● It indicates the operation of the handle

below is for controlling the retraction or
extension of outriggers.

Fig.4-118

(6) Smoking Prohibition (see Fig. 4-119)

● It is used to prohibit smoking near the

machine.

Fig.4-119

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Operation
SYG5360THB 47

(7) Warning mark for water pump usage

(see Fig. 4-120)

● Before cleanout , open the water gun

before operating the motor of water pump
to prevent damage to the water pump.

● It is prohibited using alkaline detergent

instead of clean water.

● When the temperature is below 0°C,

drain the water residue after operations
are complete to prevent frost crack which
may happen to the water pump.

Fig.4-120

(8) Identification Mark on Water Pump (see

Fig. 4-121)

● It is used to identify Off/On position of

the water pump ball valve.

Fig.4-121

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 Operation
SYG5360THB 47

(9)Mark for Water Pump Drainage

Procedure (see Fig. 4-122).

● It introduce the water pump drainage

procedure.

● Note: the time of air pumping should not

exceed 30 second after no water
draining form water gun.

Fig.4-122

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 Operation
SYG5360THB 47

(10) Mark for lubrication points (see Fig. 4-

123)

● It indicates the points where should be

added lubrication on the boom and the
swing machine. And it also indicates the
regulation of adding lubrication.

Fig.4-123

(11) Mark for left One-sided support (see Fig.

4-124)

● When the truck-mounted pump is

supported only on its left side, i.e. with
only the front and rear outriggers spread
(fully and properly, as required), it is
forbidden to turn the boom to the place
as shadowed in the figure below. Its
placing scope is confined as regulated.

Fig.4-124

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 Operation
SYG5360THB 47

(12) Mark for Warning of Electrical injury (see

Fig. 4-125)

● It indicates that the personnel is

forbidden to operate this equipment
within 5 meters of power lines.

● Death or serious injury can result from

contacting with any part of this machine
or vehicle if they become electrically
charged.

Fig.4-125

(13) Mark for Safety Guards (see Fig. 4-126)

● Do not operate the equipment without all

safety guards in position. Standing near
the running boom or outriggers is
forbidden.

● Outriggers must be fully extended and

on a firm base before raising boom.
Keep the tires off the ground while
operate the boom.

Fig.4-126

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Operation
SYG5360THB 47

(14) Mark for working on equipment (see Fig.

4-127)

● It warns personnel to stop engine before

working on equipment in order to prevent
any injury on the vehicle.

● Manual controls on the machine must

not be used for standard operation, but
only in emergency and for assembling,
dismantling cleaning, maintenance and
servicing.

Fig.4-127

(15) Mark for Arrow (see Fig. 4-128)

● It requests personnel to extend or retract

th e f our ou t r i gg er s t o t he r e qu i r e d
positions, setting where the arrows of
outriggers and lug, and the arrows of
front outrigger boom and front outrigger
boom well aligned.

Fig.4-128

(16)Mark for CCC Authentication

● It is used for authentication. Abbreviated

here

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 Operation
SYG5360THB 47

(17) Warning Mark for Accumulator (see Fig.

4-129)

● It indicates this accumulator can only be

inflated with nitrogen rather than any
other gas and the nitrogen inflation
pressure should range from 7 MPa to 8
MPa.

(18)Instruction Mark for Boom Supporting

Rack (see Fig. 4-130) Fig.4-129

● After using period of time, the last

section of boom would have natural
lateral movement to the boom supporting
rack. Please adjust the lateral position of
the boom supporting rack in time to
ensure the boom entirely contacting with
the supporting rack.

(19) Caution mark for boom usage

(see Fig. 4-131)
Fig.4-130
● It is shown to avoid the truck-mounted
concrete pump being used to lift loads
and prohibit persons standing below the
boom.

● It requests operators to stand outside the

range of boom to control the end hose. It
is forbidden to stand under the boom, or
else, the casualty may occur due to the
falling of parts.
Fig.4-131

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 Operation
SYG5360THB 47

(20) Warning Mark for Delivery tube (see Fig.

4-132)

● It warns that concrete delivery pipe is not

allowed to be mounted on the end hose.

Fig.4-132

(21) Mark about Emission (see Fig. 4-133)

● It indicates that cement dust is toxic, and

the lung protection should be used when
exposed to the dust.

Fig.4-133

(22) Mark of Grease Cup (see Fig. 4-134)

● It reminds personnel to add butter full

every week working hours.

Fig.4-134

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 Operation
SYG5360THB 47

(23) Caution mark for safety helmet (see Fig.

4-135)

● It is used to remind personnel to wear

safety helmet.

Fig.4-135

(24) Warning Mark for Outrigger Activation

(see Fig. 4-136)

● It warns the personnel to clear area

when activating outriggers and take
caution to crushing hazard.

Fig.4-136

(25)Mark for Concrete Piston Operation (see

Fig. 4-137).

● It warns to follow the operating

procedure when changing concrete
piston, otherwise it will cause physical
injury.

● It indicates the operating procedure of

changing concrete piston.

Fig.4-137

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Operation
SYG5360THB 47

(26) Prohibition for Hopper (see Fig. 4-138)

● It is used to prohibit personnel from

opening the screen during pumping,
there is a risk of injury during concrete
agitation.

● It is used to prevent personnel from

stepping on the hopper.

Fig.4-138

(27) Warning Mark for Preventing Boom

against Electric Shock (see Fig. 4-139)

● It requests personnel to make sure the

truck-mounted concrete pump is away
from electric wires. When passing
through a high-voltage wire area or
working nearby such area, the machine
should keep a certain distance away
Fig.4-139
from the high-voltage wire.

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 Operation
SYG5360THB 47

(28)Mark for Caution to Splashing Concrete

(see Fig. 4-140)

● It asks personnel to beware of splashing

concrete during pumping.

Fig.4-140

(29) Protective Mark on Swing Mechanism

(see Fig. 4-141)

● It prohibits personnel to touch the swing

mechanism when pumping.

Fig.4-141

(30) Piston protection mark (see Fig. 4-142)

● It prohibits personnel to touch the

moving piston.

Fig.4-142

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Operation
SYG5360THB 47

(31) Caution Mark for Delivery Pipe Breakage

(see Fig. 4-143)

● It instructs personnel to only use pipes

bearable for the max. delivery pressure
of the concrete pump, there is a risk of
injury from cracked pipes under a
pressure too high.
Fig.4-143

(32) Warning Mark on Stair (see Fig. 4-144)

● It asks personnel to stay off machine

while it is in operation.

Fig.4-144

(33) Mark about Agitating Oil Pressure (see

Fig. 4-145)

● It indicates the data displayed by

corresponding gauge is of agitating oil
pressure. Fig.4-145

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 Operation
SYG5360THB 47

(34) Mark about Swing Valve System Oil

Pressure (see Fig. 4-146)

● It indicates the data displayed by

corresponding gauge is of change-over
oil pressure.
Fig.4-146

(35) Mark about Main-system Oil Pressure

(see Fig. 4-147)

● It indicates the data displayed by

corresponding gauge is of main-system
oil pressure. Fig.4-147

(36) Mark for protective the pump pipe (see

Fig. 4-148)

● It is forbidden to use the hard objects (such

as stone,hammer,levering tools,etc.) knock
on the surface of the delivery pipe.

● If there is a blockage, it is not recommen-

ded to dismantle the front pipe to remove
the blockage with quite some force.If must
adopt this method,please install the block-
age protection ring.(see Fig. 8-15)

Fig.4-148

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 Operation
SYG5360THB 47

(37) Instruction Mark for Outriggers (see Fig.

4-149)

● It suggests that outrigger should be fully

extended when the boom will be used,
and the forces transmitted to the
outriggers should be absorbed by the
outrigger reinforcements.

● Never extend the boom over retracted

outriggers.

Fig.4-149

(38) Mark for right One-sided support (see

Fig. 4-150)

● When the truck-mounted pump is

supported only on its right side, i.e. with
only the front and rear outriggers spread
(fully and properly, as required), it is
forbidden to turn the boom to the place
as shadowed in the figure below. Its
placing scope is confined as regulated.

-
Fig.4-150

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 Operation
SYG5360THB 47

(39) Information Mark about Placing Range

(see Fig. 4-151)

● It shows the working range of the truck-

mounted concrete pump, which should
not be changed by any means.

(40) Instructions Mark for Use (see Fig. 4-152)

● It provides instructions for general use

and warns personnel to comply with
what indicated in the manual.
Fig.4-151

Fig.4-152

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Operation
SYG5360THB 47

(41)Mark for Warning of Breakage of Oil

Tube (see Fig. 4-153)

● It warns personnel not to touch the

leaking hydraulic oil. Get medical
examination immediately if oil splashing
on skin.

Fig.4-153

(42) Directive Mark 2 (see Fig. 4-154)

● It indicates the operation of the handle

below is for controlling the retraction or
extension of outriggers.

Fig.4-154

(43) Name Mark of Truck-mounted Concrete

Pump (see Fig. 4-155)

● It shows the basic technical parameters

of the truck-mounted concrete pump,
including model , product brand ,
max. theoretical output, max. theoretical
output pressure, max. vertical reach,
3

max. horizontal reach, engine model,

max. net power of engine, gross mass
kerb mass , overall dimension , date of
production and number.

Fig.4-155

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 Operation
SYG5360THB 47

(44) Marks for Boom Operation (see Fig. 4-

156)

● The marks indicate the control actions of

pump boom and turntable.

Fig.4-156

(45)Mark for Greasing (see Fig. 4-157).

● It indicates to add butter regularly on the

corresponding position on revolving
tower.

Fig.4-157

(46) Mark at Water Inlet (see Fig. 4-158)

● It indicates in the corresponding position

is a water inlet.

Fig.4-158

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 Operation
SYG5360THB 47

(47 )Warning Mark for Hand Injury Due to

Tyre Pressing (see Fig. 4-159)

● It calls attention to potential hand injury

caused by tyre crush.

Fig.4-159

(48)Mark for Gear Oil Draining Outlet (see

Fig. 4-160).

● It indicate the location of gear oil draining

outlet.

(49) Mark 1 on Oil Tank (see Fig. 4-161) Fig.4-160

● It gives the lowest oil level allowable
when the boom is extended. If oil falls
below this oil level, stop operating the
boom, and fill oil above this oil level
before extending the boom.

Fig.4-161

(50) Mark 2 on Oil Tank (see Fig. 4-162)

● It gives the lowest allowable oil level

when the truck-mounted concrete pump
is pumping. If oil falls below this oil level,
stop operating the boom, and fill oil
above this oil level before pumping
Fig.4-162
concrete.

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 Operation
SYG5360THB 47

(51)Instruction Mark for Sealing Oil Tank (see

Fig. 4-163)

● It instructs how to seal the hydraulic oil

during overhauling the truck-mounted
concrete pump and how to keep it clean.

Fig.4-163

(52) Mark of Exhaust Valve of Main Oil Pump

(see Fig. 4-164)

● It indicates the “OFF” and “ON” position

of the exhaust valve of main oil pump.

● The exhaust valve of main oil pump

should be remained shut off, and only
can be opened during main oil pump
exhausting.
Fig.4-164

(53) Mark for Hydraulic Oil Filler (see Fig. 4-

165)

● It indicates the corresponding part is a

hydraulic filler.

Fig.4-165

(54) Mark at Gear Oil Filler (see Fig. 4-166)

● It indicates the corresponding part is a

gear oil filler.

Fig.4-166
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SYG5360THB 47

(55)Warning Mark for Stepping on the

Covering Parts (see Fig. 4-167).

● Do not step on the covering parts of

revolving tower.

Fig.4-167

(56) Mark for Benz Cigatette Lighter (see Fig.

4-168)

● It indicates the special interface for

cigarette lighter should not be connected
with other electric equipment. Fig.4-168

(57) Mark for Speed Set and Brake (see Fig.

4-169)

● The symbols indicate setting on 14th

speed at oil pump place and stopping
and parking at driving position.

Fig.4-169

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 Operation
SYG5360THB 47

(58)Mark for Switchover of Driving and

Pumping (see Fig. 4-170 )

● It requests personnel to stop engine

before switch over of driving and
pumping.

Fig.4-170

(59) Mark for Checking Piston Head (see Fig.

4-171)

● It reminds personnel to check piston

head before pumping each time and
when water is getting turbid.

Fig.4-171

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Operation
SYG5360THB 47

E
G
PA
K
AN
BL

4-94
 Troubleshooting
SYG5360THB 47

Troubleshooting
5 Troubleshooting
5.1 General .............................................................................................................5-3
5.2 Troubleshooting Mechanical System ................................................................5-3
5.3 Troubleshooting Hydraulic System ...................................................................5-6
5.4 Troubleshooting Lubrication System ................................................................5-10
5.5 Troubleshooting Electric System ......................................................................5-11

5-1
Troubleshooting
SYG5360THB 47

WARNING
Always read the Safety section of this
manual before attempting to operate this
equipment. Failure to do this could result
in machine damage, personnel injury or
death.

5-2
 Troubleshooting
SYG5360THB 47

5 TROUBLESHOOTING
5.1 General
SANY truck-mounted concrete pumps are
designed for continuous pumping and
dispensing of liquid concrete to locations
within reach of the placement boom
configured to the pump at various elevations,
both above and below the location of the
pump itself.

5.2 Troubleshooting Mechanical System

No. Malfunction Cause Troubleshooting

Check lubrication at the

connection of axis pin and
Insufficient lubrication at the bearing. If there is slight abrasion,
connection of axis pin and bearing coat lubricating oil; if there is
Abnormal sound of serious abrasion, replace the axis
1
boom and turntable pin or bearing.

Abrasion between end faces of

Replace it with a delivery pipe with
delivery pipe after the boom is
standard length.
properly extended or retracted.

Abnormal sound Abrasion of bimetallic bearing Replace the bearing or add

during extension/ shell of contact roller assembly lubricating grease.
2
retraction of front Big sliding resistance between Add lubricating grease between
outriggers telescopic booms telescopic booms.

Improper extension of Incorrect position of drive chain

Re-install the drive chain.
front outriggers (the joint in the chain drive system
3
outriggers are driven
by chain) Powerless drive motor Replace the drive motor.

Check, clean and unblock the

Insufficient lubrication
lubricating pipeline and holes.

The concrete piston is worn out at Adjust the axiality of oil cylinder
one side. and delivery cylinder.
Short service life of Polluted water in the washing Check the washing room
4
piston room as a result of not replacing frequently and fill clean water
the water in time. timely.

Corroded concrete seal body

Replace it with a new concrete
resulting in pyrohydrolysis of
seal body.
piston

5-3
Troubleshooting
SYG5360THB 47

No. Malfunction Cause Troubleshooting

The cutting ring itself has quality

Replace it with a new cutting ring.
problem.

Quick abrasion of Serious abrasion of the spectacle Replace it with a new spectacle
5
cutting ring wear plate wear plate.

The cutting ring is not of good Replace the cutting ring or

assembly quality. spectacle wear plate.

Abrasion of spectacle wear plate Replace it with a new spectacle

itself wear plate.

Replace the transitional bushing or

Too long transitional bushing
grind it on-site.

Too big processed bottom

Distortion of spectacle diameter of spectacle wear plate
6 thread, resulting in distortion of Replace it with a new spectacle
wear plate
spectacle wear plate due to loose wear plate.
threaded connection when
ramming material

Grind the transitional bushing on-

Improperly assembled hopper and
site or replace the spectacle wear
transitional bushing
plate.

Improper reversing of hydraulic Ask hydraulic service engineer for

valve onsite adjustment.
Disalignment between
Serious abrasion of the small shaft
7 cutting ring and Replace the S-valve.
spline teeth of S-valve
spectacle wear plate
Serious abrasion of lower ball bearing Replace the lower ball bearing
seat of swing cylinder mechanism seat of swing cylinder.

The slump or formula of concrete

Adjust the slump or formula of
is in no conformity with the
concrete
requirement.

Large clearance between the Check the clearance between the

spectacle wear plate and cutting spectacle wear plate and cutting
ring resulting in large pressure ring, if it is too large, screw down
loss the locking nut of S-valve.

Conduct reverse pumping and

then forward pumping to get it
8 Tube blocked Concrete solidified in the S-valve
through. If it doesn’t work, knock
or delivery pipe
and get it through after finding out
the blockage location.

Insufficient pressure or constant

Ask electrical service engineer for
power in the main system of truck-
onsite adjustment.
mounted concrete pump

No lubrication of pipeline by using

It is necessary to lubricate the
water or mortar before concrete
pipeline before concrete pumping.
pumping

5-4
 Troubleshooting
SYG5360THB 47

No. Malfunction Cause Troubleshooting

Check the piston seal of the

Malfunction of cylinder and
cylinder for damage. If any,
pneumatic change valve
replace the seal ring.

Take off the electrical plug of the

pneumatic change valve and
conduct reversing by hand. If the
Difficult switchover of
9 result shows that it is normal, then
the transfer case Malfunction of electrical appliance
it proves that the electrical
appliance has malfunction. Ask
electrical service engineer for
onsite troubleshooting.

Increase the pressure of chassis

Insufficient pressure of chassis
to over 700 kPa before switchover.

Big tolerance of dynamic balance

of the transmission shaft and big Replace the transmission shaft
radial run-out

Damaged gear in the transfer case Replace the gear.

Severe jutter and large
10 Damaged bearing in the transfer
noise of transfer case Replace the bearing.
case

Damaged spline of connecting Replace the connecting disc

disc spline.

Damaged shock pad Replace the shock pad.

Big tolerance of dynamic balance

Huge vibration of of the transmission shaft and big Replace the transmission shaft.
11 radial run-out
complete machine
Damaged universal joint Replace the universal joint.

5-5
Troubleshooting
SYG5360THB 47

5.3 Troubleshooting Hydraulic System

No. Malfunction Cause Troubleshooting

Valve core of insertion valve of

Clean or replace the insertion
main overflow valve jammed at
valve of main overflow valve.
upper location

The main system without Abrasion of valve core of main Replace the insertion valve of
pressure or with the overflow valve main overflow valve.
1
pressure not up to the Abrasion of valve core of DT1 Replace DT1 electromagnetic
setting 31.5MPa electromagnetic change valve change valve.

Loose plug of proportional valve

Screw down the plug or replace
of main oil pump or abrasion of
the constant pressure valve.
constant pressure valve core

The control electromagnets Check circuit or replace

DT2~DT5 not electrified or get DT2~DT5 control
blocked electromagnets.
No reversing of the
pumping system (with The main four-way valve or Clean or replace the main four-
2
normal pressure of main swing cylinder four-way valve way valve or swing cylinder four-
system) blocked or damaged way valve.

Seizure of small oil controlled Clean the small oil controlled

valve valve.

Abrasion between the cones of

valve cores of insertion valves
22.1 and 22.2 leads to hydraulic
oil of main system leaking into Replace insertion valves 22.1
rodless connecting chamber and 22.2.
from cone of valve core, which
When pumping at low results in increase of hydraulic oil
pressure, concrete of rodless connecting chamber.
piston reverses more
and more frequently Abrasion between valve core
3
before backing to the set and valve sleeve for insertion
stroke closed to the valves 22.10 and 22.11 leads to Replace insertion valves 22.10
washing room of delivery hydraulic oil of accumulator and 22.11.
cylinder leaking into rodless connecting
chamber at idle speed.

Damage of piston seal that has

Replace the sealing element of
retracted out of oil cylinder leads
piston that has retracted out of oil
to hydraulic oil leaking into
cylinder.
rodless connecting chamber.

5-6
 Troubleshooting
SYG5360THB 47

No. Malfunction Cause Troubleshooting

Abrasion between valve core

and valve sleeve of insertion
valve of rod-side connecting
chamber of main oil cylinder
(insertion valve 22.9) leads to
Replace insertion valve 22.9.
hydraulic oil of rod-side
When pumping at high connecting chamber leaking into
pressure, concrete oil tank, which results in
piston steers more and diminishment of hydraulic oil of
4 more frequently before rod-side connecting chamber.
backing to the set stroke
closed to the washing Blockage of damping holes of
room of delivery cylinder cover plates of high pressure
change insertion valves
Check or replace the damping
22.1~22.4 leads to abnormal oil-
holes of cover plates of insertion
adding during reversing of main
valves 22.1~22.4.
oil cylinder, which results in
diminishment of hydraulic oil of
rod-side connecting chamber.

Insufficient nitrogen pressure of

Check it and fill nitrogen.
accumulator

The plug of the main four-way

valve or swing cylinder four-way Check it and mount the plug.
valve broken off

The shuttle valve in the main oil

Check and clean or replace the
pump blocked, resulting in the
shuttle valve in the main oil
Weak reversing of the pressure in the accumulator fled
5 pump.
swing cylinder to the main system

The one-way valve at the oil inlet

Check and clean or replace the
of the accumulator blocked,
one-way valve at the oil inlet of
resulting in no pressure
the accumulator.
preservation

Damaged dual-gear pump Replace the dual-gear pump.

Internal leakage of swing Replace the swing cylinder seal

cylinder or the swing cylinder.

Blockage of the damping hole in

Get it through with airflow.
the oil-drain valve
Random reversing of the
6 The valve core of small oil Check or replace the small oil
pumping system
controlled valve of the swing controlled valve of the swing
cylinder blocked cylinder.

The main overflow valve with

Replace the main overflow valve.
overflow during pumping
The hydraulic oil
7 temperature rising No rotation of the air-cooled
abnormally motor or with low rotation speed
Replace the air-cooled motor.
due to decline of volume
efficiency

5-7
Troubleshooting
SYG5360THB 47

No. Malfunction Cause Troubleshooting

The slewing limit Check or replace the slewing

electromagnetic valve coil limit electromagnetic valve coil or
The boom only rotates burned out or the core blocked the whole electromagnetic valve.
8
leftward or rightward
The slewing balance valve core Replace the slewing balance
blocked or damaged valve.

Check the lines, if it is the

harness causes the problem,
replace the harness; if it is the
The by-pass valve of the multi-
blocked valve core, then
way valve not electrified
dismount it for cleaning or
replace the electromagnetic
valve.

The three-way flow valve of the

Clean or replace the three-way
multi-way valve blocked or the
flow valve.
damping adaptor broken off
No action of boom and
9 For the truck-mounted concrete
outrigger
pump with boom switchover Check and replace the boom
valve, possibly it is the coil switchover valve coil or the
burned out or the valve core whole electromagnetic valve.
blocked

For the truck-mounted concrete

pump with variable boom pump,
Check, clean and replace the
possibly it is the load sensitive
control valve of the variable
valve, constant-pressure valve or
boom pump.
constant-power valve of the
boom pump blocked

Check the lines, if it is the

The reversing slide valve sheet harness causes the problem,
of the multi-way valve with replace the harness; if it is the
electrical malfunction, and the blocked valve core, then
The boom cannot act or correspondent electrical dismount it for cleaning or
rotate, or one outrigger proportional valve not electrified replace the electromagnetic
10
cannot move, while the valve.
remaining work normally
The two-way flow valve of the
reversing slide valve sheet of the Check and replace the two-way
multi-way valve blocked or its flow valve.
damping adaptor broke off

The reversing slide valve sheet

Replace the single sheet valve.
of the multi-way valve damaged

The boom extends or The pressure of the boom Lower the pressure of the boom
11
retracts slowly balance valve is set too high. balance valve.

The damping hole of the boom

Clean and get it through.
balance valve blocked

5-8
 Troubleshooting
SYG5360THB 47

No. Malfunction Cause Troubleshooting

The pressure of the boom

Increase the pressure of the
multiway valve main overflow
boom multi-way valve main
valve is set too low, resulting in
overflow valve.
overflow when the boom acts

Check and replace the three-way

The hydraulic oil flow valve (the method: check
temperature abnormally the unloading pressure when the
12 rises, although the boom is not acting under local
pumping and air cooling control state. If there is no
systems work normally. Abrasion of the three-way flow indication basically on the
valve of boom multi-way valve pressure gauge, then the three-
way flow valve is in normal
conditions; if the indication on
the pressure gauge is 3 MPa or
above, then the three-way flow
valve is in abnormal conditions.)

5-9
Troubleshooting
SYG5360THB 47

5.4 Troubleshooting Lubrication System

No. Malfunction Cause Troubleshooting

Check the pressure gauge of

lubricating grease pump. If the
pressure is abnormal (over 10
Pipeline malfunction
MPa), it indicates pipeline
malfunction. Clean the pipeline
for troubleshooting.

In case of seizure, clean and

Blockage of lubricating grease
unblock the lubricating grease
distribution valve
distribution valve.

Check the pressure gauge of

lubricating grease pump. If the
Malfunction of hydraulic
hand fails to move, remove the
synchronizing lubrication pump
lubricating grease pump plunger
and clean it with kerosene.
The lubricating grease
Check the pressure gauge of Check the pressure gauge of
distribution valve doesn’t
lubricating grease pump. If the lubricating grease pump. If the
1 act and each part is
hand fails to move, remove the hand fails to move, remove the
subject to poor
lubricating grease pump plunger lubricating grease pump plunger
lubrication.
and clean it with kerosene. and clean it with kerosene.

Remove the lubricating grease

pipe at each lubricating point on
Blockage of one or more
the seats of big and small
lubricating points on the seats of
bearing and mixing bearing in
big and small bearings and
turn to locate the malfunction.
mixing bearing
Clean and unblock the oil duct
and pipeline.

Blockage or damage of sheet oil Clean or replace the sheet oil

separator separator; clean the grease filter.

Unclear lubricating grease or Clean the lubricating grease

foreign substances in the pump, pump, pipeline and valve;
leading to blockage of pipeline replace the lubricating grease
and valve with new lubricating grease.

5-10
 Troubleshooting
SYG5360THB 47

5.5 Troubleshooting Electric System

No. Malfunction Cause Troubleshooting

Poor contact of signal wire Re-lay wires.

Check and treat it in line with the

Low base resistance
drawings.
The display screen with
1
abnormal speed The dynatron works abnormally Replace the dynatron.

Poor contact of ground wire Re-lay the wires.

Malfunction of speed sensor Replace the sensor.

Improper connection of display Re-connect the plug and screw

screen and SYMC down the screw
The display screen not
2 indicating the relevant Damage of display screen Replace the display screen.
information
Re-connect the power line of
Poor contact of power line
display.

The emergency stopping button Check and release the

pressed emergency stopping button.

Poor contact of intermediate

The display screen relay KA18, and the normally
Check the relay and its wiring.
3 indicating “Emergency closed contact not really
stop” disconnected

Check the power of remote

Malfunction of remote controller controller and replace the remote
controller.

The transfer case is not at the Switch the transfer case to oil
The display screen position of oil pump actually. pump position.
4 indicating idle speed but Adjust the installation position of
no response after acting Malfunction of proximity switch of
proximity switch or replace the
transfer case
proximity switch.

Adjust the installation position of

The display screen Malfunction of proximity switch of
proximity switch or replace the
5 indicating “Incorrect turntable encoder
proximity switch.
rotation angle”
Incorrect zero Reset the zero.

5-11
Troubleshooting
SYG5360THB 47

No. Malfunction Cause Troubleshooting

Check the toggle switch and

No signal detected by SYMC
wiring.

The transfer case not at the Switch the transfer case to oil
position of oil pump pump position.

Adjust the installation position of

Malfunction of proximity switch of
proximity switch or replace the
transfer case
proximity switch.

No startup of the engine or the Start the engine or check the

engine with malfunction in speed speed sensor and the relevant
measurement wiring.
After pressing down the
forward/reverse pumping Wrong gear engagement Engage a correct gear.
6
button, the engine
Check the emergency stopping
cannot accelerate. Under “Emergency stop” state
switch and wiring.

Poor contact of connectors on

the vehicle control modules Check, treat the wiring or replace
(applicable to BENZ chassis and it.
VOLVO chassis)

Check if the voltage value is

within the normal range (when
Abnormal output signal of circuit
idling, the voltage for wire 82 to
board (applicable to ISUZU
80 is 0.8V, and when
chassis)
accelerating, it will rise to 3V
slowly).

Check if the voltage value is

within the normal range (when
The speed doesn’t rise to the idling, the voltage for wire 82 to
specified value. 80 is 0.8V, and when
accelerating, it will rise to 3V
After pressing down the slowly).
7 forward/reverse pumping
button, no pumping No output from SYMC Check and replace the SYMC

Central distribution box relay

Check the relay and its wiring.
burned out

Fuse of central distribution box

Replace the fuse or reset it.
damaged or ejected

The proximity switch at the

location of oil pump not well Adjust the proximity switch.
The odometer with installed
8
indication when pumping
Poor contact of intermediate
Check or replace the relay.
relay tripping the odometer

5-12
 Troubleshooting
SYG5360THB 47

No. Malfunction Cause Troubleshooting

No action of cooling Replace the temperature sensor

Temperature sensor damaged
blower or display screen or relay wires.
9
indicating “Too high/low Malfunction of air-cooled
temperature” Clean or replace it.
electromagnetic valve

No water in the water tank or Fill water into water tank or

damage of float switch replace the float switch.
10 Water pump not working
No input signal of water pump
Replace the wiring.
control

Q0.0 damaged Replace the SYMC.

The output cannot be Malfunction of electromagnet Replace the electromagnet.

11
adjusted when pumping
The differential pressure sensor Replace the differential pressure
with signal all the time sensor.

No reversing for the

truck-mounted concrete
pump provided with Damage of SQ1-SQ4 proximity Replace the proximity switch or
12
electric control reversing switches or malfunction of wiring re-lay wires.
due to pressure
suppression

5-13
Troubleshooting
SYG5360THB 47

E
G
PA
K
AN
BL

5-14
 Maintenance
SYG5360THB 47

Maintenance
6 Maintenance
6.1 Routine Maintenance & Mandatory Overhaul ...................................................6-3
6.2 General Tightening Torques .............................................................................6-8
6.3 Lubrication ........................................................................................................6-11
6.4 Visual Checks ...................................................................................................6-20
6.5 Pumping System ...............................................................................................6-25
6.6 Slewing Mechanism ..........................................................................................6-62
6.7 Transfer Case and Drive Shaft .........................................................................6-67
6.8 Hydraulic System ..............................................................................................6-71
6.9 Accumulator ......................................................................................................6-75
6.10 Oil Filter ...........................................................................................................6-79
6.11 Air Filter ..........................................................................................................6-81
6.12 Hoses ...............................................................................................................6-82
6.13 Electrical System .............................................................................................6-84

6-1
Maintenance
SYG5360THB 47

WARNING
Always read the Safety section of this
manual before attempting to operate this
equipment. Failure to do this could result
in machine damage, personnel injury or
death.

6-2
 Maintenance
SYG5360THB 47

6 MAINTENANCE

In order to guarantee normal operation of the

machine and avoid malfunctions affecting
construction, all inspection and maintenance
work should be earnestly carried out. Only in
this way, can the failure rate of product be
decreased, the service life of the machine be
prolonged, and the repair cost be reduced,
thus greater profits be achieved.

Fill the inspection card for future reference,

when carrying out maintenance work.

6.1 Routine Maintenance &

Mandatory Overhaul
The routine maintenance and inspection is of
great importance for the normal operation of
the pump. Follow the Safety Inspection
Intervals (Table. 6-1), Maintenance Intervals
(Table. 6-2) and Mandatory Overhaul (Table.
6-3) during the maintenance process.

WARNING
You must follow the Safety Inspection
Intervals (Table 6-1), Maintenance Intervals
(Table 6-2) and Mandatory Overhaul (Table
6-3) during the maintenance process. The
Manufacturer accepts no liability for any
safety accident arising from the failure to
perform due mandatory overhaul.

6-3
Maintenance
SYG5360THB 47

Table 6-1 Safety Inspection Intervals

Every … Hours of Operation

Assembly Action
Daily 50 100 250 500 1000

Check outrigger for stuck rotation and abnormal

●
noise

Check outrigger chain or its protection function ●

Check limiting function of rotary encoder ●

Check slewing bearing bolts for looseness and

●
break

Revolving Check slewing mechanism idler pin-shaft for

●
tower axial play and abnormal noise

Check spread cylinder, telescopic cylinder

●
connecting axis pin for looseness and break off

Check outrigger cylinder bolts for looseness ●

Check slewing head, fixed revolving tower,

●
outrigger for abnormal deformation and break

Check main shaft of reducer for axial play ●

Check boom for stuck slewing and abnormal

●
noise

Check boom for interference ●

Check fixed bolt for conveying pipe end hose

●
clamp and safety chain for looseness
Boom
Check bolts at boom end for looseness ●

Check boom axis pin for wear and tear ●

Check delivery pipe for thickness ●

Check boom, linkage for abnormal deformation

●
and break

Check main system pressure (28~32MPa) ●

Hydraulic
Check switching pressure (8~16MPa) ●
system
Check agitator overflowing pressure (12Mpa) ●

Functional check on E-STOP button,

●
Electrical warning lamp and horn
system Check boom limit switch, outrigger limit switch
●
and hopper grill limit switch for abnormity

6-4
 Maintenance
SYG5360THB 47

Table 6-2 Maintenance Intervals

Every … Hours of Operation

Assembly Action
Daily 50 100 250 500 1000
In accordance with the maintenance
Chassis
specifications specified by chassis manufacturer
Drive shaft Check bolts for looseness ●
Check transfer switch for abnormity ●
Transfer
Check oil level ●
case
Change gear oil ●first ●
Clean out sundries for rotary bearing and gear surface,
Revolving ●
and baste lubricating grease
tower
Change reducer gear oil ●first ●
Wear check of concrete piston and dustproof ring ●
Check water tank for water level, mortar leakage,
hardness eyewinker, excessive hydraulic oil in ●
water
Check agitator motor for oil leakage, agitator
shaft for mortar leakage and agitator paddle for ●
wear
Pumping Check swing position for swing cylinder ●
system Wear check of spectacle wear plate and cutting
●
ring
Check clearance between cutting ring and end
face ●
of S-valve (≤ 4mm)
Check delivery cylinder for abnormal wear ●
Wear check of transitional bushing (not lower
●
than delivery cylinder)
Check grease level in lubricating grease pump ●
Check oil distributor and lubrication point for
●
abnormity
Check delivery cylinder lubrication for abnormity ●
●or
Fill grease to boom shaft
weekly
Lubrication Fill grease to slewing bearing? pinion and slewing ●or
system mechanism idler axis pin weekly
Fill grease to outrigger shaft, outrigger bearing ●or
roller, outrigger lock, oil cylinder joint bearing weekly
Fill grease to 66/72M front outrigger linkage ●or
mechanism connecting axis pin and joint bearing weekly
Fill grease to extension part of drive shaft, ●or
and cross bearing weekly

6-5
Maintenance
SYG5360THB 47

Table 6-2 Maintenance Intervals

Every … Hours of Operation

Assembly Action
Daily 50 100 250 500 1000
Check hydraulic oil level, oiliness ●
Check indicator on hydraulic oil filter ●
Check hydraulic elements for oil leakage ●
Drain off accumulated water in water pump ●
Drain off condensed water in hydraulic oil tank ●
Triple rubber hose ●
Check and clean radiator blade ●
Clean filter of water pump ●
In case of Shenlong water pump, check water
●
Hydraulic level in pump
system In case of Shenlong water pump, change water
●
pump oil
●or
red
Change hydraulic oil filter core
indica
tor
Clean oil suction filter core (new oil tank) ●
Change oil suction filter core (new oil tank) ●
Change oil return filter core (new oil tank) ●first ●
Change all hydraulic oil ●first ●
Clean oil tank ●
keep transmitter panel clean and check
●
transmitter rocker casing for damage
Check such threaded connectors as toggle switch
for looseness ●
Check such connectors as fuse and relay for
●
Electrical looseness
system
Check water tightness of small control box,
maintenance control box and outrigger control box ●
Check wiring for damage ●
Check mechanical encoder sensor mounting bolts
●
for looseness
Check electromagnetic valve for abnormity ●
Check the socket of oil cylinder proximity switch ●
for looseness
Check the socket of boom obliquity sensor
●
for looseness

6-6
 Maintenance
SYG5360THB 47

Table 6-3 Mandatory Overhaul

Every … Hours of Operation
Assembly Action
1 year 2 years 5 years
In accordance with the maintenance
Chassis specifications specified by chassis
manufacturer
Check gear clearance of slewing
●
mechanism
Check pre-tightening torque of slewing
●
bearing bolts
Revolving
tower Overhaul of rotary reducer, change
●
bearing of output shaft and sealing parts
Defect detect or overhaul of welds on
turntable, fixed revolving tower and ●
outrigger
Defect detect or overhaul of boom, linkage
Boom ●
and axis pin
Pumping Replace seals of main oil cylinder ●
mechanism
Check and adjust balance valve, multi-way
●
valve pressure
Check and adjust main oil pump, boom
●
pump pressure

Hydraulic Check accumulator pressure and charge

●
system nitrogen
Replace seals of all oil cylinders (main oil
●
cylinder excluded)
Replace all hoses ●
Replace all O-rings ●
Electrical
Check wiring ●
system

Replace all harness of complete vehicle ●

NOTE: The actions in Mandatory Overhaul

shall be carried out by professional
maintenance personnel in workshops or 6S
shops authorized by SANY Heavy Industry
Co., Ltd.

6-7
Maintenance
SYG5360THB 47

6.2 General Tightening Torques

NOTICE
Looseness or breakage could occur if
fasteners, hose or line couplings are not
torqued to the specified value. If you will
be doing any repairs or service
procedures on this machine, always refer
to this chart if the tightening torque value
is not listed or specified in the procedure.
Failure to do so could damage the
machine, shorten machine life or cause
premature system failure.

(1) Table. 6-4 gives the pre-tightening

torques of bolts with lubrication.

Table 6-4 Pre-tightening Torques of Bolts (with lubrication)

Strength Grade(8.8) Strength Grade(10.9) Strength Grade (12.9)

Thread
Specification Pretightening torque T Pretightening torque T Pretightening torque
(N·m) (N·m) T(N·m)

M8 23±2 34±2 39±2

M10 45±5 67±5 78±5

M12 85±5 118±8 137±8

M16 210±10 290±10 339±15

M20 408±15 568±18 666±18

M24 710±18 984±20 1147±25

M30 1410±25 1956±25 2280±25

M36 2470±30 3412±30 3988±30

(2) Table. 6-5 gives the pre-tightening

torques of bolts without lubrication.
NOTE: One bolt should be replaced with a
new one of the same size and grade.
The above pre-tightening torques for bolt
connection are not applicable to hydraulic
pipe connectors.

6-8
 Maintenance
SYG5360THB 47

Table 6-5 Pre-tightening Torques of Bolts (without lubrication)

Strength Grade(8.8) Strength Grade(10.9) Strength Grade (12.9)
Thread
Specification Pretightening torque T Pretightening torque T Pretightening torque T
(N·m) (N·m) (N·m)
M8×1 27±2 39±2 46±5
M10×1.25 52±5 76±5 90±5
M12×1.25 93±5 135±8 160±10
M12×1.5 89±5 130±8 155±10
M14×1.5 215±15 215±15 255±15
M16×1.5 225±15 330±18 390±18
M18×1.5 340±18 485±18 570±20
M20×1.5 475±20 680±25 790±25
M22×1.5 630±20 900±25 1050±30
M24×2 800±25 1150±30 1350±30
M27×2 1150±30 1650±30 1950±30
M30×2 1650±30 2350±30 2750±30

(3) Don't apply excessive force when

disassembling pipe connectors. When
tightening pipe connector, the pre-tightening
torques should be moderate, and just
ensure there is no leakage.

Table. 6-6 gives the pre-tightening torques of

common pipe connectors (rubber hose and
steel pipe).

Table 6-6 Pre-tightening Torques of Pipe Connectors

Preheating Preheating
No Metric Thread No Metric Thread
Torque(N.m) Torque(N.m)

1 M12×1.5 15~25 8 M26×1.5 85~125

2 M14×1.5 30~45 9 M30×2 115~155

3 M16×1.5 38~52 10 M36×2 140~192

4 M18×1.5 43~85 11 M42×2 210~270

5 M20×1.5 50~65 12 M45×2 255~325

6 M22×1.5 60~88 13 M52×2 280~380

7 M24×1.5 60~88

6-9
Maintenance
SYG5360THB 47

Table. 6-7 gives the pre-tightening torques of

common pipe connectors (oil port).

Table 6-7 Pretightening Torques of Pipe Connectors (close to oil port)

Type A Seal Type B Seal Type E Seal Type F Seal

(Metal Washer) (Metal Plain Washer) (Elastic-ED) (O-ring)
Series Thread G
Pretightening Pretightening Pretightening Pretightening
Torque (N·m) Torque (N·m) Torque (N·m) Torque (N·m)

M10×1.0 9 18 18 15

M12×1.5 20 30 25 25

M14×1.5 35 45 45 35

M16×1.5 45 65 55 40

M18×1.5 55 80 70 45
L
M20×1.5 65 140 125 60

M27×2 90 190 180 100

M33×2 150 340 310 160

M42×2 240 500 450 210

M48×2 290 630 540 260

M12×1.5 20 35 35 35

M14×1.5 35 55 55 45

M16×1.5 45 70 70 55

M18×1.5 55 110 90 90

M20×1.5 55 150 125 80

S
M22×1.5 65 170 135 100

M27×2 90 270 180 170

M33×2 150 410 310 310

M42×2 240 540 450 330

M48×2 290 700 540 420

NOTE: The allowable tolerance for the pre

tightening torques in the two tables
above is ±10%.
L refers to light low-pressure pipe connector;
and S refers to heavy high-pressure pipe
connector.

6-10
 Maintenance
SYG5360THB 47

6.3 Lubrication

6.3.1 Lubrication Method

The correct lubrication method should be

adopted during operation in order to reduce
the machine depreciation.

The lubrication system comprises automatic

and manual lubrication.

Automatic lubrication
T h r o u g h t h e double power lubrication
pump, the automatic lubrication system
can realize the lubrication of mixing
bearing and the large and small bearing of s-
tube. At the same time, the lubrication center
can realize the lubrication of concrete seal in
the delivery cylinder. This system is
characterized by simple structure and good
lubrication efficiency.

The key diagram of automatic lubrication

system is shown in Fig. 6-1.

Pressure oil Pressure oil

Double power lubrication pump Double-line distribution valve

Sheet oil separator

Big bearing seat Mixing bearing Small bearing Mixing bearing Big bearing seat Concrete
of S-valve seat seat of S-valve seat of S-valve piston

Fig.6-1

Before every restarting machine, check and

add grease in the tank of automatic grease
pump.

If the grease pressure is too low, clean the

overflow valve for pressure adjustment, check
valve at the outlet or discharge air.

6-11
Maintenance
SYG5360THB 47

CAUTION
The double power lubrication pump
should be always clean and free of
handle
dust and other foreign matters. In
addition, it should not contact acid or
Synchronizing lubricating Pressure regulating
alkali substances.The adopted grease grease port
overflow valve
should comply with specification and
must be clean and free of foreign matter.
Failure to do so may result in instability in
operating positions or serious damage to
the machine.
Circular lubricating grease port Drive oil port

Air-bleed valve
Discharge air in the double power lubrication
pump, as shown in Fig. 6-2.
Fig.6-2
When the double power lubrication pump
can not pump grease for a long time
due to the air absorbed caused by the initial
use of grease pump, the depletion of grease
or other reasons, unlock two exhaust valves
by half turn anti-clockwise until air is
discharged completely, the grease flows out
continuously and no air pocket is found. Then
lock them again.

Manual lubrication
The manual lubrication system has two types.
The first is adopting the forced filling grease
cup, wherein the grease is manually pressed
on the friction surface with the grease gun,
e.g. the pin shaft between booms has a
grease cup; the second is adopting the
grease cup with screw cover, wherein the
sufficient grease should be filled in the
grease cup first, and then press the grease
on the friction surface through the pressure
generated by the screw cover, e.g. each
swing valve oil cylinder seat has a grease
cup with screw cover, as shown in Fig. 6-3.
Fig.6-3
(1) Swing valve oil cylinder seat

6-12
 Maintenance
SYG5360THB 47

Both swing valve oil cylinder seat respectively

has a lubricating grease cup. Before the
pumping work, the grease cup must be fully
filled with grease. Then rotate the cup cover
and add grease for lubrication.

During pumping operation, the screw cover

should be lubricated every four hours so that
the ball friction surface of swing valve oil
cylinder can be in good lubrication status.

(2) Boom, rotary table and outrigger

The hinged adaptors on various booms of

this pump truck, connecting shaft between oil
cylinder with four outriggers and base, the
slewing bearing of rotary table, the gear shaft
of reducer, etc., should be manually
lubricated.

Lubricating points of boom, rotary table and

outrigger, as shown in Table 6-8, Fig. 6-4 and
Fig. 6-5.

The maintenance work of this part requires

the grease gun and lithium-based grease.
Unless different time is specified, grease
should be refilled in various lubricating points
every week or every 50 hours of operation.
Add grease in lubricating point until grease
flows out or grease can not be added.

NOTE: The calcium-based grease/butter is

not preferred to the lubrication system
because it is easily stuck and blocks
the lubrication line.

6-13
Maintenance
SYG5360THB 47

Table 6-8 The Grease Cup of Swing Valve Oil Cylinder

No Part to Be Lubricated Quantity of Lubricating Point Lubricating Grease
1 Each articulated joint of boom 27
2 Outrigger cylinder seat 4
Articulated shaft of rear
3 4
outrigger and revolving tower
2# extreme pressure
Articulated shaft of outrigger
4 4 lithium-based lubrication
spread cylinder
grease
Contact roller of front outrigger
5 8
telescopic boom
6 Slewing bearing 1
7 Rotary reducer and gear 2
8 Drive shaft 8 “00” or “000” lithium-
9 Swing-valve cylinder seat 2 based lubrication grease

Fig.6-4

6-14
 Maintenance
SYG5360THB 47

Fig.6-5

6.3.2 Lubricant Recommendation

Gear oil
The rotary reducer adopts the APIG14 gear
oil with the viscosity grade of SAE 85W90.

The transfer case adopts the Shell 150 gear

oil or Mobil 629 gear oil.

Grease

6-15
Maintenance
SYG5360THB 47

Lithium-based lubricating grease is adopted

for both the automatic lubrication system and
manual lubricating points.

It is recommended to use “00” lithium-based

lubricating grease when the working ambient
temperature is higher than 10° C; to use
“000” lithium-based lubricating grease when
the working ambient temperature is lower
than 10° C.

CAUTION
Do not use grease mixed with foreign
matters; otherwise the valve core of
distribution valve will be easily stuck and
lead to faults in the lubrication system.
Thus the abrasion of parts of pumping
system will be aggravated. Failure to do
so may result in instability in operating
positions or serious damage to the
machine.

The special lithium-based grease for SANY is

preferred, as shown in Fig. 6-6.

Engine oil
Under most climatic conditions, the
SAE15W40 engine oil is preferred to water
SANYSPECIAL
pump. GREASENO.00
GENUINEPARTS

(1) Quality level

The quality of engine oil has different

standards:
Fig.6-6 Special Lubricating Grease of SANY
According to the API (American Petroleum Heavy Industry Co., Ltd.
Institute) grading standards, common engine
oils include: CF-4, CG-4,CH-4.

According to ACEA grading standards

(European engine oil sequence), common
engine oils include: E1-E3-96+E4-98.

6-16
 Maintenance
SYG5360THB 47

(2) Viscosity

The selection on the viscosity grade of

engine oil is shown in Fig. 6-7. The ambient
temperature determines the viscosity grade of
engine oil.

Fig.6-7
Hydraulic fluid
The recommended hydraulic fluid types for
different ambient temperatures (see Table. 6-
9).

Table 6-9 Recommended Hydraulic Oil

-40 -30 -20 -10 0 10 20 30 40 50

32# SANY special high-grade anti-
wear hydraulic oil
Equivis ZS 46S
68# SANY special high-grade anti-
wear hydraulic oil

(1) The hydraulic fluid used in the hydraulic

system is mineral hydraulic fluid (HLP46) or
biologically degradable hydraulic fluid (HLP-
E46) or non-readily flammable hydraulic fluid
(HFC46). The original hydraulic fluid used in
this pump truck is the special top grade anti-
wear hydraulic fluid Equivis ZS 46S..

(2) As to the places in hot weather (the

temperature is higher than 35°C), the
special top grade anti-wear hydraulic fluid 68
for SANY Heavy Industry is preferred.

6-17
Maintenance
SYG5360THB 47

(3) As to the places in cold weather (the

temperature is lower than 10°C),before
pumping concrete, pre-heat the hydraulic
fluid and adopt the special top grade anti-
wear hydraulic fluid 32 for SANY Heavy
Industry is preferred.

(4) Do not mix hydraulic fluid with different

characteristics.

(5) Preheating of hydraulic fluid

(6) The temperature of hydraulic fluid is

lower than 20°C; therefore it should be
preheated so as to ensure the safety of
hydraulic system.

Start the engine and let it run idly for 5-10

minutes without load, turn the preheating
switch on the maintenance operation box to
the "preheating" position, increase the speed
of engine to 1700rpm and let it run for 10 or
more minutes, and raise the temperature of
hydraulic fluid to above 20°C.

The preheating time should be appropriately

adjusted as per local condition.

Only after the preheating of hydraulic fluid is

completed, the pumping operation can be
carried out.

NOTE: If the hydraulic fluid temperature is

lower than 20°C, the display will
show: As the hydraulic fluid
temperature is too low, preheat or
operate with small capacity.

6-18
 Maintenance
SYG5360THB 47

Recommended capacities of lubricating oil/

grease

Table 6-10 Recommended Capacities of Lubricating Oil / Grease

Adding
No Part to Be Lubricated Lubricating Oil / Grease
Capacity (L)

1 Rotary reducer 8 SAE85W90 gear oil

2 Transfer case 8 SHELL 150 gear oil or MOBIL 629 gear oil

3 Water pump 0.5 SAE 15W-40 engine oil

4 Hydraulic oil tank 650 46# SANY special anti-wear hydraulic oil

5 Automatic lubricating grease pump 4 “00” lithium-based lubricating grease

NOTE: Capacities in table are for reference.

During every replacement of
lubricating oil and grease, the oil level
must be checked at specified
checking points and with inspection
plug, oil ruler and oil level meter.
Storage of lubricants
Do not store oils and greases in the open air.
Water may be absorbed through the bung
hole in the event of changes in the exposure
to the weather.

Only ever store the barrels lying on their side

and supported on timber blocks, with the
bung hole facing upwards.

6-19
Maintenance
SYG5360THB 47

6.4 Visual Checks

Before you commence any maintenance
work, you must carry out visual checks that
this maintenance card describes. The service
intervals can be find in the maintenance
summary. The check should be carried out by
qualified personnel and the results should be
carefully recorded and kept. The potential risk
of equipment found in checking process
should be handled.

DANGER
You should particularly closely and
carefully check the electrical cables. There
is a danger of overvoltages from defective
cables, especially in high air or ambient
humidity. There is a danger of fire and
explosion through the formation of sparks
in a potentially explosive atmosphere.

6.4.1 General check

WARNING
Be sure the truck parking brake is in the
PARK position and all wheels are chocked
be fore pro ceedi ng with any servi ce.
Failure to do so may result in unexpected
movement of the truck causing injury or
possibly death.

The followings items must always be checked

before operation of this machine.
Hydraulic tank oil level
(1) Locate the oil level gauges on the front of
the tank, each side.
(2) Check the hydraulic oil level.
a. Outriggers and boom in travel position.
b. Outriggers are fully extended and in the
operating mode. (Boom is not Fig.6-8
extended).(see Fig. 6-8)

6-20
 Maintenance
SYG5360THB 47

Lubricating oil level in transfer case

(1) Position the truck chassis on a flat level

surface.

(2) Remove plug (a) and visually check to

see if the oil level reaches within 10 mm
(0.4 in) of the bottom of the plug hole.

(3) If necessary, add the correct amount of

oil as needed, see Table. 6-10, on page 6-
19 for the type of oil.

(4) Reinstall plug (a) and torque to 68 N.m Fig.6-9

(50 lbf.ft).

NOTE: See Fig. 6-9 for the location of plug (a).

Rotary reducer oil level

(1) Position the truck chassis on a flat level Min

surface.

(2) Visually checking if the oil level reaches

the Min level of the oil cup.

(3) If it is, add the correct oil as needed, see

Table. 6-9, on page 6-17 for the type of oil.

NOTE: See Fig. 6-10 for the location of Min level.

.
Fig.6-10

Pressure washer pump oil level

Remove plug (a) and insert your index finger
tip into the fill port to check the washer pump
oil level.

If oil is found on your finger tip, then the

a
washer pump oil level is correct.
If oil needs to be added, see table6-9 on
page 6-17 for the type of oil.

NOTE: See Fig. 6-11 for the location of plug

(a).
Fig.6-11

6-21
Maintenance
SYG5360THB 47

The grease amount in the lubricating device

Check the auto-grease hopper to see if it is
full to the top with grease. If grease needs to
be added, unscrew lid (1) and add grease to
t he h op per (2 ). (See Fig . 6-12 fo r th e
locations of lid(1) and hopper (2)).

● Use "00" lubricating grease in the

summer;
● Use "000" lubricating grease in the
Fig.6-12
winter.

Check the wash box

(1) The wash box is located on the chassis

deck in the center between the pumping
cylinders and the hydraulic cylinders.

(2) Unscrew knobs (a) and open cover (b) to

check the water condition. If water level is
low, add water.

NOTE: See Fig. 6-13 for the locations of

knobs (a) and cover (b).
(3) If wash box needs to be cleaned, remove
safety guard screws (d) and lift off safety
guard (c) (if equipped with a safety guard). Fig.6-13
NOTE: See Fig. 6-14 for the locations of
knobs (c) and cover (d).

NOTE: If excessive amounts of concrete,

grout or sand are found in the wash
box, this is an indication that the
pumping cylinder piston is near the
end of its life cycle and additional
service is required. For details on
replacing the pumping cylinder piston,
see “Pumping cylinder piston seal
service” on page 6-27.
Fig.6-14

6-22
 Maintenance
SYG5360THB 47

(4) Drain and clean the wash box.

● The wash box drain is located in the

wash box on the right side.

● Rotate the drain valve knob (e) to the left

to open the drain port (f).(See Fig. 6-15
for the locations of knob (e) and the
drain port (f).

(5) After cleaning, close drain (f), install

safety guard (c) and fill with fresh water. Fig.6-15
Install cover (b). See Fig. 6-13, Fig. 6-14,
and Fig. 6-15 for the locations of (b), (c) and
(f).

CAUTION
If your machine is equipped with a safety
guard, be sure this safety guard is
reinstalled before operating the pumping
system. Failure to install the safety guard
could result in possible injury to persons.

Rear outrigger tanks

(1) Locate the water level gauges on the

front part of each rear outrigger.
a
(2) Check the water level (a)l

NOTICE
If you will be operating in a cold climate,
you may want use an environmentally
approved antifreeze solution to prevent Fig.6-16
the water from freezing. Failure to do so
may cause damage to your machine.

(3) If required, remove cap (c) and add water

until the outrigger water tank is full to level

6-23
Maintenance
SYG5360THB 47

gauge (a).(See Fig. 6-16 and Fig. 6-17 for

the locations of gauge (a) and remove cap
(c).)

Check all safety equipments

Check if all safety equipments are available
and in fully functioning condition.

(1) Check if all warning signs are sound.

(2) Check if all safety auxiliary devices are

complete (e.g. if the safety chain of the hose Fig.6-17
at the end is correctly connected, if the
screen of hopper can be continuously used,
if the cover of water tank is good, if the
outrigger is extending to the desired position
and supported by the bearing plate as
required, etc.)

6.4.2 Check the hydraulic system

(1) Check all hydraulic rubber hoses for

leakage.

(2) Check all hydraulic adaptors secured by

screws for tightness or leakage

(3) Check if the oil filter is blocked. Start the

machine, allow the hydraulic system to run
without load, and observe the indicator of oil
filter. When the indicator is pointing to red,
the oil filter has been blocked, and it should
be immediately replaced.

(4) Check the oil cooler for contamination

and deposits.

(5) Check all hydraulic threaded unions for

tightness and leaks.

(6) Check all hydraulic hoses for leaks.

6-24
 Maintenance
SYG5360THB 47

6.4.3 Check the electrical system

(1) Check all electrical adaptors for tightness

and rust.

(2) Check electrical cables for open circuit.

(3) Check the insulator on electrical cables

for aging and peeling.

6.5 Pumping System

Before every pumping operation, check if the
hopper has foreign matter and put down the
screen; fill sufficient clean tap water in the
cleaning room, when the ambient
temperature is lower than 10°C, it is
practicable to add hydraulic fluid of about 1/3
capacity to improve the lubrication efficiency.

After every pumping operation, open the

water drain plug to completely drain off water
in the cleaning room and draw out the piston
head to conduct cleaning and checking. The
cleaning room should be clean and no
deposit is allowed on the piston rod of oil
cylinder. During forward pumping or reverse
pumping, if water in the cleaning room is
muddy, immediately stop the machine and
check the concrete seal. During pumping, if
the water temperature in the cleaning room is
too high, timely replace with fresh water.

For construction in cold weather, e.g. winter,

completely drain off water in the cleaning
room to avoid icing. Do not add lithium-based
grease in the cleaning room; otherwise the
hydraulic system is easily be polluted and
faults will frequently occurs.

6-25
Maintenance
SYG5360THB 47

6.5.1 Pumping cylinder piston

Overview
connecting rod, bayonet adaptor and various
seals, as shown in Fig. 6-18

1 3
2
4

6
7

Fig.6-18 Structural of Piston Head

[1] Screw
[2] Washer
[3] Connecting rod
[4] Guide ring
[5] Concrete seal body
[6] O-ring
[7] Pressure plate

6-26
 Maintenance
SYG5360THB 47

Pumping cylinder piston seal service

Pre-inspection procedures
Remove the wash box cover and safety
guard (if equipped). For details on accessing a
the wash box and cleaning, see “Check the
wash box” on page 6-22.

NOTE: Do not fill the wash box after

cleaning.

(1) Pull the pumping cylinder piston into the

wash box.

Hold the switch (a) in the EXIT position as

shown in illustra tion until the pumpin g
cylinder piston is completely in the wash box.
See Fig. 6-19 for the location of switch (a).

NOTE: This function will position the pumping Fig.6-19

cylinder piston in the wash box for
inspection or removal.
(2) Once the pumping cylinder piston is in
the wash box, release switch (a) and allow it
to return to the KEEP position. See Fig. 6-
19 for the location of switch (a).

(3) Inspect the condition of the piston seals

(b) for extensive wear or damage. If
extensive wear or damage to the piston
seals (b) are found, the piston assembly
needs to be replaced. Follow the
replacement procedures listed below. (See
Fig. 6-20 for the location of (b).)

NOTE: When inspecting piston seals, always

keep in mind both pumping cylinder
pistons must be inspected. Follow the
procedures outlined underlying for
each pumping cylinder piston.

Fig.6-20

6-27
Maintenance
SYG5360THB 47

Replacement procedures

(1) Shut the truck engine OFF.

(2) Remove the hydraulic control system

housing cover.

(3) Locate the circuit dump valve (c) as

shown in the illustration. See Fig. 6-21 for
the location of (c).

(4) The circuit dump valve will be in the

CLOSED position for normal operation.
Move the circuit dump valve to the OPEN
position as shown in the illustration to
relieve any excess pressure in the
accumulator circuit.

WARNING
Failure to set the circuit dump valve in the Fig.6-21
OPEN position could result in unexpected
movement of the pumping cylinder piston
during service procedures. Unexpected
movement of a component could result in
serious injury.

(5) Loosen the pumping cylinder piston

locking collar fasteners (d) and remove the
top section of the locking collar (e), see Fig.
6-22.

d d

Fig.6-22

6-28
 Maintenance
SYG5360THB 47

(6) Lift the worn or damaged pumping

cylinder piston assembly out of the wash
box. See Fig. 6-23.

(7) Install a SANY approved new or

refurbished pumping cylinder piston
assembly.

(8) Reinstall the pumping cylinder piston

locking collar top section (e) and fasteners
(d). Torque all fasteners using the torque
values listed on page 6-8.

(9) Close the wash box drain valve and fill

the wash box with fresh clean water. Rotate
the circuit dump valve to the CLOSED Fig.6-23
position as shown in Fig. 6-21.

(10) Start the truck engine. Using the rear

boom quick-check switch panel, hold switch
(a) in the RESET position to insert pumping
cylinder piston back into the pumping
cylinder bore.

(11) Once the pumping cylinder piston is in

the cylinder bore, release switch (a) and
allow it to return to the KEEP position. See a
Fig. 6-24.

(12) Fill the wash box with fresh clean water.

(13) Reinstall the wash box safety guard (if

equipped) and cover, see “Check the wash
box” on page 6-22 for details.

If necessary, contact your SANY distributor

for repair procedures.

Fig.6-24

6-29
Maintenance
SYG5360THB 47

6.5.2 Agitator shaft and leaf

Check the agitator shaft for tightness daily

through the viewport on the agitator motor
seat. Check the abrasion of agitator blade,
which will result in the unsatisfied material
absorption efficiency and increment in deposit
at the bottom of hopper. Replace the agitator
blade (see Fig. 6-25) timely or reinforce it.

NOTE: For overlaying welding of agitator

blade, the distance between the blade
Fig.6-25 agitator shaft and agitator blade
and any position on hopper wall
should not be less than 5cm;
otherwise the hopper will be worn out. [1] Agitator shaft [6] Flat washer
During installation of left and right [2] Left agitator blade [7] Nut
agitator blades, pay attention to the [3] Right agitator blade
correct installation direction of agitator [4] Bolt
blades. [5] Spring pad

6-30
 Maintenance
SYG5360THB 47

6.5.3 S-valve Assembly

Overview

Fig.6-26 S-valve Assembly (I)

[1] Transitional bushing [3] Screw [5] Spectacle wear plate [7] Rubber spring
[2] O-ring [4] Washer [6] Cutting ring [8] S-tube

Checking the S-tube and wear ring

Inspect the S-tube and wear ring for signs of
2 1
looseness, wear, damage or any abnormal
conditions.

The S-tube and wear ring assembly should

be replaced if the following conditions are
found:

(1) Excess wear or damaged to the surface

(1) or swing mechanism (2) are found.

(2) The thickness of S-tube surface (1) is

less than 10 mm (0.4 in). Fig.6-27

NOTE: See Fig. 6-27 for the items (1) and

(2).

6-31
Maintenance
SYG5360THB 47

If you find ex cessive wear, damage or

abnormal surface conditions on the S-tube,
contact your SANY distributor for repairs. If
concrete flow is weak at the end hose outlet
or abnormal concrete leakage is found in the
hopper during pumping operations, check the
clearance between the spectacle wear plate
(3) and S-tube (4). If the clearance (1) is less
than 4 mm (0.2 in) the wear ring (2) is at the
end of its service life and should be replaced.
Contact your SANY distributor for repairs. If
the clearance (1) between the spectacle wear
plate (3) and S-tube (4) is greater than 4 mm
(0.2 in) adjust the clearance until 4 mm (0.2
in) is achieved between the spectacle wear
plate (3) and S-tube (4).

NOTE: See Fig. 6-28 for the items (1),(2), (3) Fig.6-28
and (4).

Adjustment
If concrete flow is weak at the end hose
outlet or abnormal concrete leakage is found
in the hopper during pumping operations,
check the clearance between the spectacle
wear plate (3) and S-tube (4).

If the clearance (1) is less than 4 mm (0.2 in)

the wear ring (2) is at the end of its service
life and should be replaced. Contact your
SANY distributor for repairs.

If the clearance (1) between the spectacle

wear plate (3) and S-tube (4) is greater than
4 mm (0.2 in) adjust the clearance until 4 mm
(0.2 in) is achieved between the spectacle
wear plate (3) and S-tube (4). Follow
adjustment procedures be-low.

To adjust the clearance (1), rotate nut (5) Fig.6-29

clock-wise or counterclockwise.

6-32
 Maintenance
SYG5360THB 47

Clockwise - decreases the clearance between

the spectacle wear plate (3) and S-tube (4).

Counterclockwise - increases the clearance

between the spectacle wear plate (3) and S-
tube (4).

NOTE: See Fig. 6-28 and Fig. 6-29 for the

items (1),(2), (3),(4) and (5).
Removing spectacle wear plate and wear ring

(1) Unloading, stop and switch off the power

supply Open the unloading ball valve of
accumulator to unload the pressure oil of
accumulator. Close the engine, take out the
start key, and switch off the power supply to
avoid the unauthorized starting.

(2) Remove the limit screw of rocker arm

and abnormal nut as shown in Fig. 6-30,
unlock the abnormal nut but do not loosen it
completely, wherein 2-3 turns of threads
should be left.

(3) Remove the coupling which connects the

delivery line with the hinge elbow; take out Fig.6-30 Abnormity Nuts and Limiting Screws
the split pin on the axle pin of the hinge [1] Abnormity Nuts
elbow. Take out the axle pin, and then
[2] Limiting Screws
remove the hinge elbow as shown in Fig. 6-
31

6-33
Maintenance
SYG5360THB 47

7
1

8
6

9 5

4
10

3
11

Fig.6-31 Hinge Elbow and Discharge Outlet

[1] Axis pin [5] Supporting bolt [9] O-ring

[2] Pin [6] Protective sleeve [10] Locknut
[3] Plug-in board [7] Nut [11] Cross pin stud
[4] Hinge elbow [8] Discharge outlett

(4) Disassemble the material outlet by

loosening connecting screw between
material outlet and bearing seat.

(5) Hoist the S-tube with crow bar to move

the S-tube towards the material outlet about
30mm. At this time, there will be about
30mm clearance between the spectacle
wear plate and wear ring.

(6) For replacement of wear ring, knock the

flange edge of wear ring with a brass rod,
take out the wear ring and then take out the
rubber spring. For replacement of spectacle
wear plate, remove the fastening screw of
spectacle wear plate and hopper, and take out
the spectacle wear plate.

6-34
 Maintenance
SYG5360THB 47

(7) Clean and care the installation positions

of spectacle wear plate and wear ring.

NOTICE
When loosening the abnormal nut, do not
remove it completely so that the hoist
stroke of S-tube can be limited. If the S-
tube removes unlimitedly when hoisting,
and drops in the hopper, the installation
position of S-tube can be recovered after
disassembling the front and rear bearing
seats and swing cylinder system.

NOTE: Pay special attention to the cleaning

of concrete at the installation position
of rubber spring.

Fitting the spectacle wear plate and wear ring

Fig.6-32 Spectacle wear plate and wear ring (I)

[1] Bolt [3] Spectacle wear plate [5] Rubber spring
[2] Washer [4] Cutting ring [6] S-tube

6-35
Maintenance
SYG5360THB 47

(1) Install the lubricated spectacle wear plate

in the corresponding positions of hopper.
Note that the spectacle wear plate must be
flat, and the clearance between the
spectacle wear plate and the fitting surface
of hopper should not be more than 0.1mm.

(2) Check the O-rings in the intermediate

rings on which the spectacle wear plate is
placed.

(3) Clean the mounting surfaces and grease

them.

CAUTION
The spectacle wear plate rests only
against the O-rings of the intermediate
rings. There is a small clearance between
the spectacle wear plate and the hopper
wall. The outer fastening bolts should
therefore initially only be tightened finger-
tight, as otherwise the spectacle wear
plate may be broken.

(4) Fit the new spectacle wear plate.

(5) Put the new spectacle wear plate in place

and fasten it with the outer fastening bolts.
Tighten these only to finger-tightness
initially.

(6) Bolt down the spectacle wear plate with

the top and bottom and tighten them to the
appropriate tightening torque.

(7) Tighten the outer fastening bolts to the

tightening torques given in the
accompanying spare parts sheet. The
spectacle wear plate may only be distorted
by a maximum of 0.5mm when the bolts are
tightened.

6-36
 Maintenance
SYG5360THB 47

Replacing the wear ring

Replace the wear ring in the event of heavy
visible wear, if concrete is leaking or if there
is inadequate pressure buildup in the delivery
line.

(1) Remove the old wear ring and the thrust

ring.

(2) Fit a new thrust ring and a new wear ring

in the S-tube.

Checking the agitator motor

Check the agitator motor mounting for loose
or missing fasteners (a), leaking hydraulic
lines (b) or concrete leakage between the
motor and hopper mounting. If missing
fasteners are found, replace then with SANY
factory approved fasteners. See Fig. 6-33 for
a
the locations of (a) and (b).
b
If loose fasteners or hydraulic lines are found,
torque the fasteners or hydraulic lines using
the torque values in Table. 6-4,Table. 6-5 and
Table. 6-6on page 6-9. If any damage,
excessive wear or abnormality is found,
contact your SANY distributor for repairs.

Fig.6-33
Removing the agitator motor

(1) Stop, switch off the power supply and

unloading. Open the unloading ball valve of
accumulator to unload the pressure oil of
accumulator. Close the engine, take out the
start key, and switch off the power supply to
avoid the unauthorized starting.

(2) Remove the screen, unlock the

installation screw of agitator blade and
remove the agitator blade.

(3) Disassemble three oil pipe adaptors and

lubrication pipe (see Fig. 6-34) connecting to

6-37
Maintenance
SYG5360THB 47

the agitator motor. Seal the oil pipe and

adaptor with plug to prevent the dust
entering the hydraulic system.

(4) Loosen the fastening screw between the

agitator motor seat and hopper, remove the
motor seat and motor, and then remove the
waterproof plate (see Fig. 6-35, Fig. 6-36).

(5) Loosen the fastening screw of end cover

at both ends outside hopper and remove the
end cover.

(6) Loosen M5 screw at both ends inside

hopper, remove the pressure ring and allow Fig.6-34 Mixing Motor and Oil Tube
the seal retainer ring to contact with the
shoulder.

(7) Loosen the fastening screw of seal cover

and hopper at both ends outside hopper.

(8) On the side of motor, knock the agitator

shaft with a brass rod to move the agitator
shaft towards another end. With the force of
shoulder, push the seal cover at another
end out from hopper hole and remove the
seal cover.

(9) Push out the seal cover with the same

method at the another end.

(10) Push the agitator shaft towards one end

and take out the agitator shaft from the top
of hopper.

6-38
 Maintenance
SYG5360THB 47

5
15

14
19
18

17
5
10 16

8 13
12
6
11 31
30
29
9
7 28

26
3
5
4 24

2 21
27
20 25
1

23
22

Fig.6-35 agitator device (1)

[1] Screw M10 [17]Bearing seat

[2] Motor [18] Seal Ring
[3] Spline housing [19] O-ring 150 x 3.55
[4] Blot M12 [20] Oil Seal B
[5] Washer 12 [21] Bolt M8x16
[6] Motor seat [22] Seal cover
[7] Water catcher [23] Packing plate (2)
[8] Felt ring [24] J-type dust-proof ring
[9] Screw M8×20 [25] Shaft sleeve
[10] End sealing cover [26] Screw M5×8
[11] Packing plate [27] O-ring 46.2×2.65
[12] Retainer ring [28] Seal retainer ring
[13] Roller bearing [29] Pressure ring
[14] Base ring [30] Screw M5×12
[15] Screw M12x20 [31] Rubber plug
[16] Screw M12x35

6-39
Maintenance
SYG5360THB 47

4
26
3
25
2
1 24
23
22
16 17
21
15
20
14
13 19

12 18
16
10

11

Fig.6-36 Agitator device (2)

[1] Rubber plug [14] Seal Ring

[2] Screw M5×12 [15]Bolt M12x20
[3] Pressure ring [16] Washer 12
[4] Seal retainer ring [17] Bearing seat
[5] O-ring 46.2×2.65 [18] Blot M12x35
[6] Screw M5×8 [19] Base ring
[7] Shaft sleeve [20]Rolling Bearing
[21] Shaft end pressure plate
[8] J-type dust-proof ring
[22]Washer
[9] Packing plate (2)
[23]Blot M8x25
[10] Seal cover
[24] Packing plate
[11] Bolt M8x16 [25]End cover
[12] Oil Seal B [26] Screw M8×20
[13] O-ring 150 x 3.55

6-40
 Maintenance
SYG5360THB 47

Remove the coupling which connects the

delivery line with the hinge elbow; take out
the split pin on the axle pin of the hinge
elbow. Take out the axle pin, and then
remove the hinge elbow as shown in Fig. 6-
31 on page 6-33.

Disassemble the material outlet

Disassemble the material outlet by loosening
connecting screw between material outlet and
bearing seat.

S-tube bearing seal set

Fig.6-37 S-valve Assembly (II)

[1] Screw M8×20 [7] Bearing seat

[2] Pressure ring [8] Nylon bearing
[3] Rubber pad [9] O-ring
[4] Wearing sleeve [10] Discharge outlet
[5] J-type dust-proof ring [11] Bolt
[6] YX-type seal ring

6-41
Maintenance
SYG5360THB 47

(1) Remove two grease pipes on the bearing

seat.

(2) Loosen the screw of pressure ring in

hopper and remove the pressure ring.

(3) Hoist the S-tube with crane and flexible

cable.

(4) Push the bearing seat out with two long

bolts and remove the bearing seat.

Removing the rocker arm and small bearing

seat

3 14
14
8 10
4
11
6 8
4
2 3
15
12
1 7
5

9 2 3

4 14
13
6

5
1
15

Fig.6-38 Swing Mechanism

[1] Bearing plate [9] Rocker arm

[2] Screw M8x16 [10] Conversion joint
[3] Screw M8x16 [11] Washer 16
[4] Washer 8 [12] Upper ball bearing
[5] Lower ball bearing [13] Right swing valve cylinder
[6] Limit baffle [14] Oil cup M8x1
[7] Left swing valve cylinder [15] Bolt M16x20
[8] Ball head baffle

(1) Remove the ball head baffle and limit

baffle. Take out the piston rod of swing
valve oil cylinder from the spherical bearing.

6-42
 Maintenance
SYG5360THB 47

(2) Loosen the limit screw of rocker arm and

abnormal nut and remove the abnormal nut.

(3) Remove the ball head baffle which

connects the rocker arm and swing valve oil
cylinder.

(4) Remove two grease pipes on the bearing

seat.

(5) Loosen the screw connecting the bearing

seat at the end of rocker arm and hopper,
push out the bearing seat with two bolts and
remove the bearing seat.

Checking other wear parts

Fig.6-39 S-valve Assembly (III)

[1] Transitional bushing [5] Spectacle wear plate

[2] O-ring [6] Cutting ring
[3] Screw [7] Rubber spring
[4] Washer [8] S-valve

6-43
Maintenance
SYG5360THB 47

(1) Move the S-tube toward the material

outlet with a crow bar until the small shaft is
detached from the hopper.

(2) If necessary, unlock the bolt of scraper at

the bottom of S-tube and remove the
scraper.

(3) Adjust the position of S-tube at the small

end and hoist S-tube from the hopper.

(4) Knock the flange edge of wear ring with a

brass rod, remove the wear ring and then
take out the rubber spring.

(5) Unlock the fastening bolt of spectacle

wear plate and remove the spectacle wear
plate.

(6) Check the reducing bushing connecting

to the delivery cylinder and replace as per
abrasion degree.

(7) Check the wear sleeve at the material

outlet end of S-tube and replace as per
abrasion degree.

Replacing the wear sleeve

The wear sleeve can be replaced without the
requirement to replace the S-tube if the wear
sleeve is heavily worn. The S-tube must be
removed to do this.

(1) Carefully cut the wear sleeve at two

opposing points using an angle grinder and
remove the two parts.

NOTICE Fig.6-40 S-valve and Wearing Sleeve

Do not damage S-tube when cutting the [1] S-tube
wear sleeve. [2] Wearing sleeve

(2) Heat the wear sleeve with heater and

keep the heating temperature at 200-210°C
for about 10 minutes.

6-44
 Maintenance
SYG5360THB 47

(3) Place the heated wear sleeve over the

tube outlet and allow the wear sleeve to
cool.

(4) Replace the S-tube.

NOTE: When heating the wear sleeve, the

temperature can not be too high.
If no heater is provided, the wear sleeve can
be put into an appropriate vessel and heated
after diesel oil is added. The oil level should
exceed the wear sleeve. The heating
temperate is kept at 200-210°C for about 10
minutes.

Note that the heating temperature should not

be too high and firing should be avoided.
Never directly use flame to ignite the wear
sleeve.

NOTE: When assembling the wear sleeve,

note that the inner bevel of the wear
sleeve should face towards the large
end of S-tube and the outer bevel
should face towards the small end of
S-tube.

Fitting the S-tube

(1) Install the wear sleeve into the straight

pipe position of S-tube.

(2) Hoist the S-tube with crane and flexible

cable, put rubber pads on both ends, set the
S-tube to the inclined position, put the outlet
port of S-tube in the installation hole for
material outlet of hopper, push it into the
end position and put the small end of S-tube
in the installation hole of hopper. Apply
grease on the rubber spring and wear ring
and install them on S-tube.

(3) Replace the Yx-type seal ring, J-type

dust ring, dust ring and seal ring with new
one, apply grease on the inner and outer of

6-45
Maintenance
SYG5360THB 47

seal, bearing and bearing seat; install the

nylon bearing, Yx-seal ring and J-type dust
ring onto the large bearing seat at the outlet.
Install the bearing, dust ring and seal ring
onto the small bearing seat.

NOTICE
During installation, pay attention to the
correct installation direction of seal ring
and dust ring. Failure to do so may result
in oil leaking and the dust crushing into
the containers or pipes.

(4) Install the large bearing seat of seal

between the hopper hole and S-tube, set
both grease inlets at 15°included angle to
the horizontal surface, and then install the
lubricating oil pipe and adaptor.

(5) Install the small bearing seat of seal in

the hopper hole; install the lubricated O-ring
in the end bearing sleeve, then install the
spline teeth, and then install the end bearing
sleeve at the small shaft end into the
bearing seat hole from outside of hopper
with a brass rod.

(6) Install rocker arm on the shaft end of S-

tube.

6-46
 Maintenance
SYG5360THB 47

NOTICE
When installing the rocker arm, allow the
S-tube to hang down freely. The center
lines of gravity of S-tube and rocker arm
must be overlapped when viewed from the
right behind the hopper (see Fig. 6-41).
Or fit the key way, which is located on
rocker arm and symmetrically coincides
with the center line, on the spline teeth
located on the shaft end of S-tube and has
a center line symmetrically coincides with
that of S-tube.
If the installation positions of S-tube and
rocker arm is not correct, S-tube can not
swing to the desired position.

Fig.6-41 Assembly Requirements for Rocker Arm and S-valve

[1] S-valve [2] Rocker arm

(7) Install the swing valve oil cylinder and

then install the ball head baffle and limit
plate.

(8) Install the O-ring into the key way at the

end face of abnormal nut, screw the
abnormal nut in the spline shaft of S-tube

6-47
Maintenance
SYG5360THB 47

until the distance between the end face of

S-tube and the wear ring is about 4mm,
align the notch on the abnormal nut with the
thread hole on the rocker arm and install the
limit screw.

(9) Install the pressure ring in the hopper,

tighten the screw of pressure ring and press
the rubber pad tightly.

(10) At last, secure the material outlet from

outside of hopper with screw M24×160 and
spring pad, and the tightening torque is
650±18N.m.

(11) Install the hinge elbow, insert the cross

pin and split pin and then install the
coupling.

Fitting the agitator

(1) Apply the grease on O-ring, insert two O-

rings into the key way at both ends of
agitator shaft, install seal retainer ring on the
shaft shoulders at both ends, and put the
agitator shaft in the related hole of hopper.

(2) Install the lubricated lip-Like seal ring with

inner frame and dust ring in the seal cover,
install the assembled seal cover into the
hole of hopper and secure it with bolt
M8×16 on the hopper.

(3) Install two shaft sleeves on the shaft,

align the notch with screw hole M5 on the
shaft and secure it with screw M5×8
(applied with sealant).

(4) Install the O-rings, seal ring and base

ring applied with grease on both bearing
seats, and secure the bearing seat on the
end face of shaft hole with bolt M12×35
applied with sealant and washer. The
lubricating oil hole of bearing seat should be
Installed towards the lower-rear section.

6-48
 Maintenance
SYG5360THB 47

(5) Install the roller bearing into the left and

right bearing seats with the assembling tools
for bearing.

(6) At the end without motor, secure the

pressure plate at the shaft end with screw
and then install the end cover; at the end
with motor, apply grease on the seal ring
and then install the seal end cover, then
install the seal end cover and waterproof
plate on the agitator shaft.

(7) Install the motor seat: install the motor

seat on the dome of the right plate for
hopper, set the installation groove of grease
inlet pipe towards the lower-right side,
secure it with bolt M12×40 and spring pad,
and tighten bolt in strict accordance with the
tightening sequence.

(8) Measure the run out: measure the run

out of installation hole and end face of motor
seat to the center line of agitator shaft,
wherein the maximum permissible radial run
out is 0.32mm, and the maximum
permissible end run out is 0.16mm. This can
be ensured through adjustment.

(9) Install the hydraulic motor and its

hydraulic fluid pipe align the hydraulic motor
with the spline, then install it on the motor
seat, and secure it on motor with screw
M10×90. Tighten bolt in strict accordance
with the tightening sequence.

(10) At last, install the agitator blade. Secure

the screw blade on the agitator shaft with
bolt M16×65, spring pad and nut, where in
the threads of said bolt should be cleaned,
dried and applied with sealant.

6-49
Maintenance
SYG5360THB 47

NOTE: During replacement of said parts, all

related rubber seals should be
replaced. The clearance between the
spectacle wear plate and wear ring
should not be too large or small, and
the clearance between the wear ring
and the end face of S-tube should be
4mm.

6.5.4 Hopper

Frequent inspection and maintenance of the

hopper and related parts (see Fig. 6-42) can
effectively avoid the abnormal abrasion of
hopper.

(1) After pumping, clean the hopper and no

deposit is allowed; otherwise the lower
section of S-tube will be easily worn and
even out of service.

(2) After every pumping, the recession in the Fig.6-42 Hopper

S-tube must be cleaned to avoid blockage in
next pumping.

(3) The transition section between the

spectacle wear plate and delivery cylinder is
furnished with transition sleeve and should
be frequently checked. In the event of
severe abrasion, when its height is lower
than delivery cylinder, the transition sleeve
should be timely replaced; otherwise the
service life of delivery cylinder will be
influenced.

(4) The agitator motor must not be packed.

Check if there is slurry leakage via the
observation hole on the agitator motor seat
every day. When conducting the inner
cleaning, checking and maintenance work of
hopper, close the agitator shutoff valve (see Fig.6-43 Agitator control valve and agitator
Fig. 6-43) and press the E-STOP button shutoff valve
synchronously; otherwise there will be injury [1] Auxiliary valve block
to person. [2] Agitator shutoff valve
[3] Agitator motor

6-50
 Maintenance
SYG5360THB 47

6.5.5 Delivery cylinder

Because the working conditions of delivery
cylinder (see Fig. 6-44) are adverse and
there i s long-term friction between the
concrete and delivery cylinder, if slurry
leakage not caused by the damage of
concrete seal is found, check if the delivery
cylinder is damaged or broken during pulling.
The broken position and damage degree of
delivery cylinder must be inspected with light
when the engine and agitator shutoff valve
are closed.
Fig.6-44 Delivery Cylinder

6.5.6 Delivery line

All metal pipes and pipeline components
should be checked for wall thickness and
condition at frequent intervals and all results
of such inspections must be recorded. Any
used components in storage should be tested
before being returned to service. Delivery
pipe that has a wall thickness less than the
recommended thickness for the pump’s
designed maximum concrete pressure should
not be used. Hoses that are used to pump
concrete should be visually inspected before
concrete pumping operations. Damaged or
worn hoses shall not be used.

Overview
The delivery line is composed of tube
assembly and boom tube. The tube assembly
comprises the tube from the hinge elbow to
the slewing center of rotary tower. Boom pipe
comprises the tube from the slewing center to
the top of boom. The delivery line mainly
comprises straight tube, elbow, tapered tube,
coupling, tube support, etc.

The straight tube mainly comprises the

standard 3m straight tube and matching
straight tube with customized length. The
delivery line of boom is attached at outside

6-51
Maintenance
SYG5360THB 47

place of boom, and its length matches with

the boom length through adjusting the
matching straight tube.

(1) Clearance

There must be 3mm clearance between

various tubes (see Fig. 6-45) of delivery line.
This clearance can be automatically gained
through installation a seal ring.

(2) Matching straight tube

The lengths of matching straight tubes for

platform and boom are different. Before
replacing the matching straight tube,
according to the related information on
matching tube assembly and matching tubes
of boom in the Spare Parts Drawing Volume,
confirm the positions and lengths of all
matching tubes.
Fig.6-45 Mounting Clearance of Pipeline
The related dimensions of pipelines produced
by SANY Heavy Industry Co., LTD can be [1] Pipe clamp
gained from the specifications. [2] Seal ring
[3] Delivery pipe

Use of delivery line

Proper use of delivery line can effectively
prolong the service life of delivery line.

(1) Straight tube

Turning the straight tube by 120o or 180 o

every pumping 5000 cubic meters can lead to
even distribution of abrasion and increment in
service life of straight tube. Especially to the
delivery line with longer service life (generally
the service life is not less than 2 cubic
meters), the efficiency is more obvious.

(2) Elbow

a. Turning the elbow by 180 o every

pumping 5000 cubic meters can lead to Fig.6-46 Elbow

6-52
 Maintenance
SYG5360THB 47

even distribution of abrasion (see Fig. 6-

46). The outside abrasion of an elbow is
larger than the inside abrasion or the
abrasion of straight tube.
Therefore, when measuring the wall thickness
of an elbow, special attention should be paid
to the wall thickness at the side of external
arc.

b. As to the same type of elbow, since they

are installed at different positions of
boom, their service lives are also
different. Generally, the service life of the
second last elbow is the shortest. In
addition to the general flow friction wear,
the elbow at this place also is subjected
to the impact of the gravity of concrete
when working, which increases the
abrasion of pipeline (see Fig. 6-47)

In order to uniform the service lives of the

whole set of delivery pipeline, SANY Heavy
Industry Co., LTD has specially produced
thickened elbow for this place. The detailed
specifications for this elbow refer to the Spare
Parts Drawing Volume.

6-53
Maintenance
SYG5360THB 47

NOTE: The replacement of the whole set of

pipeline is more economic than
replacement of the worn tube

Fig.6-47 Delivery Pipe

[1] Elbow [6] End hose
[2] Matching straight tube [7] Seal ring
[3] 3m standard straight tube [8] Clamp
[4] Boom (5) [9] Fixing clamp
[5] Elbow (thickened) [10] Rubber pad

6-54
 Maintenance
SYG5360THB 47

Measuring the wall thickness

Wall thickness testing should be tested using
an ultrasonic test instrument or other suitable
approved methods. All testing shall be carried
out by competent authorized personnel. The
test equipment shall be calibrated regularly
and maintained according to the
manufacturer's requirements.

Pipe must not be used if the wall thickness is

less than that recommended by the pipe
manufacturer for the maximum concrete
pressure of the pump. The suppliers of pipes
for concrete pumps should be able to provide
data on the minimum pipe wall thickness for
differing pump pressures. The minimum wall
thickness of single wall pipe is dependent on
the grade of pipe, the maximum working
concrete pressure of the pump and the
diameter of the pipe.

Where the supplier's information is not

available, minimum wall thickness shall be
calculated using the formula in AS 4041. The
table below is calculated using the formula in
AS 4041 which provides default minimum
pipe wall thicknesses for 108 mm & 133 mm
(4.3 in. & 5.2 in.) outside diameter seamless
steel pipes at different concrete pressures.

6-55
Maintenance
SYG5360THB 47

These minimum thickness values cannot be

used for pipe with diameters greater than
those specified, nor can the table be
extrapolated for other grades of pipe.

Table 6-11 Minimum Pipe Wall Thickness

Minimum Pipe Wall Thickness/mm (in.)

Outside Diameter Of Pipe

Max.Pressure
Grade 200 Grade 250 Grade 350/ST-52

KPa psi 108mm(in) 133mm(in) 108mm(in) 133mm(in) 108mm(in) 133mm(in)

4.500 653 2.2(0.1) 2.7(0.11) 1.7(0.06) 2.1(0.88) 1.3(0.05) 1.6(0.06)

6.000 870 2.9(0.2) 3.5(0.14) 2.3(0.1) 2.8(0.11) 1.7(0.06) 2.1(0.08)

8.000 1.160 3.8(0.15) N/A 3.0(0.12) 3.7(0.15) 2.3(0.10) 2.8(0.11)

10.000 1.451 N/A N/A 3.8(0.15) N/A 2.9(0.12) 3.5(0.14)

12.000 1.741 N/A N/A N/A N/A 3.4(0.13) N/A

The min. wall thickness of delivery line (see

Fig. 6-48).

(1) Follow the Operating Instructions

supplied with the test instruments when
carrying out measurements. Do not measure
the wall thickness of the delivery line at just
one point, but around the entire
circumference of the delivery pipes. The
minimum wall thickness is shown in the
graph below.

(2) When the wall thickness of delivery tube

reaches the min. value, immediately replace it.
Especially before pumping concrete with large
cubic meters, the pipelines with wall
thicknesses approaching the min. value must
be replaced. Otherwise, explosion may occur Fig.6-48 Minimum Wall Thickness
during construction, the progress of
engineering will be influenced, and even the
life will be threatened.

6-56
 Maintenance
SYG5360THB 47

NOTICE
Pipes and bends must be replaced as
soon as the wall thickness has declined to
the value for the minimum wall thickness.
It should be specially noted that the
influence on delivery line caused by the
impact of dynamic load during pumping
can not be accurately calculated. It
depends on many factors in the procedure
of pumping; therefore, the delivery line
may break even if the working pressure is
within the permissible range. In the event
of blockage, the working pressure also
will fluctuate. If the wall thickness can not
reach requirements, the delivery line will
also break.

(3) If no test instrument is available, a hard

wood hammer or rubber hammer can be
used to knock the delivery line when the line
is empty, and judge the wall thickness
through the sound (see Fig. 6-49). The
method has large error and requires rich
practical experience.

NOTICE
No not use metal substances to knock the
delivery line; otherwise dent will occur
and lead to acceleration in abrasion as
well as the inner peeling of the reinforced
Fig.6-49 Check of Delivery Pipe Wall
layer on the high-strength compound Thickness by Knocking
wear-resistance tube.

6-57
Maintenance
SYG5360THB 47

CAUTION
Never increase the wall thickness, outer
diameter and length of delivery line;
otherwise the service life of boom will be
reduced, influencing the stability of this
pump truck and potentially leading to
breaking of boom and tilting of pump.

Checking the pipe coupling

Check the concrete pipe couplings for signs
of leakage, damage, loose fasteners, wear or
any abnormal condition.

If a coupling is found to be damaged, worn or

in an abnormal condition, replace it with a
new SANY approved coupling.

If a coupling is leaking or has loose fasteners,

torque the fasteners using the torque values
Fig.6-50
in “Pre-tightening Torques of Bolts (without
lubrication)” on page 6-8.

Replacing the delivery line

The delivery line is subdivided into two sections:
boom delivery line; pump-boom delivery line.

Wall thickness
The starting points for laying the pipe on the
boom are the hinge pivot points. The straight
delivery line run from pivot point to pivot
point. They are no more than 3 m long. The
delivery line is matched to the arm length
concerned by means of the adapter pipes.

The length of the pump-boom delivery line is

also adapted by means of adapter pipes.

6-58
 Maintenance
SYG5360THB 47

NOTICE
Do n ot exceed the delivery line wall
thickness specified on the rating plate and
in the machine card. The machine’s
stability can be impaired by additional
weight.

NOTICE
Should you wish to re-equip your machine
to a delivery line of greater wall thickness,
the machine’s stability will have to be
recalculated and checked and approved
by an authorized inspector.

Untensioned assembly
The boom delivery line must be fully fitted
with the arm assembly relieved of tension:
the arm assembly is not under tension in the
transport position if each arm is lying freely
on the rest provided for this purpose; when
unfolded if each arm is supported, the arm
assembly is not under tension.

CAUTION
If the tension on the arm package is not
fully relieved during assembly, stresses
may occur in the delivery line on
movement of the placing boom and
consequential damage may be caused to
the pipe brackets and to the placing
boom. Furthermore, the boom may swing
up and down causing the end hose to
swing and strike out during pumping
operations.

Clearance
A clearance of 4 mm must be maintained
between the delivery pipes over the whole of
the delivery line, so that the welding neck

6-59
Maintenance
SYG5360THB 47

rings can butt against the couplings without

play. This clearance is achieved either:

● automatically, through the use of a C

seal (triple-lip seal), or

● manually, by adjustment, using a feeler

gauge. seal C seals (triple-lip seals) are
used where the delivery line runs in a
straight line and there is no rotational
movement. The 4 mm clearance is
created automatically.

NOTE: No triple-lip seals may be used in the

pivot joints in the pipe bends. A seals
are used:
● if the delivery line does not run in a
straight line;

● in the pivot joints; and at the assembly

coupling at the tip of the boom. The
spacing of 4 mm must be set using
the feeler gauge.

Coupling
Couplings with a threaded closure are closed
using self-locking nuts. These nuts may not
be re-used, but must be replaced each time
the coupling is fitted.

Fitting an A seal
● Push the A seal over the fixed delivery
line pipe.

● Lay the pipe to be attached in the pipe

bracket and push it up to the fixed pipe.

● Set the clearance of 4mm between the

pipes using a feeler gauge.

● Fix the pipe to be attached in the pipe

brackets.

● Push the A seal over the two weld-on

rings.

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● Fit the coupling and secure it.

Fitting a triple-lip seals

● Push the triple-lip seals over the welded-
on ring of the fixed delivery line pipe.

● Lay the pipe to be attached in the pipe

bracket and push it up to the fixed pipe.

● Push the pipe to be attached as far as

the stop in the ring seal.

● Fix the pipe to be attached in the pipe

brackets.

● Fit the coupling and secure it.

Boom delivery line

The starting points for laying the pipe on the
boom are the pivot points.

● Grease all couplings and seals well

internally before assembly.

NOTE: Use a multipurpose grease based on

lithium soap marked K2K. Install the
bends in the fitting couplings at the
pivot points.
● Align the bends such that the straight
pipes can be connected without tension.

Fix the bends.

● Install the fixed length delivery pipes.

● Install the adapter pipes last.

Pump boom delivery line

The pressure pipe is the starting point for
assembly.

NOTE: You should use only high-pressure

pipes when replacing these delivery
line pipes. Only C seals (triple-lip
seals) are used throughout the pump-
boom delivery line.

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● Grease all couplings and seals well

internally before assembly.

NOTE: Use a multipurpose grease based on

lithium soap marked K2K.
● Fit the reducer pipe to the pressure pipe
with a coupling. The coupling must be
capable of rotating with the pressure
pipe. The reducer pipe, which must be
located in a vibration absorber, may not
turn either.

● Fit the boom connection pipes as far as

the bend on the riserpipe.

6.6 Slewing Mechanism

6.6.1 Overview
The slewing mechanism is a transmission
mechanism composed of the ball-bearing
slewing ring, Slewing gear transmission and
gear, as shown in Fig. 6-51.

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Fig.6-51Slewing Mechanism
[1] Rotary reducer [13] Washer [25] Annular plate
[2] Gasket [14] Bolt [26] Screw
[3] Washer [15] Bolt [27] Pin
[4] Bolt [16] Rubber protective bush [28] Shaft sleeve component
[5] Dust-proof ring [17] Washer [29] Oil cup
[6] Gear [18] Screw [30] Sealing plate
[7] Gear [19] Washer [31] Lubricating grease tube
[8] Copper mat [20] Washer [32] Cycloid motor
[9] Double metal bearing [21] Bolt [33] Screw
[10] Pin [22] Oil cup [34] Washer
[11] Slewing bearing [23] Tube connector [35] Washer
[12] Nut [24] Screw plug [36] Oil cup

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6.6.2 Slewing gear transmission

Overview
The structure of Slewing gear transmission
(see Fig. 6-52), check and maintenance
intervals.

Checking slewing gear transmission brake

function
Below is the procedure outlining how to test
the performance of the braking function for
the slewing gear transmission.

(1) Set up the machine in a clear area for

normal concrete pumping operations.
8
(2) Extend the boom as shown in the
9
illustration. See “Extending the Boom” on 11
page 4-34 for details on operating the boom
system.
10 12
(3) Carefully slew the boom in both
directions while monitoring the brake
function stopping distance.
Fig.6-52 Structure of Slewin g gear
● If the stopping distance is unusually long transmission
or slow to stop, the slewing gear
transmission braking system may be at [1] Output Shaft
[2] oil cup
the end of its life cycle. [3] vent plug
[4] vent elbow
● If the stopping distance is normal the [5] Reducer
[6] vent plug
slewing gear transmission braking [7] Nameplate
system is functioning properly. [8] Oil drain
[9] Rubber hose for brake
(4) After testing procedures are complete, [10] Brake
[11] Oil drain
retract the boom and outriggers and shut the [12] Fender cover
truck engine OFF.

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(5) Remove the drain plug (a) from the

slewing gear transmission and inspect the
drained fluid condition.(see Fig. 6-53)

● Dark colored fluid with a strong, unusual

odor indicates the fluid is probably
burned. As a result, the braking system
has been overheated and should be
a
replaced.

● Chunks or small fragments of braking

material in the fluid indicates that the
braking material is failing or the brakes Fig.6-53
are simply worn out and in need of
replacement.

● Contact your SANY distributor if the

braking system needs repair.

Changing the slewing gear transmission oil

(1) Position the truck chassis on a flat level

b
surface.

(2) Place a suitable container under the drain

Min
plug to catch the oil. Remove plugs (a)
to allow reducer case to properly drain.

(3) Once drained, install plug (a) and fill case

through oil cup (b) until oil level reaches Min
level of the oil cup. a

(4) For correct oil and amount. See Table 6-

9 on page 6-17 for the type of oil.

(5) Torque plugs (a) to 15 N.m.

Fig.6-54

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6.6.3 Ball-Bearing Slewing Ring

Overview
The structure of ball-bearing slewing ring (see
Fig. 6-55), maintenance interval (see Table.
6-1 on page 6-4, Table. 6-2 on page 6-5 and
Table. 6-3 on page 6-7 ).

Fig.6-55 Structure of Ball-bearing Slewing ring

[1] Slewing bearing [6] Screw
[2] Ring plate [7] Oil cup
[3] Screw [8] Plug
[4] Gear [9] Pipe connector
[5] Washer [10] Lubricating grease tube

Checking the ball-bearing slewing ring

(1) Grease the ball-bearing slewing ring

through the filling seat of ball-bearing
slewing ring every 50 hours of operation or
every week. As to the lubrication of ball-
bearing slewing ring, apply grease on

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various lubricating points of bearing through

the delivery line of grease.

(2) Check if foreign matter exists between

gears. If any, immediately remove them.

(3) Check the gear surface of reducer for

abrasion every three months and apply
grease on the gear surface.

NOTE: After long-term stop of pump, apply

sufficient grease on the ball-bearing
slewing ring.
Checking the connecting bolts on the ball-
bearing slewing ring

(1) Check the torque condition for the

fasteners (a) on the rotary tower system
every 1000 hours of operation or every year.

(2) The tightening torque for the slewing

bearing fasteners is 1,210 N.m (892 lbf.ft).
Visually inspect all connecting bolts on the
ball-bearing slewing ring for looseness, ware
or damage. Any missing bolts should be
replaced.

NOTE: The loosened connecting bolt of ball-

bearing slewing ring should not be
directly tightened. Replace it with new
high-strength bolt of the same size.
Oil the thread and the head bearing
surface and tighten the replacement
bolts.

6.7 Transfer Case and Drive Shaft

The transfer case is used to switch the power
output, and transfer power to the chassis
during traveling as well as the oil pump
during concrete pumping.

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6.7.1 Transfer case

The structure of transfer case is as shown in

Fig. 6-56.

Fig.6-56 Transfer Case

[1] Oil filler connector
[2] Plug at oil level checking port
[3] Plug at oil-drain outlet

Daily inspection and maintenance of transfer

case
Check the lubricating oil for transfer case and
the pre-tightening torque for the bolts for
connecting the drive shaft and transfer case
as well as the bolts of the transfer case
hanger, and fill lubricating grease to the
extension section of drive shaft once every
week or every 50 working hours.

(1) After the pump is placed horizontally,

close the engine and cut off the power
supply to avoid unauthorized starting.

(2) Check two stroke switches and cables on

the transfer case for readiness, water
resistance and insulation.

(3) Check the tightening torques of bolts

connecting the drive shaft and transfer case
and transfer hanger bolt for looseness. If
any, tighten them.

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CAUTION
When the lubricating oil level in the
transfer case exceeds the required
position, the transfer case will easily
generate heat when working, so as to
make the lubricating oil easily get bad,
affecting the lubrication of inner gear and
bearing of the transfer case. In case of
serious situation, the bearing and tooth
surface of gear will be burnt out due to
bad lubrication.

Changing the transfer case oil

Change the lubricating oil of transfer case
every 500 hours of operation or every half
year and clean the transfer case. Remove dirt
and hazardous substance to ensure the
reliable operation of transfer case.

(1) Park the truck-mounted concrete pump

flatly, shut down the engine and cut off the
power to avoid unauthorized startup.

(2) Screw off the plug at oil-drain outlet to

drain the lubricating oil in the transfer case.

(3) Screw off the breathing cover and fill

appropriate volume of diesel oil into the
transfer case to remove the deposits and
dirt inside. The breathing cover of transfer
case filler pipe is at the inner side of the Breathing
cover
revolving tower (see Fig. 6-57).

(4) Collect the drained lubricating oil with a

proper container, and then dispose it
according to the relevant environmental
protection regulations.
Fig.6-57 Schematic Diagram of Breathing
(5) Mount the plug at the oil-drain outlet. Cover of Transfer Case Filler Pipe

(6) Fill gear oil of the appropriate grade from

the oil filler at the breathing cover till it
reaches the bottom of oil level checking port
of the transfer case and some oil overflows.

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(7) Mount the plug at oil level checking port

and the breathing cover.

(8) Start the truck-mounted concrete pump

and check if the transfer case works
normally.

6.7.2 Drive shaft

Connecting to transmission Connecting to rear axle

Fig.6-58 Drive Shaft

Use a grease gun to apply lubricating grease

to the extension section of the front/rear drive
shaft and the cross bearing of the transfer
case once a week (See Fig. 6-58).

Check the pre-tightening torque for the

connecting bolts of drive shaft and transfer
case, gearbox and differential, etc. Check if
the seal rings of cross bearings at both ends
of drive shaft are in good condition.

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6.8 Hydraulic System

The hydraulic system is composed of the
hydraulic pump, valve bank, accumulator,
hydraulic motor, oil cylinder, line, etc. When
pumping, carefully observe the working status
of hydraulic system, e.g. if the hydraulic fluid
temperature is normal, the operation of
radiator is normal and if the oil pump and
motor have abnormal noise, etc.

6.8.1 Overview

1
5

Fig.6-59 Structural Drawing of Hydraulic Oil Tank

[1] Air filter [4] Oil filler

[2] Oil-drain valve [5] Hydraulic oil tank
[3] Oil level gauge

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6.8.2 Changing the hydraulic fluid

NOTE: Cleanliness is of the greatest possible

importance in the maintenance of
hydraulic systems. You must make it
impossible for dirt or other impurities
to enter the system. Even small
particles may cause valves to be
scored, pumps to seize and choke
and control bores to become blocked.
Hydraulic fluid drums must stand for
some time before the fluid is taken
from them. Never roll the barrels to
where you will be drawing off the fluid.
Clean bungs, filler caps and their
surroundings before opening them. If
possible, you should use a filler unit to
fill up the hydraulic system. Never
leave the tank lid open longer than
necessary.
Preparation
The following work must be completed before
starting the full fluid change:

(1) Switch off the remote control.

(2) Switch the hydraulic pumps off.

(3) Reduce fluid pressure completely.

(4) Check the contamination indicator on the

vent filter of the fluid reservoir. When the red
check ring is visible in the inspection glass,
you must replace the filter element for the
vent filter .Close the engine.

(5) Switch the drive engine off.

(6) Secure the system against unauthorized

starting.

(7) Secure your working area and fix notices

to the blocked controls and setting devices.

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WARNING
The accumulator pressure in pressurized
systems must be released. Failure to do
so may result in a sudden rupture in the
accumulator or even endanger persons.

Changing the fluid

NOTICE
You must make sure you collect the old
hydraulic fluid and dispose of it in
accordance with the regulations.
Biologically degradable hydraulic fluids
must also be disposed of separately from
other waste, just like mineral hydraulic
fluids. Failure to do so will result in
pollution to the environment.

(1) Remove a hose from the hydraulic

system tank and drain off the fluid. Position
of the drain valve.

(2) hen disconnect all hoses from the tank.

(3) Wipe out all the openings with a lint-free

cloth. Wipe as far into the tank as possible
when doing this. You should also remember
that there may also be separate apertures
intended for tank cleaning.

(4) Remove all filter inserts.

(5) Change all filters and refit the filter

elements.

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NOTICE
Only fill the tank through the mesh in the
filler inlet. Fill up the tank up to the
Maximum" marking after bleeding and a test
run. Use only the hydraulic fluids specified in
the lubrication recommendations. Failure to
do so may result in instability in operating
positions or serious damage to the machine.

(6) Replace any defective hoses.

(7) Fill the tank with new fluid.

(8) Remove the dirt deposits from the oil

cooler.

(9) Check all screwed joints and tighten

where necessary. Check all flared screwed
joints.
b
(10) Check the electrical connections.
52

(11) Carry out all function checks.

(12) Bleed hydraulic system.

a
(13) Carry out several test runs.

(14) Refit all the safety equipment, markings Fig.6-60

and notices you have removed.

Draining the hydraulic oil tank

(1) Remove the vent filters (b) from the

hydraulic tank fill port (a).

(2) Locate the drain locations (c) below the

pump chassis hydraulic tank on the left side
of the unit. See Fig. 6-61for the position of
(c).
c

(3) Place an appropriate container under the

drain port.

NOTE: For proper container size, see Table. e

d
6-10 on page 6-19 for details.
Fig.6-61

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(4) Remove plug (d) and open valve (e) to

drain the hydraulic oil from the tank. See
Fig. 6-61 for the position of (d) and (e). f
Cleaning and inspecting the hydraulic tank

(1) Remove covers (f) to inspect or clean the

inside of the tank sections after it has been
emptied.

NOTICE
Never use water or toxic liquids to clean
the inside of the tank. These chemicals Fig.6-62
could damage the system.

(2) If you will be cleaning the tank, it is

recommended to use mineral spirits to wash
the inside of the tank.

(3) Once the tank is clean and dry, reinstall

access covers (f).

(4) Close valve (e) and reinstall plug (d). See

Fig.6-61 for the location of e and d.

(5) Refill hydraulic tank with fresh oil through

the vent fill ports on the top of the tank. 1

NOTE: For fluid type and amount, see table

2
6-9 on page 6-17 and table 6-10 on page 6-
19. 3

(6) Install the vent filter and resume normal

operation.
4

6.9 Accumulator

6.9.1 Overview
The accumulator is composed of housing, Fig.6-63 Structure of accumulator
capsule, oil valve, gas valve, etc. (see Fig. 6-
[1] Gas valve
63). Common sense about the use of
[2] Capsule
accumulator:
[3] Housing of accumulator
[4] Oil valve

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(1) The rubber capsule storing nitrogen in

the accumulator has slight gas permeability. Air pressure
bar (MPa)
After using for a certain time, the gas 78.4 (8)
pressure will decrease; therefore the
working pressure of accumulator should be Upper limit
68.6 (7)
checked at least once every year. When the
63.7 (6.5)
oil temperature is 50°С, its pressure is Allowable
pressure
7MPa (68.6bar). The permissible pressure 58.8 (6) range

range of accumulator (see Fig. 6-64). 53.9 (5.5)

49 (5) Lower limit

(2) If the actual value is 75% or less than
44.1 (4.5)
specified value, the accumulator must be
filled with gas.(3) The accumulator can only 0 10 30 50 70
oil temperature (°C)
be filled with nitrogen. Never use other
gases.(4) The working pressure, gas filling Fig.6-64 Allowable Pressure of Accumulator
pressure and capacity (See Table. 6-12).

Table 6-12 Charging Pressure and Capacity

Working Charging
Capacity
Pressure Pressure

16MPa 7-8 MPa 10L

NOTICE
T h e c h e ck i n g a n d o i l f i l li n g w o r k o f
accumulator must be performed by
professional person to avoid nonstandard
operation.

DANGER
The accumulator should be filled with
nitrogen. Never use other gases. If it is
filled with air, nitrogen, etc., explosion
may occur.

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6.9.2 Checking the nitrogen pressure

of accumulator

How to test the nitrogen pressure of the

accumulator when no gas filling equipment is
available:

(1) Start the machine to build the pressure in

accumulator until it reaches 10MPa.

(2) Press E-STOP button.

(3) Slightly open the unloading ball valve of

accumulator to slowly relieve pressure in the
accumulator. With the gradually relieving
pressure in accumulator, the pointer on the
pressure gauge will move slowly. As soon
as the pre-filled pressure of accumulator is
reached, the reading on pressure gauge will
suddenly decrease, that is, the indication at
this time is the nitrogen pressure in the
accumulator.

(4) If the nitrogen pressure in the

accumulator is not between 7-8MPa, adjust
it to 7-8MPa.

6.9.3 Nitrogen filling and pressure

adjustment of accumulator

(1) Preparation work before nitrogen filling:

● remove the gas filling gap and protective

hood from the accumulator;

● turn the handle of gas filling tool anti-

clockwise to the end position and then
connect it to the gas filling valve on the
accumulator;

● Connect the joint at another end of hose

to the nitrogen bottle.

(2) Gas filling or gas supplement: screw in

the handle of gas filling equipment clockwise
until the pressure gauge on the gas filling

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SYG5360THB 47

equipment displays pressure; then slowly

open the cut-off valve on nitrogen bottle to
gradually fill nitrogen in the capsule, and
then close the cut-off valve on the nitrogen
bottle. Observe the pressure gauge on the
gas filling equipment and repeat above
procedure until the reading reaches the
upper limit in figure; unlock the vent valve
on the gas filling equipment to discharge the
remained nitrogen; disassemble the gas
filling equipment; check the gas filling valve
for leakage; if not, install gas filling cap and
protective hood.

(3) Gas discharging or adjustment: open the

vent valve; turn the handle clockwise to
allow the crown bar to open the vent valve
core downwards for discharging gas; when
the gas discharging is completed, turn the
handle back to the original position; remove
the gas filling equipment; check the gas
filling valve for leakage; if not, install the gas
filling cap and protective hood.

The method of pressure adjustment is similar

to that of gas filling. If the pressure is high,
operate as per gas discharging procedure; if
the pressure is low, operate as per gas
supplement procedure.

(4) Temperature compensation of nitrogen:

the gas pressure changes with the
temperature. The gas pressure of
accumulator at 50 ℃ is set as 7MPa
(68.6bar).

For gas filling at normal temperature, adjust

in accordance with figure; for general
inspection, observe the hydraulic fluid
temperature, e.g. if pressure is lower than the
lower limit, refill gas.

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6.10 Oil Filter

6.10.1 Replacing hydraulic oil filters

Cleanliness is a key factor in maintenance of
hydraulic system.If the hydraulic oil is
polluted, the hydraulic system will not work
normally
For new vehicle, oil return filter element GP
must be replaced when running 500h.After
that, oil intake filter and oil return filter
element GP must be replaced every 1000h.
When replacing hydraulic oil, oil intake filter
and oil return filter element GP should be
changed, either.

You should obey local effective regulation

when dealing with old filter core
Replacing oil return filter element

(1) Release pressure, stop the machine and

cut off the power.

(2) Remove the bolt on the oil-return cover of

hydraulic oil tank.

(3) Remove the oil-return cover.

(4) Get out the oil return filter element GP

from the oil tank.

(5) Reinstall the new oil return filter element

GP into the oil tank.

(6) Put the oil-return cover back and tighten

all bolts.

Replacing and cleaning oil intake filter)

(1) Release pressure, stop the machine and

Fig.6-65 Oil intake Filter
cut off the power.
[1] Compressing [5] Nut
(2) Remove the bolt on the oil-intake cover
spring [6] Tie rod
of hydraulic oil tank.
[2] Nut [7] Filter core
(3) Remove the oil-intake cover. [3] Plan cushion [8] O-ring
[4] Spring cushion

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(4) Get out the oil intake filter from the oil
tank and remove the filter core.

(5) Reinstall the new oil intake filter on tie

rod. Please notice the fitted position
requirements when assembling, You should
obey the rule that the pin on oil-intake cover
can be pressed tightly to the tie rod.

(6) Put the assembled oil intake filter into the

oil tank.

(7) Put the oil-intake cover back and tighten

all bolts.

NOTICE
You should make sure the fitted position
unchanged when assembling the oil intake
filter element. If the fitted position is
greater than the specified, the oil-intake
cover will cannot be covered. If the the
fitted position is less than the specified,
the oil-intake filter will might be dumped
in the oil tank.

The cleaning method of oil intake filter:

Immerge the filter core into the coal oil for 10
minutes, Get out. the core and blow it from
inside to outside by compressed air which is
<=0.6MPa until the exterior surface of the
filter core is cleaned.

NOTICE
It is prohibited that contacting with the
filter core by such things as hand and
brush that might lead screen to deform
and break down. If deformation and
breakage happed, replace the filter core
immediately.

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Replacing high pressure filter element)

If high pressure filter is installed, you should
often check whether blocked. When the
indicator shows red, the filter core must be
replaced (The core of high pressure filter
cannot be cleaned, replace only). Steps as
follows:

(1) Release pressure, stop the machine and

cut off the power.

(2) remove canister (a) and get out the

hydraulic filter element
a
(3) Clean the canister inside.

(4) Reinstall new filter element and canister

(a) Fig.6-66

NOTE: When installing the filter cartridge, if

the threads are not aligned, the screwing of
filter cartridge will immediately be subjected to
large resistance. Do not apply excessive force
and the installation threads of filter cartridge
should not be damaged. Draw back the filter
cartridge, realign the tread and screw it to
install it. When the filter cartridge is tightened
to the end position, it should be unscrewed by
1/4-1/2 turn.

6.11 Air Filter

The air filter is located on the hydraulic fluid
tank of revolving tower (see Fig. 6-67). Since
the construction site has plenty of dust, the
air filter should be replaced every year. The
air filter is integrated with its filter element.
For replacement, remove the old filter and
just install a new one.

NOTICE
Treat the old filter in accordance with the
local regulation to avoid the pollution to Fig.6-67 Air Filter
the environment.

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6.12 Hoses

WARNING
Check all hoses (including hose fittings)
with the machine running. The hoses at
the slightest sign of damage or even mere
indications of threatened damage must be
replaced. Know the maximum pressure
that your machine can exert on the
concrete, and be sure that the hoses,
pipes and clamps are capable of handling
the pressure. Failure to do so may result
in a sudden rupture in the hose or piping
system or hose end-swing and personal
injury.

6.12.1Checking the hoses

(1) Hydraulic hose (see Fig. 6-68)

Check the hydraulic hose: Dark and moist

patches on the fitting are external signs of
incipient damage, and carefully check:

a. The hose for any defect, break or porous Fig.6-68

surface.

b. The coupling of hose for tightness.

c. The middle part of hose is nonmetal. The

hose should be prevented from aging due
to strong sunlight, thermal effect and
chemical action.

NOTE: Hoses should not be more than six

years old, including a storage time of
two years. Take note of the date of
manufacture on the hoses.
(2) hose joints

a. Check the house joint for tightness.

b. The hose joints with leakage only can be

tightened with the permissible torque. If

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no torque wrench is available, tighten the

joint until hand feels obvious increment of
force. If the leakage can not be stopped,
replace these hose joints.

6.12.2Replacing the hoses

The procedure for replacing hoses is as
follows:

(1) Close the engine.

(2) Completely relieve the residual pressure

in the hydraulic system.

(3) When disassembling the hose joints,

slightly open it to allow the hydraulic fluid to
flow out. After relieving the residual pressure
of hydraulic fluid in hose, continuously
disassemble the hose.

(4) Take care when undoing the joints.

(5) Close the connection points with a plug

immediately you have removed the old
hoses. No dirt may enter the hydraulic circuit
and the hydraulic circuit must not run empty.
Collect the overflowed oil with a vessel and
treat it in accordance with the environment
protection requirements.

(6) Keep the hoses free from dirt.

(7) Fit the hoses to be free from bends or

points of abrasion.

(8) Bleed the hydraulic system.

(9) Carry out a test run and inspect all hoses

again after fitting new hoses.

CAUTION
The hydraulic line can not work without
oil. The inner of new house should be
cl ea n a nd fr e e o f d us t. Th e c r oo ke d
hydraulic hose is subjected to mechanical
pre-stressing force; therefore, the hose

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will rebound when disassembling and lead

to injury.

6.12.3Identifying the hoses

The hose is composed of the hydraulic hose
in the middle and joints at both ends

(1) Type of hose

1SB —- hydraulic rubber hose wrapped with

a layer of steel wire.

2SN—- hydraulic rubber hose wrapped with

two layers of steel wire.

4SP —- hydraulic rubber hose wrapped with

four layers of steel wire (medium pressure).

4SH —- hydraulic rubber hose wrapped with

four layers of steel wire (high pressure)

(2) Identification of hose

The related specifications of hose produced

by Sany Heavy Industry Co., LTD can be
obtained from the name of material. Take
hose 4SP20-DKOS-DKOS90-1000- V90-XXX
for example:

Rubber hose 4SP20-DKOS-DKOS90-1000-V90-XXX

Rubber hose type Type of accessory

Type of connector at one side Mounting angle

Type of connector at the other side Assembly length

6.13 Electrical System

The electrical system is composed of the
control cabinet, remote control, control box,
harness, etc. Periodically check the cables on
the plug of electromagnetic valve, joint of

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 Maintenance
SYG5360THB 47

sensor, terminal row, toggle switch,

instrument, etc. for tightness.

WARNING
The electrical cables can not connect
other unauthorized electrical elements.
Failure to do so may result serious
damage to the elements or even personal
injury.

6.13.1Electric control cabinet

The electric control cabinet is the key part of
pump truck control system and composed of
the electrical control cabinet body, SANY
motion controller assembly (SYMC), Central
Power Distribution Box, SANYcomunication
display (SYCD), etc. (see Fig.6-69).Check and
maintenance interval (see table 6-1 on page
6-4).

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SYG5360THB 47

1 2 3 4 5 6

7/8

Fig.6-69 Structural Drawing of Electric Control Cabinet

[1]Electric control cabinet body
[2]Circuit board assembly SYEB
[3]Central distribution box
[4]SYMC special controller
[5]Emergency stop
[6]SYCD display
[7]SANY Truck pump electric plate SYMCEB
[8]SANY Truck pump electric plate SYEB

CAUTION
Do not put other items in the electric
control cabinet, e.g. tool, gloves to avoid
disrepair to the items inherent in the
electric control cabinet. The door of
e le c tr i c c o nt r o l c ab i ne t is ge n er a ll y
closed. Do not open it casually. In
addition, the inner of cabinet should also
be dry and protected from rain water and
washing. Failure to do so may result in
the circuitry or connection in the electric
control cabinet to be affected with damp.

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 Maintenance
SYG5360THB 47

CAUTION
When repairing other components, if
welding work is required, the general
switch of power supply for chassis should
be closed, and the ground wire of welder
should be directly connected to the part to
be welded so as to avoid damage to the
electrical elements in the electric control
cabinet.

(1) Periodically check the connection of relay

and box for tightness. If the relay is
damaged, replace it with new one of the
same specification.

(2) If trip occurs in the circuit breaker, timely

check the circuit to find the reason. When
short-circuit or other faults of circuit are
eliminated, replace it with new circuit
breaker of the same specification. If you
have any question about the specification of
circuit breaker and in the event of circuit
fault, connect the after-sale service engineer
in time.

(3) Periodically check the connections

between plug board and central power
distribution box, electric circuit board, SANY
motion controller (SYMC), SANY comunication
display (SYCD) and aviation plug for
tightness. If any, tighten it timely.

WARNING
When replacing the circuit breaker, only
the circuit breaker of the same
specification can be adopted. Never use
product with current larger than specified
value. Failure to do so may result in
serious damage to the circuitry or even
injury to persons.

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SYG5360THB 47

6.13.2Maintenance operation box

The maintenance operation box is located on

the main support of boom and mainly used to
operate the pump truck when checking and
maintaining it (see Fig. 6-70). Check and
maintenance interval (see table 6-2 on page
6-5).

(1) Periodically check the E-STOP button of

maintenance operation box, push-button
switch and aviation plug for tightness. If any,
tighten it in time.

(2) Periodically check the waterproof seal

between the panel and box. If necessary,
replace it.

NOTICE Fig.6-70 Control Box for Maintenance

The maintenance operation box is

generally closed. Do not open it casually.
The inner of operation box should be dry
and protected from rain water and
washing. Failure to do so may result in
the circuitry or connection in the
maintenance operation box to be affected
with damp.

CAUTION
After every construction, the concrete on
maintenance operation box panel should
be timely cleaned; otherwise it will cure at
the acting position of switch and result in
malfunction of switch which may cause
injury to persons or machines. Do not
damage switch and its wire during
construction or handling items.

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SYG5360THB 47

6.13.3Small operation box

The small operation box is located near the
main support of the platform and convenient
for operating this pump truck when pumping
(see Fig. 6-71). Check and maintenance
intervals (see table 6-2 on page 6-5).

(1) Periodically check the E-STOP button of

small operation box, toggle switch and
aviation plug for tightness. If any, tighten it
in time.

(2) Periodically check the waterproof seal

between the panel and box. If necessary,
replace it.

NOTICE
The maintenance operation box is generally
closed. Do not open it casually. The inner of
operation box should be dry and protected Fig.6-71
from rain water and washing. Failure to do
so may result in the circuitry or connection
in the maintenance operation box to be
affected with damp.

CAUTION
After every construction, the concrete on
maintenance operation box panel should be
timely cleaned; otherwise it will cure at the
acting position of switch and result in
malfunction of switch which may cause
injury to persons or machines.

6.13.4Outrigger operation box

The outrigger operation box is mainly used to
conduct related operation on outrigger
through cooperating with the multi-way valve
of outrigger (see Fig. 6-72). In the event of
emergency, the E-STOP button on panel can
be used to ensure the safety of equipment.

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SYG5360THB 47

Check and maintenance intervals (see Table

6-2 on page 6-5) 3

(1) Periodically check the installation screw

of support operation leg for tightness. If any,
2
immediately tighten the screw to ensure it is
reliably secured.

(2) Waterproof seal is used between the

operation box panel and box. If the fixing 1
screw of panel is loosened, check the seal.
If necessary, replace it and then tighten the
installation screw of panel.

(3) Periodically check the E-STOP button of

operation box, toggle switch, and aviation
plug for tightness. If any, tighten it in time. Fig.6-72 Control Box for Outriggers

CAUTION [1] E-STOP button

[2] Toggle switch
After every construction, the operation
[3] Control box
box panel should be timely cleaned;
otherwise the concrete will cure at the
acting position of E-STOP button or push-
button switch and result in malfunction of
switch.

6.13.5Mechanical encoder
1
The mechanical encoder is used to measure 2
and limit the rotation control angle of boom
(see Fig. 6-73). Check and maintenance 3
intervals (see Table 6-2 on page 6-5)

(1) Apply grease on the slewing part of

mechanical encoder every 50 hours of
operation or every week.

(2) Periodically check the working condition

of two sensors on the mechanical encoder
Fig.6-73 Mechanical Encoder
and the sensing distance of sensor (less
than 5mm); if the installation nut of sensor is [1] Sensor
loosened, re-adjust the measuring distance [2] Mechanical encoder
of sensor and tighten it. [3] Rotary reducer

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 Maintenance
SYG5360THB 47

(3) Periodically check the tightening condition

of plug board of mechanical encoder and
harness for tightness. If not, tighten it timely;
the plug board should be fixed with the
harness to prevent the wire from
disconnecting.

(4) After every maintenance operation of

mechanical encoder, re-fix the wire to avoid
damage caused by gear.

6.13.6Temperature sensor
The temperature sensor is used to measure
the hydraulic fluid temperature. Its measuring
range is -30°C~90°C(see Fig. 6-74. In the
event of fault in temperature sensor, timely
check the connection between sensor and
plug board of harness for tightness. In the
event of fault in sensor itself, replace it timely.
Fig.6-74Temperature Sensor
NOTE: The pump truck is furnished with 2 [1] Temperature sensor [3] Hydraulic oil tank
temperature sensor. When the display [2] Seal ring
shows the temperature sensor 1 has
fault, switch the default setting of
control system to the temperature
sensor 2 through the operation of
display to ensure the normal operation
of construction.

6.13.7Liquid level sensor

The liquid sensor is used to measure the
water level in the water tank. If the water
level is too low, the water pump will stop (see
Fig. 6-75).

(1) Periodically check the connection

between the liquid level sensor and plug
board for tightness. If not, secure it timely.

(2) If the water tank is fully filled with water Fig.6-75 Liquid Level Sensor
but the liquid level sensor is not active, it
may be stuck in the water tank or has been [1] Rear outrigger [3] Water drain ball valve
damaged. Adjust or replace it in time. [2] Liquid level gauge

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6.13.8Limit switch of boom

The limit switch of boom is used to control
the downward stroke of boom and provide
limit protection (see Fig. 6-76).

Periodically check the limit switch arm of

boom to ensure the flexible rotation. In the
event of failure to reset or coupling stagnation
of rotation, replace it timely.

NOTICE Fig.6-76 Boom Limit Switch

Do not put items on the limit switch of
boom; otherwise the controller will receive
the wrong information and influence the
motion of boom.

CAUTION
After every construction, the concrete on
limit switch of boom should be timely
cleaned; otherwise it will cure at the
acting position of switch and result in
malfunction of switch. Do not damage
switch and its wire during construction or
handling items.

6.13.9Limit switch of outrigger

Fig.6-77 Limit Switch of Front Outrigger
The limit switch of front outrigger and limit
sensor of rear outrigger are used to control
the withdraw stroke of outrigger and provide
limit protection (see Fig. 6-77 and Fig. 6-78).

(1) Periodically check the connection

between the limit switch of outrigger, sensor
and plug board of harness for tightness. If
not, secure it timely.

(2) Periodically check the installation nut of

limit sensor of outrigger and sensing
distance of sensor (less than 5mm) for
tightness. If not, adjust and tighten it timely. Fig.6-78 Limit Sensor of Rear outrigger

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SYG5360THB 47

(3) Periodically check the limit switch arm of

front outrigger to ensure the flexible rotation.
In the event of failure to reset or coupling
stagnation of rotation, replace it timely.

6.13.10 Limit switch of transfer case

The limit switch of transfer case is used

to switch the pumping and traveling status. If
this limit switch has fault, the pumping may not
be conducted (see Fig. 6-79).

(1) Periodically check the transfer case

switch for tightness. If not, secure it
timely.

(2) If the transfer case switch can not be

turned to desired position or has damage,
adjust or replace timely.
Fig.6-79 Limt Switch of Transfer Case

6.13.11Rocker switch

The rocker switch is located in cab (see Fig.

6-80).

Periodically check the performances of rocker

switches for general power supply, pumping,
traveling, etc. If some plug board for switch is
loosened, secure it timely.

NOTE: When switching the pumping and

traveling status, the chassis gearbox
must be in neutral position. Never
conduct forced switching under when 1 2 3

putting into gear.

Fig.6-80 Rocker Switches in Cab

[1] Switch power supply of electric control cabinet

[2] Switch for pumping
[3] Switch for travelling

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SYG5360THB 47

6.13.12Electromagnetic valve and its

plug

Periodically repair the electromagnetic valve

to ensure the normal operation of equipment
(see Fig. 6-81).

(1) The plug of electromagnetic valve has its

own working indicator. When the power
supply is switched on, the indicator will be
on, by which the following reasons for
malfunction of electromagnetic valve can be Fig.6-81 Boom Multi-way Valve
confirmed: circuit fault or electromagnetic
[1] Electromagnetic valve for switch-over
valve fault.
between outrigger and air cooler
(2) In order to prevent the installation screw [2] Rotary electromagnetic valve
for plug of electromagnetic valve, the [3] Electromagnetic valve for arm 1
installation hole is filled with silica gel. When [4] Electromagnetic valve for arm 2
the plug of electromagnetic valve is removed [5] Electromagnetic valve for arm 3
for maintenance, re-fill the silica gel and re-
[6] Electromagnetic valve for arm 4
tighten the screw.
[7] Electromagnetic valve for arm 5

6.13.13Wire
The wire is used to connect different
electrical elements (see Fig. 6-82).

(1) Periodically check the plug board of wire

and the seal of three-way and corrugated
tube outside the wire. If one of them is
loosened, secure it timely.

(2) Remove concrete and foreign matters on

wire timely to avoid prevent circuit from
damage.

(3) During construction and maintenance, Fig.6-82 Wire

carefully protect the circuit from the damage
of circuit or failure in seal structure caused
by external force.

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SYG5360THB 47

6.13.14Wireless remote control system

T h e m a i nt e n a n c e , c ar e a n d s e r v i c e o f
wireless remote control system are conducted
as per the maintenance manual supplied by
the manufacturer of this remote control
system. In addition, the safety operation is
conducted as required by the manufacturer of
remote control system.

Plug to completely drain off water in the

cleaning room and draw out the piston head
to conduct cleaning and checking.

The cleaning room should be clean and no

deposit is allowed on the piston rod of oil
cylinder.

During forward pumping or reverse pumping,

if water in the cleaning room is muddy,
immediately stop the machine and check the
concrete seal.

During pumping, if the water temperature in

the cleaning room is too high, timely replace
with fresh water.

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Maintenance
SYG5360THB 47

CAUTION
For construction in cold weather, e.g.
winter, completely drain off water in the
cleaning room to avoid icing to damage to
machine.

CAUTION
Do not add lithium-based grease in the
cleaning room; otherwise the hydraulic
system is easily be polluted and faults will
frequently occurs.

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Specifications
7 Specifications
7.1 Technical Data ..................................................................................................7-3
7.2 Dimension .........................................................................................................7-5
7.3 Boom Operating Range ....................................................................................7-6

7-1
Specifications
SYG5360THB 47

WARNING
Always read the Safety section of this
manual before attempting to operate this
equipment. Failure to do this could result
in machine damage, personnel injury or
death.

7-2
 Specifications
SYG5360THB 47

7 SPECIFICATIONS

7.1 Technical Data

Overall Parameters

Length 12500mm

Width 2500mm

Height 4000mm

Total weight 36450

0kg

Boom and Outrigger Specifications

Vertical reach 47.0

Horizontal reach 42.0

Reach depth 29.3 m

Minimum unfolding reach 13.9 m

Length 9760 mm
1st section
Articulat ion 89°

Length 7670 mm
2nd section
Articulation 180°

Length 7410 mm
3
Articulation 180°

Length 9670 mm
4th section
Articulation 235°

Length 8545mm
5th section
Articulation 21 5 °

Rotation ±360°

Outrigger spread L-R-front 9300mm

Outrigger spread L-R-rear 9620 mm

Outrigger spread width-front-rear on LH 9240 mm

Outrigger spread width-front-rear on RH 9240 mm

7-3
Specifications
SYG5360THB 47

Chassis specifications

Chassis brand BENZ

Chassis model Actros 4141
Engine model OM501LA. III/17
Engine maximum net power 300kW/1800rpm
Emission standard Euro III
Fuel tank capacity 400L
Output 11.946 L
Maximum speed 80km/h

Pump Specifications

Low pressure 170 m3/h

Output
High pressure 120 m3/h

Low pressure 8.3 MPa

Delivery pressure
High pressure 1 2 M Pa

Low pressure 29 times/min

Strokes/min
High pressure 19 times/min

Delivery cylinder diameter 260 mm

Stroke length 1900 mm

Hydraulic system Open loop

System oil pressure 32 MPa

Fuel tank capacity 680 L

Water tank capacity 620 L

Pipeline size 125 mm

End hose length 3m

End hose diameter 125 mm

7-4
 Specifications
SYG5360THB 47

7.2 Dimension
4000mm

1440mm 2020mm 4280mm 1350mm

12500mm

9.24m

6.06m
5.9m
9.3m

Fig.7-1

7-5
Specifications
SYG5360THB 47

7.3 Boom Operating Range

Fig. 7-2

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 Specifications
SYG5360THB 47

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 Appendix
SYG5360THB 47

Appendix
8 Appendix
8.1 Hydraulic Basic Diagram ..................................................................................8-3
8.2 Electrical Basic Diagram ...................................................................................8-5
8.3 Specifications of twin pipes ........................... ....................................................8-14

8-1
Appendix
SYG5360THB 47

WARNING
Always read the Safety section of this
manual before attempting to operate this
equipment. Failure to do this could result
in machine damage, personnel injury or
death.

8-2
 Appendix
SYG5360THB 47

8 APPENDIX
8.1 Hydraulic Basic Diagram

Fig.8-1 Basic Diagram of Pumping Hydraulic System

8-3
Appendix
SYG5360THB 47

Fig.8-2 Basic Diagram of Boom Hydraulic System

8-4
 Appendix
SYG5360THB 47

8.2 Electrical Basic Diagram

General electrical schematic diagram，which are subject to actual configuration.

CAN Communication interface

Fig.8-3 Basic Diagram 1 of Power Supply Distribution

8-5
Appendix
SYG5360THB 47

CAN Communication interface

Fig.8-4 Basic Diagram 2 of Power Supply Distribution

8-6
Appendix

8-7
SYG5360THB 47

Storage Side Marker Upper- Work Lamp

Controlling power engine flameout Chassis Odometer Signal
Remote Control Remote Control Local Control Main spillover
reverberator chassis horn Controlling power supply start Bypass Valve E-stop GPS Trigger
Battery Lamp structure horn power supply E-stop E-stop
valve E-stop supply in hand switchover

Fig.8-5 Basic Diagram 3 of Power Supply Distribution

Chassis
or

Key Switch of
Chassis
NOTE(4F): 15 corresponds to

37F corresponds to VOLVO

Benz\MAN\ISUZU chassis;

chassis.
8-8
Appendix
SYG5360THB 47

Emergency
Inductive Switch, temperature sensor Hydraulic
Inductive small operation box maintenance operation box Sensor, pressure
Switch, water Forcible stop
Switch, oil level
pumping level drainage pump pump pressure Discharge Discharge remote water swing cylinder swing cylinder main cylinder main cylinder Oil Pressure manual manual piston agitate main agitate tempera tempera-
Running horn preheat piston accumulator detection Remote manual
farward backard high/low control pump agitate move leftwardmove rightwardmove leftward move rightward Gauge speedup speeddown exit reset reverse system system ture 2
increase reduce switch ture 1

Fig.8-6 Basic Diagram of SYMC 1

to chassis control interface circuit

running pump running pump speed, speed, oil inlet, oil inlet, oil inlet, oil inlet, return
engine gearbox cruise Left Right Left Right Left Right Forward Backward return Low-pressure High-pressure
position position position position Speed increase decrease Main High Left right Left right piston 1 piston 2 remote
low Flushing accumulator Blower
Governing spillover pressure pressure Main cylinder , Main cylinder , power
position position Speed Main oil pump Main oil pump Swing cylinder valve Oil fill valve
Speed cruise valve reversing, reversing, agitate return piston
switch indicator meterage (front pump) (rear pump) reversing high-pressure low-pressure
 Mechanic encoder outrigger position detection Emergency stop Arm outrigger Arm 2 Arm 3 Arm 4 Arm 5 Boom pump

left proximity piston side rod side piston side rod side piston side rod side piston side
right proximity left front left rear right front right rear limit switch rod side
switch remote manual operation chamber chamber chamber chamber Pressure
switch chamber chamber chamber chamber

Fig.8-7 Basic Diagram of SYMC 2

to Coil KA6

to Coil KA18-1
to Coil KA18-2

Arm(1) Arm(1) Arm(2) Arm(2) Arm(3) Arm(3) Arm(4) Arm(4) Arm(5) Arm(5) Arm(6) Arm(6) rotate rotate outrigger bypass Antiswing
right limit left limit Boom pump up part horn chassis horn engine flameout
extension retraction extension retraction extension retraction extension retraction extension retraction extension retraction leftward rightward valve valve valve

Multiple valve of boom arm rotary protect,valve group

SYG5360THB 47

8-9
Appendix
Appendix
SYG5360THB 47

Fig.8-8 Chassis circuit of BENZ (optional)

8-10
 Appendix
SYG5360THB 47

engine throttle
control circuit

Fig.8-9 Chassis circuit of ISU ZU (optional)

8-11
Appendix
SYG5360THB 47

Fig.8-10 Chassis circuit of VO LVO (optional)

8-12
 Appendix
SYG5360THB 47

Fig.8-11 Chassis circuit of MA N (optional)

8-13
Appendix
SYG5360THB 47

8.3 Specifications of twin pipes

To regulate the use of twin pipes, bring down

the cost for customers and avoid misoperation
which lead to premature failure,warranty period
fault and the reduction of service life, specially
designed the specification.

Must ensure that the weight of the conveying

pipe which is installed or increased is in acco-
rdance with the requirements of equipment
manufacturers of concrete pump. Cannot
exceed the weight limit.

If it is not in accordance with the instructions

to install, the consequences will be not within
the scope of the warranty of Hunan SANY
Zhongyang Machinery Co., Ltd.

8.3.1Installation Instructions

(1) During the installation and operation of the

individual pipeline components,make sure
that the axes of the joint collars. Thereby
the pipes are not axially offset or at angle
with each other.If this is not the case, the
joints and flanges will be unequally stressed.
(see Fig. 8-12 )

angle offset

Fig. 8-12

8-14
 Appendix
SYG5360THB 47

WARNING

The centre lines of the respective compone-

nts must be aligned and centred with each
other.If this is not the case, the joints and
flanges will be unequally stressed and
single-sidedly overloaded in the event of
high internal pressure.

(2) During transportation or for assembly and

disassembly work,the conveying pipe should
be properly handled with care. It is prohibited
to throw the pipe to the ground or other hard
objects. The direct impact on conveying pipe
by the forks of the forklift truck should be av-
oided. During transportation, wood or other
soft package should be used between pipes.
(see Fig. 8-13)

Fig.8-13

(3) It is forbidden to use the hard objects (such

as stone,hammer,levering tools,etc.) knock on
the surface of the delivery pipe. If it is needed
to positioned by knocking the conveying pipe
during assembly, must use soft tools, and
gradually tapping in order to reduce the impact
on the conveying pipe. (see Fig. 8-14)

Fig.8-14

WARNING

Do not use hard objects (such as stone,

hammer, levering tools ,etc.) konck the
delivery pipe, otherwise it will lead to dam-
nification of the inner tube.

8-15
 Appendix
SYG5360THB 47

(4) If there is a blockage, it is not recommen-

ded to dismantle the front pipe to remove
the blockage with quite some force.If must
adopt this method,please install the block-
age protection ring.(see Fig. 8-15)

Fig. 8-15

WARNING
If blockage protection ring is not installed,
the inner tube and wearing sleeve of the
bloc kage pipe may be in the risk of being
rushed out when dismantle the front pipe
to remove the blockage with quite some
force.

(5) The pipe may be wearied unequally in

turn around
pumping process. It is suggested to rotate
the pipe by 180° or change its direction in
order to increase the lifetime of the pipe.
(see Fig. 8-16)

NOTICE turn

When installed conveying pipe, if there is a

direction tab on the conveying pipe, you
should be strictly in accordance with the
direct ion for installation. Ensure the cleann-
ess of the connection head and the mounted
Fig. 8-16
surface of the flange. There should not be
any sundries caused wear.

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SYG5360THB 47

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www.sanygroup.com

SANY AUTOMOBILE MANUFACTURING CO., LTD.

SANY Industry Town, Economic and Technological Development Zone, Changsha,

Hunan China 410100
Tel: 0731-84031888 Fax: 0731-84031999
Email: [email protected]
Service Hotline: 4008 87 8318 Complaint Hotline: 4008 87 9318

Materials and specifications are subject to change without notice in accordance with our continuous technical innovations.
Featured machines in photos may include additional equipment.

Copyright SANY HEAVY INDUSTRY CO., LTD.

No copy or reproduction without the written permission from SANY HEAVY INDUSTRY CO., LTD.