L8车载泵说明书译文

Loxa Heavy Machinery Truck-Mounted
Concrete Pump
Operation Manual
Beiqi Foton Motor Co., Ltd.

Operation Manual of Loxa Heavy Machinery Truck-Mounted Concrete Pump
Foreword
Sincerely thank you for choosing Loxa Heavy Machinery truck-
mounted concrete pump (hereafter referred to as truck-mounted pump).
We will provide you with high quality product and star-level after-
services.
This operation manual describes in details the technical characteristic,

performance parameters, working principles, structural composition,
operation safety, and maintenance of the truck-mounted pump. This
operation manual shall be considered as one indispensable part of the
truck-mounted pump and shall be carried along with the machine.
Please carefully read this manual before the operations, which will:
○ Help you understand the structure and performance

characteristics of the truck-mounted pump.
○ Prevent the machine malfunctions due to improper operations.
○ Avoid the safety issues arising from mis-operations.
○ Improve the operation reliability of the truck-mounted pump.
○ Prolong the service life of truck-mounted pump.
Guarantee normal downtime and repair cost. Ensure that the manual is
easily accessible as the tools in the toolbox, in order to ease the reading
at all times. You can operate this truck-mounted pump in a skilled and
safe way only after you fully understand the contents of this manual.
Dear friends, thank you for your trust on Loxa Heavy Machinery. We
sincerely wish you to realize own ambition in your career and achieve
great success.

1
Tips
Please maintain and operate Foton truck-mounted pump correctly. Our
company will not be liable for the consequences arising from the
violations of the following regulations.
Carefully read this operation manual before the startup and operations of
this machine.
○ Operate this machine within the specified operation scope and do

not use for any other purpose.
○ The operator must be the personnel qualifying the training and

shall have stable emotion, clear mind, and quick reaction during
operations.
○ Do not ask non-skilled technicians for repair or disassembly of this

machine without prior consent.
○ Fulfill all technical maintenances as per the requirements of this

operation manual.
○ To guarantee the normal running of the machine, please use the

parts supplied by our company. The use of any substituent part or
imitated part will probably lead to serious damage to this product,
for which our company will not be liable thereof.
○ In pursuit of advancement and perfection, this product is subject to

continual improvement by our company. The figures, schematic
diagrams, and other structural diagrams provided in this manual
are provided to the operation personnel for reference only and all
changes will be made without further notice.

2
Contents
Chapter I Main Structure and Function Introduction............................... 5
1. Exterior Diagram of Truck-Mounted Pump ........................6
2. Basic Parameters and Main Technical Performance

Indicators .......................................................................................7
3. Structural Introduction of Truck-Mounted Pump...............9
Chapter II Safety Rules ...................................................................... 11
1. Basic Principles:....................................................................12
2. Qualifications and Responsibilities of Truck-Mounted

Pump Operator............................................................................12
3. Safety Precautions ................................................................12
Chapter III Electric System and Operations.................................... 17
1. Electric Operating System of Truck-Mounted Pump ......18
2. Electric Operation Specification, Maintenance, and

Operation Instructions ...............................................................28
Chapter IV Operation Instructions.................................................... 29
1. Operation Preparations.........................................................30
2. Operation Functional Tests..................................................31
3. Pumping Procedure ..............................................................32
4. Cleaning .................................................................................33
5. Reset of Machine ..................................................................34
Chapter V Safety Rules ...................................................................... 35
1. Maintenance Periods ............................................................36
2. Overview ................................................................................36
3. Daily Maintenance ................................................................36
4. First 50h Maintenance ..........................................................36
5. Every 100h Maintenance .....................................................37

3
6. Every 500h Maintenance .....................................................37
7. Every 1,000h Maintenance ..................................................37
8. Lubrication.............................................................................38
9. Replacement and Adjustment of Wearing Parts ...............38
10. Maintenance of Diesel Engine ..........................................41
11. Technical Data Related to Repair of Equipment ............45
Chapter VI Troubleshooting.............................................................. 46
1. Typical Malfunctions ...........................................................47
Chapter VII Safety Rules ................................................................... 50
1. Action Table of Solenoid Valves.........................................51
2. Electric Schematic Diagram ................................................52
3. Hydraulic Schematic Diagram ............................................53

4
Chapter I
Main Structure and Function Introduction
1. Exterior Diagram of Truck-Mounted Pump

2. Basic Parameters and Main Technical Performance Indicators
3. Structural Introduction of Truck-Mounted Pump

5
1. Exterior Diagram of Truck-Mounted Pump
Figure 1-1
6
2. Basic Parameters and Main Technical Performance Indicators
Table 1-1 Parameter Table 1 of Truck-Mounted Pump
BJ5124THB BJ5124THB BJ5124THB BJ5130THB BJ5130THB BJ5130THB
Product model
90142 90181 100221 90141 90181 100221
Length mm 8980
Exterior
Width mm 2490
Height mm 3120
Vehicle Parameters
Chassis model Auman BJ5133THB-AA Auman BJ5123THB-1

Engine model ISDe 185-40 CA4DF3-17E3
Emission standard China-IV GB3847/GB17691 China-III GB3847/GB17691
Power kW 136 132
Fuel tank capacity
200+140 200+200
L
Wheelbase mm 4700
Engine model Deutz / BF6M1013ECP
Engine power
195/2300
kW/rpm
Maximum
theoretical concrete
displacement 66（16） 52（17） 62.4（20） 66（16）/ 52（17） 62.4（20）
(reversing number) /99( 24 ) /102（33） /107（35） 99（24） /102（33） /107（35）
(high pressure/low
pressure) m3/h
Theoretic pumping
pressure (high
Superstructure parameters
14/9 18/8.7 22.4/11.8 14/9 18/8.7 22.4/11.8

pressure/low
pressure) MPa
Inside diameter ×
stroke of delivery Φ230×1600 Φ200×1600 Φ230×1600 Φ200×1600
cylinder mm
Hopper capacity
0.6
m3
Feeding height mm 1480
Water tank
300
capacity L
Fuel tank capacity
700
L
Operation mode Local control/wire-control
Lubrication mode Manual/automatic lubrication
Switching between
high pressure and Automatic switching
low pressure
Table 1-2 Parameter Table 2 of Truck-Mounted Pump

BJ5131THB BJ5131THB BJ5131THB BJ5132THB BJ5132THB BJ5132THB
Product model
120161 120181 120201 120161 120181 120201
Length mm 9215 9280
Exterior
Width mm 2490 2490

Height mm 3120 3120
Vehicle Parameters
Chassis model Ollin BJ5139XXY-FD Auman BJ5133THB-AB

Engine model ISF3.8s4168 ISDe 185-40
Emission standard China-IV GB3847/GB17691 China-IV GB3847/GB17691
Power kW 125 136
Fuel tank capacity
200+200 200+200
L
Wheelbase mm 5000
Engine model Deutz/BF6M1013ECP
Engine power
195/2300
kW/rpm
Maximum
theoretical
concrete
displacement 63（14）/ 76（17）/ 70（16）/ 63（14）/ 76（17）/ 70（16）/
(reversing 108（23） 125（27） 120（27） 108（23） 125（27） 120（27）
number) (high
pressure/low
pressure) m3/h
Theoretic
pumping pressure
15.5/8.2 18/10 20/11 15.5/8.2 18/10 20/11
(high pressure/low
Superstructure parameters
pressure) MPa
Inside diameter ×
stroke of delivery Φ230×1800
cylinder mm
Hopper capacity
0.6
m3
Feeding height
1480
mm
Water tank
300
capacity L
Fuel tank capacity
700
L
local
Local control/wire- local control/wire- local control/wire-
Operation mode control/wireless-
control control control
control
Lubrication mode Manual/automatic lubrication
Switching
between high
Automatic switching
pressure and low
pressure
8

3. Structural Introduction of Truck-Mounted Pump
The truck-mounted pump is generally composed of chassis, power system, cooling system, electric
system, hydraulic system, support system, water cleaning system, lubrication system, and pumping
system.
The main hydraulic system adopts open-type system, the electric system adopts double-module
programmable controller, the mixing system adopts single motor system, the water cleaning system
adopts high pressure piston water pump, and the lubrication system adopts automatic lubrication
system.
The pumping system adopt S-valve delivery cylinder pumping system, which mainly includes main
cylinder, water tank, delivery cylinder, concrete piston, swing valve cylinder, mixing mechanism,
hopper, and S-pipe valve. Please refer to Parts Catalog of Truck-Mounted Concrete Pump for the
detailed structure.
1. 1’ - main cylinder; 2 - water tank; 3.3’ - delivery cylinder; 4. 4’- concrete piston;
5. 5’ - swing valve cylinder; 6 - hopper; 7 - S-pipe; 8 - Discharge port
Figure 1-2
Working principle of pumping mechanism:

Forward pumping: During the pumping of concrete, under the action of the main cylinders 1 and
1’, the concrete piston 4' moves forward and the concrete piston 4 moves backward. In such case,
the swing valve cylinder 5’ is under extended status and the cylinder 5 is under retracted status. By
means of the swing arm, the S-pipe 7 is connected with concrete delivery cylinder 3’ so that the
concrete in the cylinder 3’ is driven by the piston 4’ into the delivery pipeline through S-pipe. The
concrete in the hopper 6 is sucked into the concrete delivery cylinder 3 by the continuously
retracting piston 4. When the piston 4’ moves forward and the piston 4 moves backward in places,
the control system issues signals to extend the swing valve cylinder 5 and retract the cylinder 5. At
the same time, the main cylinders 1 and 1’ reverse to drive forward the piston 4 and backward the
piston 4’. The concrete sucked into the delivery cylinder 3 in the previous cycle is driven into S-
pipe 7 and the delivery pipeline. At the same time, the delivery cylinder 3’ sucks the concrete. The
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above-mentioned cycles are repeated to complete the pumping of concrete.

Reverse pumping: In reverse order of forward pumping, the concrete cylinder from the suction
process is connected with the S-pipe valve and the concrete cylinder under pushing process is
connected with the hopper to pump the concrete within the pipeline back to the hopper. The above-
mentioned cycles are repeated to complete the concrete operations.
Figure 1-3 Reverse Pumping Diagram
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Chapter II
Safety Rules
1. Basic Principles
2. Qualifications and Responsibilities of Truck-Mounted Pump
Operator
3. Safety Precautions
11
1. Basic Principles:
This machine can be used for pumping of concrete only and it’s prohibited to use for any other
application, especially those impairing the safety of the machine.
The following precautions shall be guaranteed during the operations of this machine:
(1) The safety devices (including emergency stop button and screen on the hopper) shall never
be removed or altered without consent.
(2) Any safety devices removed during the repair shall be re-assembled immediately at
completion of the repair.
Before operations each time, make sure to check the machine to guarantee the operation safety. Any
detected or suspected malfunction shall be solved immediately. If such malfunctions may impair the
operation safety, stop the operation.
Resale
In event of resale of the truck-mounted pump, pay attention to the following precautions: Hand over
all data of truck-mounted pump (including operation manual, maintenance manual, diagrams, truck-
mounted pump nameplate, and inspection certificate) to the new operator and submit the resale
information or newly procurement information to Loxa Pumping, in order to guarantee your
availability of improvement or safety updates of truck-mounted pump.
2. Qualifications and Responsibilities of Truck-Mounted Pump Operator
The operation personnel of the truck-mounted pump must pass the operation safety training
qualification examinations. The training includes the operation principles of truck-mounted pump,
relevant national regulations, and this operation manual. The untrained operation personnel have the
possibility of endangering your own life and others.
The truck-mounted pump shall be operated and repaired only by the personnel qualifying following
conditions:
(1) The operation personnel must be 18 years old or above. The personnel below 18 are
prohibited for operating this machine.
(2) The operation personnel must be competent for this job in both physical status and mental
status.
(3) The operation personnel must pass the special training for operation and repair of this
machine, get familiar with this operation manual, and bear the training certificate.
(4) The operation personnel must be competent to own job. It’s absolutely prohibited to remove
or replace any safety device and the safety devices must be correctly used during operations.
Before starting the operations of the truck-mounted pump, check all functional parts for normal
functioning. Upon detection of abnormal functioning of certain functional parts, immediately take
measures to solve the malfunction.
3. Safety Precautions
As the truck-mounted pump contains high pressure fluid during the working, the following safety
precautions must be cautioned during the operations.
3.1 Precautions before operations
(1) Check the installation condition of the truck-mounted pump. The truck-mounted pump shall
be installed on a level and solid ground. To prevent the automatic slippage accident, the
truck-mounted pump can’t be parked on slopes.
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(2) Check delivery pipelines for correct arrangements and whether the mode and capability for
the delivery and feeding of concrete can guarantee the normal working.
(3) Check the power supply and water supply and ensure that the power supply and water supply
can guarantee the normal working and the electric system, hydraulic system, and mechanical
system are correct.
(4) Check the oil level of hydraulic oil tank and top up if insufficient. The hydraulic oil added
shall meet the specification.
(5) Check whether the lubricating grease in the lubricating grease pump is sufficient and top up
if insufficient. For those with manual lubricating pump, firstly conduct the manual
lubrication and then dry apply the lubricant to check whether the supply of lubricating grease
is normal for various lubricating points.
(6) Before starting the truck-mounted concrete pump in accordance with the operation
specification, check whether the hopper screen is properly closed and check the water tank
for presence of foreign material and add clean water to the water tank. After the diesel engine
is started, idle at (800r/min) for (3~5) min.
(7) Under cold weathers, idle the diesel engine for a certain period, till the temperature of
hydraulic oil is above 20ºC, before feeding the materials and starting the pumping.
(8) Idle for 10min, check all instruments (including oil suction and return indicators) for normal
indications, check mixing device for reverse pumping capability, and check for normal
reverse pumping.
3.2 Precautions during operations
(1) Before pumping the concrete, firstly pump the water and check the locations of various pipe
clamps to ensure the air-tightness and leakage-free. Then pump the pipeline lubricant.
Generally the mortar is used and the cement paste may be also used). The volume of mortar
will be 0.5m3/200m.
(2) Pour the mortar into the hopper for pumping. When the pumping of mortar is almost
completed, pour the qualified concrete for normal pumping. In event of blockage during the
pumping of mortar, disassemble the most forward section of piping, remove its internal
dehydrated block, and connect the piping to resume normal pumping.
(3) The slump of the pumped concrete shall not have high variation and the variation shall be
controlled within (80~230) mm. Before pouring the concrete into the hopper by concrete
mixer truck, mix rapidly in the mixing drum for several minutes.
(4) While starting or stopping the pumping of concrete, get in touch with the front end hose
operator.The bending radius of the front end hose shall be higher than 1m and the operator
shall not stand at the pipe outlet to prevent the sudden spray of concrete from causing
personal injury.
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(5) When the truck-mounted concrete pump is working, it’s strictly prohibited to insert your
hand into the hopper or water tank.
Figure 2-1
(6) The delivery pipeline shall be secured and solidly cushioned and it’s strictly prohibited to
bend the delivery hose, in order to prevent the explosion of hose.
Figure 2-2
(7) While resuming the pumping after the blockage of pipeline is solved, the end of hose will
rapidly swing and the concrete may spray out instantaneously. In such case, the operators
shall keep away from the hose.
Danger
Figure 2-3
14
(8) Never grasp with hand the end hose by standing at the edge of a building, as the swing of
hose or spray of concrete may cause the operators to fall off from the building.
Danger
Figure 2-4
(9) During the pumping, ensure that the concrete is above the mixing axis. No empty suction or
empty pumping is allowed.
(10) When it’s necessary to pause the pumping for a relatively long period, start the pumping at
an interval of (15~30) min to reverse pump for 1~2 strokes and forward pump for 1~2
strokes, in order to prevent the solidification of concrete within the pipe.
(11) During the pumping, if the pumping pressure increases suddenly or there are vibrations in
the delivery pipeline, immediately turn on the reverse pump button for 2~3 strokes and then
resume forward pumping. Alternatively, knock the locations vulnerable to blockage (such as
taper pipe and bend) with a wooden hammer. If the pumping pressure is still high after the
above method is repeated for several times, the pipe may be blocked. In such case, pause the
pumping and conduct the pipeline blockage treatment.
(12) During the pumping, frequently pay attention to the temperature of hydraulic oil. If the oil
temperature rises to 55ºC, the air cooling is automatically started. If the oil temperature
increases further to be higher than 80ºC, stop the machine for checking.
(13) During the pumping, the hopper shall not be fully emptied, otherwise the concrete residue
will probably spray out at high speed to damage the machine and injure surrounding
personnel.
(14) If the slump of the concrete is too low, it’s disallowed to add water into the hopper for
mixing. Instead, add the cement mortar (of which the water-cement ratio shall be same with
that of the concrete being pumped) into the mixer truck or mixer for uniform mixing and
then feed into the hopper.
(15) The hopper screen shall not be fully stacked with concrete. The feeding rate shall be
controlled and the oversized aggregate and foreign material shall be timely removed.
(16) If the mixing shaft is blocked against rotation, pause the pumping and timely solve the
malfunction.
(17) Upon detection of separation phenomenon in the concrete feeding into the hopper, pause the
pumping and mix uniformly before resuming pumping. Upon detection of serious separation
of aggregate and clearly insufficient mortar in the hopper, remove some aggregates and add
the mortar for re-mixing.
(18) When resuming pumping after the vertically upward pumping is paused, firstly reverse pump
to recover the concrete of distributor valve back to the hopper.
15
(19) Whenever the working is paused, if the pipeline is equipped with gate pipe, properly insert
the gate plate to prevent the backflow of concrete in the vertical or upward inclined pipeline.
3.3 Precautions after stop
(1) Idle run the diesel engine for (3~5) min before stop at the completion of pumping.
(2) At completion of concrete pumping each time, immediately clean the concrete residue from
the truck-mounted pump and the pipeline.
(3) When the ambient temperature is below 5ºC, fully drain the cooling water from the truck-
mounted pump (especially the residual water in the water cooler) to prevent the frost
cracking of the machine parts.
(4) Before the after-shift maintenance (For instance: tighten parts and add lubricating oil to the
transmission parts), make sure that the power unit stops rotation and the pressure of
accumulator is relieved.
(5) During driving, make sure that the outriggers are fully retracted.
3.4 Precautions for repair
(1) During the repair of this machine, please carefully read the Operation Manual and Parts
Catalog. In event of any procedure or technical questions, please consult with our after-
service department.
(2) To prevent any accident during repair, stop the engine, relieve the pressure of accumulator,
and ensure that the switches of all electric devices are placed at position OFF.
(3) When it’s necessary to conduct the electric welding on the truck-mounted pump, the high
voltage generated may damage the electric units of remote control system and wire control
system. Therefore, make sure to take following measures before the welding:
① Remove the remote control plug from the remote control socket and cover the
connecting socket with a cap.
② Disconnect the positive and negative connectors from the battery.
③ While disposing fuel, hydraulic oil, or other functional fluid (such as battery electrolyte),
to eliminate the possibility of combustion and explosion, please abide by the relevant
product safety specifications and local laws and regulations for recovery or recycling.
(4) Do not add seawater or salty water into water tank or hopper.
(5) Cautions shall be taken to avoid interconnecting the positive and negative posts of the battery
or avoid connecting the positive post of battery to a metal, in order to prevent the electric
discharge from causing personal injuries.
16
Chapter III
Electric System and Operations
1. Electric Operating System of Truck-Mounted Pump

2. Electric Operation Specification, Maintenance, and Operation
Instructions
17
1. Electric Operating System of Truck-Mounted Pump

The electric operating system of truck-mounted pump can be divided into chassis operations,
outrigger operations, control cabinet operations, and remote control operations.
1.1 Chassis operations
The chassis operations denote the driving of vehicle. Please refer to the Operation Manual of
Chassis for details.
1.2 Outriggers operations
After the superstructure engine is started normally, press the buttons on the outrigger control box
and at the same time operate the hydraulic control valve lever as per the instructions of outrigger
operation label. At the same time, the engine speed will automatically increase to 1,450rpm. The
outrigger control box is shown in Figure 3-1 (one each on left and right sides. The red emergency
stop button can be used only in event of emergency) and the outrigger operation label is shown in
Figure 3-2.
Figure 3-1 Outrigger Control Box
Red emergency stop button
Buttons on control box

(Press to operate the actions of
outriggers)
18
Figure 3-2 Outrigger Operation Label
Outrigger operation label

Outrigger control box

Front outrigger control lever

Rear outrigger control lever

1.3 Operations of control board

1.3.1 The control board is located on the right rear of the superstructure walking board and the
right front of the hopper. The control board is composed of operation panel cover,
operation panel, electric cabinet, and accessories. The control board is shown in Figure 3-
3 and the operation panel is shown in Figure 3-4.
Figure 3-3 Control Board
Operation panel cover Electric cabinet door Pressure gauge
Beveled seat Interface of wired remote External power socket

controller
19
Figure 3-4 Operation Panel

Engine oil pressure gauge Color display Control button Engine coolant
temperature gauge
1.3.2 Color display

1.3.2.1 Under the startup main interface, press corresponding button of “Parameter settings” and
press “OK” button (press two buttons at the same time).
20
Monitoring System of Foton Loxa Truck-Mounted Pump
Local Remote High Low

control control pressure pressure
Pumping number Pumping volume
Pumping time
Input Output Parameter Next page
1.3.2.2 In such case, the parameter setting interface pops up.
Parameter Settings
Concrete return
displacement
Minimum
displacement
Maximum
displacement
Minimum energy-saving
displacement
Homepage Previous page
In above figure, the “concrete return displacement” can be adjusted within 200~350, the “maximum
displacement” can be adjusted within 600~750, the “minimum displacement” can be adjusted
within 200~400, and the “energy-saving speed” can be adjusted within 1,350~1,750.
21
1.3.2.3 After the setting of parameters, press corresponding functional button of “Homepage” to
return to homepage. Press the corresponding function button of “Input” in the homepage
to access the input point detection interface.
Input Status of CR0303

Remote control Proximity switch B Motor position 2
forward pumping
Remote control Remote control Manual speed
reverse pumping signal down
Displacement up Diesel engine Manual speed up
speed
Displacement down Local control High pressure
forward pumping switchover
Motor start Local control Oil pressure
reverse pumping signal
Proximity switch A Motor position 1 Oil temperature
signal
Homepage Output Previous page Next page
The input detection interface has two pages. Press the Previous Page and Next Page to turn pages.
Input Status of CR2012

Inching of main Temperature Fan
cylinder A alarm
Inching of main Reverse mixing Mixing
cylinder B
Inching of swing Outrigger Water cleaning
cylinder A operation
Inching of swing Return of piston
cylinder B A
Pressure alarm Return of piston
B
Homepage Output Previous page Next page
22
1.3.2.4 Press the corresponding function button of “Output” in the homepage to access the output
point detection interface.
Output Status of CR0303
Main cylinder A Accumulator Concrete return

valve valve
Main cylinder B High pressure Mixing valve
valve
Swing cylinder A Accelerator ON Water cleaning
valve
Swing cylinder B Accelerator
direction
Starter relay
Proportional valve Remote control

relay
Homepage Input Previous page Next page
The main interface has two pages. Press the Previous Page and Next Page to turn pages.
Output Status of CR2012
Cooling valve
Outrigger valve
Reverse mixing
Homepage Input Previous page Parameter
23
1.3.2.5 The diesel engine speed, displacement setting (adjustable within 0~100), working status,
diesel engine working time, pumping time, pumping number, and pumped volume are
displayed in the main interface.
Monitoring System of Foton Loxa Truck-Mounted
Local Remote High Low

control control pressure pressure
Pumping number Pumping volume
Pumping time
The main interface has two pages. Press the Previous Page and Next Page to turn pages.
Monitoring System of Foton Loxa Truck-Mounted

Oil temperature
Main pump pressure
Diesel engine running time
Display program version
Controller program version
24
1.4 Remote control

Pumping operation: Set the button on the local control panel to remote control mode. In such case,
all other buttons on the local control panel are non-operational and the simple pumping operations
can be controlled only by the buttons on the remote control box. The symbol meanings of the
control buttons are listed in 1.5 Electric Symbol Table. The remote control panel is shown in Figure
3-12.
Figure 3-12 Panel of Remote Control Box
1.5 Proximity switches

(1) The proximity switches are installed on the locating grooves of water tank cover, one each
on each side. When the suction stroke of the drive cylinder is completed, the proximity
switch senses the signal and provides it to the controller module for processing, in order to
realize the pumping reversing.
(2) The gap between bottom face of proximity switch and the sensing sleeve shall be maintained
at 5~12mm. If the gap is larger than 15mm, the sensing will be ineffective. If the gap is too
small, the sensing sleeve will probably collide with the proximity switch. The proximity
switch shall be as backward as possible in longitudinal direction, in order to sufficiently
utilize the travel of main cylinder piston. The principle is that the main cylinder piston will
not collide with the cylinder.
(3) The installation misplacement or excessive sensing distance of the proximity switch, the
contamination of oil dirt on bottom of switch, or the over-high water temperature will
probably lead to false operation.
(4) In event of reversing failure (pressure holding status) at end of drive cylinder travel during
the pumping, please firstly check and verify the sensing distance (the general sensing
distance is 5~12mm) between the proximity switch and sensing part (piston rod connecting
flange) and sense (by closing to) the sensing probe of proximity switch by a metal object and
observe whether the indicator lamp turns on (The turn-on of indicator is normal). If the
indicator lamp fails to turn on, please check the circuit of proximity switch. Ensure that there
is no open-circuit (If the circuit is normal, replace the proximity switch). If it’s confirmed
25
that the proximity switch circuit is normal, check the hydraulic circuit (Refer to hydraulic
schematic diagram).
Figure 3-13 Proximity Switch
26
1.6 Electric Symbol Table

No. Term and function Symbol Description
Realize the local control of operation
1 Local control
board pumping operation.
Realize the wired remote control of
2 Remote control
pumping operation
3 Engine stop Control remote stop of engine
4 Engine start Control remote start of engine
Deliver concrete from hopper to the

5 Forward pumping
working area during pumping
Suck the concrete from delivery pipe to

6 Reverse pumping
hopper
Inching of drive Control independent movement of drive

7
cylinder cylinder
Control turn-off and turn-on of main
8 Power control
power supply
Control switchover between high
High/low pressure
9 pressure pumping and low pressure
switchover
pumping
Pumping displacement
10 Increase/reduce pumping displacement
up/down
11 Engine speed up/down Increase/reduce engine speed
Inching of swing Control independent swing of swing

12
cylinder cylinder
Stop engine in event of emergency
13 Emergency stop
during working of truck-mounted pump
Retract the piston from delivery
14 Piston retraction
cylinder to water trough
Run the mixing motor in forward
Forward/reverse direction for normal feeding/
15
mixing Run the mixing motor in reverse
direction to solve blockage
Power on the water pump motor for
16 Flushing water pump
high pressure water cleaning
17 Radiator Control the actions of radiator
The turn-on of this indicator lamp

18 Power indicator lamp
indicates the power-on of power supply
27
2. Electric Operation Specification, Maintenance, and Operation Instructions

2.1 Operation specification
(1) After the stop of the machine, cut off the power supply of the electric cabinet.
(2) After the stop of machine, withdraw the key and lock the inner and outer doors.
(3) Under the driving or pumping status, make sure to lock the inner and outer doors to prevent
the ingress of foreign material, dust, oil, or water into the electric cabinet from damaging the
units.
(4) Under power-on status, it’s prohibited to disassemble any internal unit (such as module,
relay, and air switch) of the product.
(5) Under power-on status, strictly guard against breach of external power supply (such as
grounded electric welding, high voltage wires, and lightning stroke).
(6) Do not damage the connector of external proximity switch during the handling, disassembly,
and installation of the electric cabinet.
(7) Do not damage the key switch during the handling, disassembly, and installation of the
electric cabinet.
(8) During the installation of harnesses, face the drainage pipe port towards the ground.
2.2 Maintenance of equipment
(1) For long-term outdoor operations, please attach a protective cover (such as a rubber sheet or
a jute bag) onto the top of the electric cabinet, in order to prevent the ingress of dirt (such as
concrete and cement) into the electric cabinet.
(2) After the continual pumping of 5,000m3 concrete, the service personnel shall check the
screws at the electric cabinet, local control box, wiring box, and main harnesses for presence
of looseness and tighten as appropriate.
(3) The service personnel shall add the records for the manufacture number of the electric
cabinet to ease the replacement of after-service parts.
(4) The user shall solely bear the consequences arising from own irregular repairs. The electric
repairs must be fulfilled by professionals.
(5) Please refer to the Appendixes for the electric schematic diagram.
2.3 Operations of equipment
(1) The user shall not change or input the programs of the control module without prior consent,
otherwise all consequences arising thereof will be solely borne by the user.
28
Chapter IV
Operation Instructions
1. Operation Preparations
2. Operation Functional Tests
3. Pumping Procedure
4. Cleaning
5. Reset of Machine
29

1. Operation Preparations
1.1 The machine shall be installed on a solid and level cement ground and the working site shall
be larger than the minimum arrangement space of the truck-mounted pump.
1.2 The working ambient temperature shall be -25ºC~45ºC. However, the average temperature
within 24 hours shall not exceed 35ºC and the lowest ambient temperature during the non-
working period shall not be below -40ºC (fully drain the oil and water from the concrete
pump). The maximum working temperature of the hydraulic oil in the oil tank shall not
exceed 80ºC during the working. The relative humidity in the working environment shall be
30%~95%.
1.3 Checking of electric units
(1) All switches on the operating board and remote control box are at position OFF.
(2) The electric units shall be free of broken wire, off wire, loose contact screw, and short-circuit.
1.4 Checking and preparation of engine
(1) Before the start, make sure to check that the coolant suitable to environment temperature is
added to the designated level of the water tank.
(2) Use the fuel and engine oil suitable to local environmental temperature and check the levels
of fuel and engine oil.
(3) Check the battery and circuits. Ensure that the voltage is within (24±2) and the circuits are
free of broken wire, off wire, and looseness.
(4) Check the connectors and sealing surfaces of the fuel, engine oil, and coolant pipes for
presence of leakage.
1.5 Extending/retracting of truck-mounted pump outriggers
After the position of the truck-mounted pump is properly adjusted, start the diesel engine and
operate the hydraulic outrigger operating lever to lower four outriggers onto the ground
simultaneously. In event of any factor leading to deteriorated stability, immediately stop the
operations, retract the hydraulic outriggers, and solve the malfunction before reinstallation as per
the specification. The factors leading to deteriorated stability include:
(1) The variation of ground conditions due to rain, snow or other water source.
(2) Sink of ground on one side of hydraulic outriggers.
(3) Leakage of outrigger cylinder.
1.6 Pipe arrangement
1.6.1 Vertically upward pipe arrangement and concrete pumping
While arranging the vertically upward pipes, when the distribution valve of truck-mounted pump
reverses to suck in concrete (or the pumping is stopped), the gravity force of the concrete within the
vertical pipes will generate a counter-flow pressure (referred to as backpressure) to the truck-
mounted pump. The higher the vertical pipe is, the higher the counter-flow pressure is. This
counter-flow pressure will reduce the volumetric efficiency of concrete, influence the displacement
of truck-mounted pump, and cause blockage of pipe due to separation of concrete. Therefore, take
the following measures to overcome this counter-flow pressure during vertically upward pipe
arrangement:
(1) When the vertical height is low, a certain length of horizontal pipe shall be set between lower
end of vertical pipe and truck-mounted pump. Generally, the length proportion between
30
vertical pipe and horizontal pipe shall be 3:1 and the length of horizontal pipe shall be no
less than 15m, in order to utilize the friction force between concrete mixture and walls of
delivery pipe within the horizontal pipe to balance the counter-flow pressure.
(2) In event of high vertical height or site limitations, the setup of horizontal pipe is difficult to
balance the counter-flow pressure. It’s preferable to setup one gate valve pipe (also referred
to as gate pipe) between the tapered pipe of delivery pipeline and straight pipe so that, when
the pumping is stopped, the gate valve can be closed to prevent the back-flow of concrete.
The elbows shall have solid foundation to avoid transmitting the vibration of truck-mounted
pump to the vertical pipes as far as possible and the vertical pipes shall be securely fixed to
prevent vibrations.
If the pumping height is higher than 30m during vertically upward pumping, arrange the
new or wear-free pipes or the pipes with thick walls at the start position of the pipeline, in
order to prevent the accidents due to over-high pressure within pipes. When necessary,
inspect the wall thickness of pipes. In event of high wear of pipes due to long-term service,
replace all pipes with high pressure.
1.6.2 Downward pipe arrangement and concrete pumping
During downward pipe arrangement and pumping, to prevent the blockage of delivery pipe due to
self-flow and separation of concrete, arrange a horizontal pipe equivalent to more than 5 times of
fall on the front end of downward inclined pipe, in order to utilize its friction resistance to restrain
the self-flow of concrete. In addition, an air bleeding valve shall be arranged on the upper end of
downward inclined pipe. During the pumping, if there are voids in the inclined pipe, firstly open the
air bleeding valve to bleed the air. When the inclined pipe is full of concrete and the motor
overflows from the air bleeding valve, close the air bleeding valve and start the normal pumping. If
there is no room to arrange the horizontal pipe on the front of the downward inclined pipe due to
limitation of site conditions, the horizontal pipe may be substituted by hose, elbow, or annular pipe
to increase the friction resistance and restrain the self-flow of concrete within downward inclined
pipe.
During the downward pumping of concrete, the self-flow of concrete is closely related to the
concrete slump. To prevent the downward self-flow and the separation of concrete, during large-
angle downward pumping, install the foamed rubber balls into the pipeline before the start of
pumping.
1.7 Start of truck-mounted pump
The truck-mounted pump can be started after all checking works are completed:
(1) Disengage the engine from the driven devices (to stop the forward/reverse pumping).
(2) Engage the power switch and press the “start control power supply”. The indicator lamp
turns on and the instruments indicate the current status.
(3) Press “Start diesel engine” button and hold for (approximately 2~10s). After the diesel
engine is started, immediately release the start button. In such case, all instruments indicate
the current working status of the diesel engine. The interval between two consecutive starts
shall be 2~3min.
(4) Once the engine is started, immediately observe the parameter measurement devices
(instruments), including engine oil pressure, voltage, and diesel engine speed, and start the
loaded works after all parameters are normal.
2. Operation Functional Tests
2.1 Inch the swing cylinder or drive cylinder. When the swing cylinder or drive cylinder reaches
its travel end, the system pressure of the main pump indicated by pressure gauge shall not
31
exceed 30~35MPa and the pressure of swing cylinder shall not exceed 20MPa. At the
reversing instant of distribution valve, the pressure will drop (by approximately 4~6Mpa). If
the pressure drop is too high, the probably insufficient pressure of the accumulator shall be
taken into consideration (Refer to 2.9 for the nitrogen charging method). The mixing relief
pressure is 12MPa.
2.2 Increase the engine speed to 2,000~2,100r/min, adjust to maximum displacement, run the
pistons at rated speed, and measure whether the reversing number per minute meets the
specification (Refer to Table 1-1 and Table 1-2).
2.3 Check the vacuum pressure gauge on the oil suction filter. When the oil temperature is
higher than 40ºC and the concrete pistons are running at highest speed, check whether the
pointer of vacuum pressure gauge is beyond the green zone (The vacuum pressure shall not
exceed 0.04MPa). Generally, the oil suction vacuum pressure shall be less than 0.02MPa and
the reading of oil turn pressure gauge shall be less than 0.35MPa. If beyond above values,
clean or replace the filter element.
2.4 Rotate the reverse pumping switch to check for presence of reverse pumping.
2.5 Operate the lever of mixing control valve and observe whether the mixer is running.
2.6 Operate the water pump control valve lever to operate the water gun and observe whether the
high pressure water is pumped out.
2.7 Check the charged pressure of accumulator, maximum swing pressure, and minimum swing
pressure.
2.8 Press the “emergency stop" switch and observe whether the pumping cylinder can stop
pumping.
2.9 Nitrogen charging method of accumulator
(1) Unscrew the protective nut of accumulator charging valve, connect one end of charging tool
pressure gauge to a nitrogen cylinder, and connect the other end to the accumulator. The
nitrogen outputted from the nitrogen cylinder must flow through a reducing valve.
(2) Slowly open the air valve of nitrogen cylinder. When the reading of pressure gauge reaches
the specified valve (8.5MPa), close the air valve of nitrogen cylinder, maintain for
approximate 20min, and observe whether the pressure drops.
(3) Disassemble the end of charging tool from the accumulator and disassemble the charging
tool.
(4) Tighten the protective nut of accumulator charging valve. Caution: The accumulator can be
charged only by nitrogen and the charging pressure must meet the specification.
3. Pumping Procedure
The concrete pumping can be started after the test run of the truck-mounted pump is normal and the
hydraulic oil temperature increases to 20~25ºC.
3.1 Before pumping the concrete, firstly pump the water and check the locations of various pipe
clamps to ensure the air-tightness and leakage-free. Then pump the pipeline lubricant.
Generally the mortar is used and the cement paste may be also used).
3.2 When the pumping of mortar is almost completed, pour the qualified concrete for normal
pumping. In event of blockage at the pumping of mortar, disassemble the most forward
section of piping, remove the internal dehydrated block, and connect the piping to resume
normal working.
3.3 In event of blockage during pumping, immediately conduct the reverse pumping for 3~4
32
travels to suck back the concrete within the pipeline into the hopper for re-mixing. Then,
pump slowly, till the blockage is solved, before resuming normal pumping. It’s disallowed
for reversing at will during normal pumping.
3.4 Blockage causes:
(1) Poor workability of concrete.
(2) Under-low sand ratio or disqualified grading.
(3) Insufficient mixing of concrete or separation of concrete due to long retention time.
(4) Unstable slump, poor cohesiveness, and poor water retention of concrete.
(5) Poor sealing of delivery pipe and loss of mortar.
(6) Improper parameter settings of hydraulic system.
(7) Residual concrete in S swing pipe and delivery pipe from previous operations.
(8) Solidification of concrete due to long stop or waiting time.
In event of pipe blockage, immediately conduct the reverse pumping for dredging. If the
reverse pumping fails to dredge the blockage, immediately judge the blockage location, stop
the machine, and clean the pipeline. Resume the pumping after the blockage is solved.
4. Cleaning
During the cleaning of the machine, do not use corrosive solvent, acid, alkali, or aggressive solution,
otherwise it will damage the surface paint, chrome plating, and all non-metallic parts of the machine.
Do not spray the water flow or water mist towards personnel, machine control cabinet, or electric
units, otherwise it will lead to serious danger. At completion of pumping, timely clean the delivery
pipeline, hopper, and whole machine.
4.1 Cleaning of pipeline
Insert the gate plate into the gate pipe, disassemble the front end hose, disassemble the pipe
connector from the taper pipe, pour out the concrete from this taper pipe, properly install the
cleaning tools (sponge plug and cleaning piston), reconnect the taper pipe, secure the pipe clamps,
top up the hopper with water and connect it with water source, unplug the gate plate, start the truck-
mounted pump, and press “forward pumping” to start the pumping of water. The cleaning tools are
driven forward through the pipeline, till the sponge plug and cleaning piston are emerged from the
front end. Continue the pumping of water, till there is no further outflow of subsequent residual
concrete. The cleaning of delivery pipe is completed.
4.2 Cleaning of truck-mounted pump
(1) Firstly adjust the main oil pump to minimum displacement, idle for 3~4 strokes to drain
residual concrete, and then stop the idling strokes.
(2) Remote the residual concrete from the hopper and S-pipe by auxiliary tools (including shovel
and crowbar), open the bottom gate of hopper, flush the inside and outside of hopper by
water thoroughly, and then clos the gate.
(3) Top up the hopper with water and run for 3~4 strokes to pump out the residual concrete
along with the water. After the water is fully pumped, idle for 20min to further supply the
lubricating grease.After the cleaning, stop the machine and cut off the power supply.
(4) Open the bottom cover of hopper to drain residual water and thoroughly clean the S swing
pipe, hopper, delivery cylinder, water trough, and all portions in direct contact with concrete
by high pressure water.
(5) If there is a danger of freezing, drain the water from the water tank, water trough, and
33
flushing water pump. Normally, drain the water from the water trough whenever the water is
not in use (at overnight or weekends).
5. Reset of Machine
At completion of operation, reset the cleaned truck-mounted pump as per the following procedure:
(1) Properly retract the outriggers.
(2) Stop the machine and cut off the power supply.
(3) During the driving, abide by the road traffic regulations.
34
Chapter V
Safety Rules
1. Maintenance Periods
2. Overview
3. Daily Maintenance
4. First 50h Maintenance
5. Every 100h Maintenance
7. Every 1,000h Maintenance
8. Lubrication
9. Replacement and Adjustment of Wearing Parts
10. Maintenance of Diesel Engine
11. Technical Data Related to Repair of Equipment
35
1. Maintenance Periods
(1) Daily maintenance: The maintenances before the operations and after the operations each
day.
(2) First 50h maintenance: The maintenance to be conducted after the truck-mounted pump
works for the first 50 hours.
(3) Every 100h maintenance: The maintenances to be conducted once every 100 working hours
of the truck-mounted pump.
(4) Every 500h maintenance: The maintenances to be conducted once every 500 working hours
of the truck-mounted pump.
(5) Every 1,000h maintenance: The maintenances to be conducted once every 1,000 working
hours of the truck-mounted pump.
2. Overview
The pump shall be checked once every 1,000 hours and at least once a year by our trained
professionals. Checking items: Control pressure and high pressure of pump, pressure of
accumulator, mixing pressure, and oil leakage and permeation of pump.
3. Daily Maintenance
Make sure to fulfill the maintenance items before the operations of truck-mounted pump each day:
(1) Check for sufficient fuel, hydraulic oil, engine oil, and coolant and add if insufficient.
(2) Drain the sediments from the bottom of the hydraulic oil tank, till the hydraulic oil flows out.
(3) Check the parts in direct contact with concrete for damage and replace damaged parts.
(4) Check the wear status of the delivery pipes by knocking method or wall thickness gauge and
replace worn pipes.
(5) Lubricate the pressure casing and seals on two ends of mixing shaft.
(6) Observe the hydraulic pipelines to ensure leakage-free.
(7) Remove dust and dirt from the surfaces of hydraulic oil radiator.
(8) Lubricate all lubricating points on the S swing pipe cylinder and top up the grease distributor
with lubricating grease (add once every two hours during operations).
(9) Check the electric switches for sensitivity and reliability.
(10) Check the gap between S swing pipe reversing valve and anti-wearing plate. If above 5mm,
the adjustment is required.
(11) After the operations each day, make sure to carefully clean all parts coming into contact with
the concrete and the complete vehicle to guard the concrete delivery system against being
blocked by residual concrete.
4. First 50h Maintenance
Make sure to fulfill the following maintenance items after the truck-mounted pump works for the
first 50 hours:
(1) Replace the oil of engine and power takeoff.
36
① Stop the machine when the oil temperature is at 40ºC~50ºC and drain the lubricating
oil and hydraulic oil from the tanks while the oils are still hot.
② The new oils for replacement shall follow the oil trademarks specified by this manual.
(2) Sufficiently lubricate the lubricating points and add specified lubricating grease to the
lubricating center.
(3) Clean the filter element and screen and the dirt collector of the hydraulic system and replace
damaged filter element or blocked paper filter element.
Make sure to fulfill the following maintenance items every 100 working hours of the truck-mounted
pump:
(1) Fulfill all maintenance items and first 50h maintenance items.
(2) Check the lock bolts and nuts of the concrete piston connecting flanges for presence of
damage or looseness. If loose, re-tighten the hexagon bolts on the piston and flange. If
damaged, replace.
(3) Check the reversing number at maximum delivery capacity.
(4) Check the oil filter element, clean the magnetic bar and filter cartridge, and replace the oil
filter element depending on actual situation. Only use the filter element products provided by
our company.
(5) While cleaning the magnetic bars, use a cloth strip to wipe from the head to the tail.
(6) While cleaning the filter screens, immerse the filter screens into the fluid capable of
dissolution of lubricating oil (such as acetone, petroleum ether, and crude oil) for
approximate 10~15min and then use high pressure air to blow the filter screen from outside
to inside. During the air blowing, place a round bar wrapped with paper tape into the filter
screen so that the particulates are attached to the paper tape.
Make sure to fulfill the following maintenance items every 500 working hours of the truck-mounted
pump:
(1) Fulfill all maintenance items of every 100h maintenance.
(2) Clean the water pump suction filter.
(5) Clean the hydraulic oil tank and replace hydraulic oil after the first 500 working hours.
(4) Afterwards, handle depending on the actual hydraulic oil quality every 500 hours (The solid
particulate contamination level of hydraulic oil shall not be higher than 18/15).
7. Every 1,000h Maintenance
Make sure to fulfill the following maintenance items every 1000 working hours of the truck-
mounted pump:
(1) Fulfill all maintenance items of every 500h maintenance.
(2) Check all mechanical and hydraulic devices by professionals dispatched by our company
along with the user.
37
8. Lubrication
To guarantee the service life of the truck-mounted pump, it’s necessary to periodically lubricate all
portions with relative movements.
8.1 Trademarks of lubricating grease:
Summer: Select 00# lithium-based lubricating grease.
Winter: Select 000# lithium-based lubricating grease.
Caution: It’s prohibited to use molybdenum disulfide lubricants.
8.2 Lubrication regulation
(1) After 100 pumping hours (there is a hourmeter on the control cabinet), make sure to check
the bearings and seals and replace when necessary.
(2) Upon detection of oily or cement mixture or oil or mortar leakage at the hopper bearings,
make sure to replace the bearings immediately.
(3) At the time of repair, make sure to tighten the casing of S swing pipe to prevent the axial
movement of casing under high pressure.
9. Replacement and Adjustment of Wearing Parts
9.1 Disassembly and installation of concrete piston
Press the concrete return button to return one cylinder piston rod to the root position and replace the
piston as per the following procedure.
Caution: Replace the piston within the water trough only after the engine is stopped.
(1) Fully drain the water from the water trough.
(2) Loosen the clamp screws, withdraw the concrete piston, replace corresponding worn parts,
and reinstall the concrete piston.
9.2 Disassembly and installation of S-valve Refer to Figure 5-1.
38
Figure 5-1 S-valve assembly
1. Anti-wearing plate 2. Cutting ring 3. Rubber spring 4. S-valve 5. Nylon bushing 6. Bearing block
7. Anti-wearing sleeve 8. Flange plate 9. Rubber plate 10. Anti-wearing sleeve 11. Hexagon socket screw
12. Hexagon socket screw 13. Spring washer
The S-valve, anti-wearing plate, and cutting ring are subject to wear after being serviced normally
for a period. Measure the gap between the cutting ring and anti-wearing plate (Above figure). Use
the adjustment bolt ① to adjust the gap to 1~3mm. If the gap is above 5mm, make sure to replace
the anti-wearing plate and cutting ring.
Caution: Make sure to stop the engine before adjustment of S-valve and
disassembly/installation of anti-wearing plate.
39
9.3 Disassembly, installation, and checking of oil filter element

Caution: Make sure to stop the engine before replacement of oil filter element.
Some hydraulic oil will leak during the replacement of oil filter element. Therefore, prepare a
container. Replace as fast as possible. To prevent the ingress of dust into the hydraulic system,
prepare new filter element, O-ring, and rag in advance.
Oil suction/return filter:
If the pointer of vacuum pressure gauge is not within green zone, the oil filter must be replaced.
(1) Loosen and unscrew the screw (2).
(2) Remove the cap (1). In such case, the check
valve (3) automatically closes the oil suction port.
(3) Repeat step 1 and step 2 for the second oil filter.
(4) Disassemble the oil suction pipe connector (4) of
the oil filter gear and drain the oil from the oil
filter housing (5).
(5) Slowly rotate the cap to pull out the filter
element (7).
Figure 5-2 Oil Suction/Return Filter
(6) Take out the filter element and clean the
magnetic bar. Check two O-rings for presence of damage.
(7) Thoroughly clean the disassembled parts, replace with new filter element, and install as per
reverse order of above procedure.
(8) Finally make sure to tighten all bolts on the filter element, or it will increase the oil suction
resistance.
9.4 Replacement of other parts
(1) After pumping the concrete for 100h, make sure to check the S-valve guide ring or seal ring
within the hopper. Upon detection of overflow of cement mortar or lubricating grease form
the support shaft, make sure to replace the guide ring and seal ring. At the time of repair,
make sure to fix the S-valve support sleeve with adhesive to prevent the axial movement
under the action of high pressure.
(2) Frequently check the seals on two ends of the mixing shaft. Upon the detection of serious
wear of seals or mixing shaft and permeation of cement mortar into supports on two ends of
mixing shaft, replace the seals or mixing shaft.
(3) The high pressure hoses under sunshine must be frequently checked. Upon detection of
brittleness or rupture, replace with new one immediately.
40

10. Maintenance of Diesel Engine

10.1 Daily maintenance table 5-1 of diesel engine
Every
First
10h or 125h 250h 500h 1000h 1500h 2000h Checking Cleaning Replacement Work description
50h
daily
● ● Engine oil level
● ● Leakage status
● ● Dry air filter
● ● Battery and wiring
● ● ● ● ● ● Cooling system
Engine oil (based on

● ● ●
working condition)
Engine oil filter

● ● ●
element
● ● ● Diesel filter element
● ● ● Fuel coarse filter
● ● ● Fuel system
Valve clearance
● ● ● (adjust when
necessary)
● ● ● Engine suspension
● ● ● V-belt
● ● Alarm device
● ● Fasteners
● ● Preheating plug
● ● Coolant
Concentration of
● ● cooling medium
additive
● ● Coolant level
Hose connector/pipe
● ●
clamp, air intake side
41
10.2 Maintenance Method

(1) Engine oil level: If the oil level is slightly higher than the marking “MIN”, it’s necessary to
add the engine oil to marking “MAX”.
Figure 5-3 Engine Oil Filler Port Figure 5-4 Engine Oil Dipstick
(2) Check the engine oil, diesel, and coolant pipe connectors for presence of fluid permeation.
(3) Check the intake pipeline for presence of damage and check connector clamps for presence
of looseness and air leakage.
(4) Check and clean the dry air filter.
Figure 5-5 Air Filter Structure Figure 5-6 Dust Drainage of Air Filter
(5) Check the battery and wires.
(6) Check and add coolant: Please carefully read the self-adhesive maintenance diagram label on
the diesel engine radiator for details.
(7) Replace the engine oil filter element.
Figure 5-7 Replacement of Engine Oil Filter Element
42
(8) Replace diesel filter element.

The replacement method for diesel fine filter element is
same with that for engine oil filter element. The
replacement of integral coarse filter element for diesel
pump filter is shown in Figure 5-8.
① Cut off the oil line and collect the drained oil.
② Loosen the water drainage valve 5 to drain the
water and diesel and then tighten.
③ Rotate counter-clockwise to unscrew the filter
element 2. Figure 5-8 Integral Coarse Filter of
Pump Filter
④ Rotate counter-clockwise to disassemble the water
collector 3 and clean.
⑤ Install new filter element 2 and water collector 3
together, lubricate the sealing surface 8 by some
engine oil, and pour diesel into the filter element 2.
⑥ Reinstall to the base 1 and connect the oil line.
⑦ Loosen the air bleeding bolt 7, press the manual
pump 6 till the fuel drains from 7, and tighten the
air bleeding bolt 7.
⑧ Start the engine and check for presence of air
leakage.
10.3 First Start Checking and Operation of Engine
(1) Add engine oil: The filling position of engine oil Figure 5-9 Fuel System
(5090HB8100047) is shown in Figure 5-3. The
filling capacity of engine oil is generally 20L. The CF-
4 engine oil is required for 5090HB8100047 and the
CG-4 or CH-4 engine oil superior to CF-4 may be used
as well.
(2) Check the air filter whether the filter element is
installed and drain the dust, as shown in Figure 5-5 and
Figure 5-6.
(3) Add diesel to the fuel tank, as shown in Figure 5-9.
① Choose the corresponding summer or winter diesel
depending on the atmospheric temperature.
② Do not add the diesel during the running of engine.
(4) The adding and air bleeding of the cooling system is
shown in Figure 5-10. Adding and air bleeding
method:
Figure 5-10 Cooling System
① Unscrew the filler port cap.
② Add coolant (5090HB8100048) to the upper edge of filler neck.
The filling capacity is generally 30L. Choose (-15ºC coolant) depending on the weather
condition. The -40ºC coolant is required for 5090HB8100048.
43
③ Observe the coolant level during running and timely add the coolant.
④ Install the filler port cap 1.
(5) Check the battery and wires.
(6) Bleed the air from the diesel engine before start.
Figure 5-11 Manual Pump (integral coarse Figure 5-12 High Pressure Fuel Pipe of Diesel
filter of pump filter) Engine
① Pump the fuel of diesel engine by manual pump "1" on the fuel-gas separator.
② When the resistance of the manual pump is too high for further pumping, loosen 6
monoblock pump high pressure fuel pipe connectors "2" of diesel engine to relieve the air
bubbles.
③ After there is no more air bubble, lock 6 monoblock pump high pressure fuel pipe connectors
"2" of diesel engine.
④ Further pump the fuel of diesel engine by manual pump "1" on the fuel-gas separator and
attempt to start the diesel engine. If the engine fails to start in 10s, repeat the step ② and step
③. If the engine fails to start, wait for at least 1min before retry.
⑤ Start the diesel engine and at the same time pump the fuel of diesel engine by manual pump
"1" on the fuel-gas separator, till the diesel engine is running completely.
(7) Conduct the test run.
After the engine is running under no-load for approximately 10min:
① Check the engine for presence of leakage.
② After the engine is stopped, check the engine oil level. If the oil level is lightly higher than
the minimum marking “Min”, make sure to add engine oil, as shown in Figure 5-4 (Engine
Oil Dipstick).
44
11. Technical Data Related to Repair of Equipment

11.1 Capacities:
(1) Capacity of hydraulic oil tank: Approximately 750L.
(2) Concrete delivery pipe: ① Φ125mm in diameter, approximately 12L/m.
② Φ150mm in diameter, approximately 18L/m.
11.2 Oil Trademarks
(1) Hydraulic system oil trademark: Kunlun L-HV46 anti-wear hydraulic oil, with oil volume at
least at 80% of hydraulic oil tank capacity.
(2) Lubricating oil for water pump: N40 in winter and N68 in summer.
(3) Diesel engine oil: CF-4.
Caution: It’s disallowed to mix the hydraulic oils of different trademarks for use. Before
replacement with oil of other trademark, make sure to fully drain the hydraulic oil from the
oil tank and system and then add new oil.
11.3 Please refer to the Bolt Tightening Torque Table 5-2 for the tightening torques of common
bolts.
Pitch Wrench Dimension Strength grade (tightening torque N.m)
Specification
h Sw1 Sw2 6.9 8.9 10.9 12.9
M4 0.7 7 3 2.4 2.9 4.1 4.9
M5 0.8 8 4 5 6 6.5 10
M6 1 10 5 8 10 14 17
M8 1.25 13 6 21 25 35 41
M10 1.5 17 8 41 49 69 83
M12 1.75 19 10 72 86 120 145
M14 2 24 14 180 210 295 355
M16 2 24 14 180 210 295 355
M20 2.5 30 17 345 410 580 690
M24 3 36 19 600 710 1000 1200
M27 3 41 19 890 1050 1500 1800
M30 3.5 46 22 1200 1450 2000 2400
M8×1 1 13 6 23 27 38 45
M10×1 1 17 8 44 52 73 88
11.4 Tightening torques for special threads

Please contact our company for the tightening torques for the connecting bolts of hopper, water
trough, and delivery cylinder.
45

Chapter VI
Troubleshooting
46
1. Typical Malfunctions
Precautions:
(1) The electric cabinet and hydraulic system must be repaired by the professionals.
(2) The table below describes the simple typical malfunctions and troubleshooting. The specific
complicated malfunctions can be solved only through site analysis. In event of special
malfunctions, please contact the After-Service Department of our company for
troubleshooting assistance.
Symptom Possible Malfunction Troubleshooting

The main system has no (1) The main relief valve core is
(1) Repair or replace main relief
pressure or the main blocked.
valve.
1 system pressure can’t (2) The constant pressure valve
reach 32MPa (at (2) Tighten the connector or replace
connector of master oil pump is loose or
pressure holding) constant pressure valve.
the valve element is worn.
(1) The air-cooling motor has no
rotation or its reduced volumetric
Abnormal temperature efficiency leads to low speed of air- (1) Replace air-cooling motor.
2 increasing of hydraulic cooling motor. (2) Remove the dusts from the
oil (2) The radiator fins of the wind cooler radiator fins.
are blocked by dust to cause insufficient
cooling.
(1) The nitrogen pressure of
accumulator is insufficient. (1) Check and refill nitrogen
Weak reversing of (2) The inlet check valve of accumulator (2) Check or replace inlet check valve
3
swing cylinder has stagnation so that the pressure can’t of accumulator.
be maintained. (3) Replace constant pressure pump.
(3) Constant pressure pump is damaged.
(1) Concrete piston is seriously worn. (1) Replace concrete seals.
Mortar leakage of water
4 (2) Concrete delivery cylinder is
tank (2) Replace delivery cylinder.
excessively worn.
(1) Stop the machine and remove the
(1) The S pipe valve is blocked by
S-pipe can’t swing to foreign material from the hopper.
foreign material in the hopper.
5 required position on one (2) Stop the machine and disassemble
side (2) The seal for piston of swing valve
the swing valve cylinder for
cylinder is excessively worn.
replacement of piston seal.
No speed rise at forward (1) Stepping motor driver is damaged. (1) Replace stepping motor driver
6
or reverse pumping (2) Stepping motor is damaged (2) Replace stepping motor.
(1) Replace or repair starter

(1) Starter electromagnet is damaged. electromagnet.
(2) Starter motor is damaged. (2) Replace or repair starter motor.
Start failure of diesel
7 (2) Stop electromagnet is damaged. (2) Replace or repair stop
engine
(4) Fuel in fuel tank is insufficient; The electromagnet.
fuel tank pipeline is leaking. (4) Add fuel and bleed air; check
fuel pipeline and bleed air.
47

Symptom Possible Malfunction Troubleshooting
(5) Replace with winter fuel and

pump oil or immerse with hot water
(5) The fuel filter screen or pipeline is
the bottom of filter to melt the olefin,
blocked by indigenous olefin in winter.
bleed the air, and clean the pipeline.
(6) The screen of fuel filter is blocked
(6) Clean coarse filter screen or
Start failure of diesel by dirt.
7 replace filter.
engine (7) Poor diesel quality (such as
(7) Drain poor diesel and use
containing water content)
qualified diesel
(8) Insufficient voltage of battery or
(8) Check battery voltage, clean or
loose or oxidized wiring posts
tighten wiring post and apply the
carbon-free grease.
(1) Replace filter, bleed air, clean

(1) The fuel flow is too low. coarse filter screen, and tighten pipe
Reduced power and (2) The valve clearance is out of connector.
8 abnormal working of tolerance or valve spring is broken. (2) Adjust valve clearance or replace
diesel engine (3) Fuel injector is damaged. spring
(4) Air filter is too dirty. (3) Replace fuel injector.
(4) Clean or replace filter element.
(1) Replace coolant pump

(1) Coolant pump is damaged.
(2) Ask professionals for adjustment.
(2) Fuel injection amount of injector
Diesel engine pump is incorrectly adjusted. (3) Dredge the air inlet pipe.
overheating, in which (4) Check and adjust exhaust
case the thermometer (3) Insufficient cooling airflow of
9 cooling fan. regulator and check belt for looseness
points to red area and and rupture.
engine stops (4) Low speed of cooling fan
(5) Adjust till the oil level reaches
immediately. (5) Insufficient or excessive engine oil.
marking MAX of dipstick.
(6) Insufficient coolant.
(6) Add coolant to required level.
(7) Poor sealing of intake pipe.
(7) Check air intake pipe
(1) Malfunction of water pump motor or

(1) Check relief valve pressure, water
connection
10 No rotation of pump pump motor, and connectors
(2) Malfunction of water pump motor
(2) Check operating valve.
operating valve
(1) Empty water tank. (1) Add water.
No water output or
(2) Low pressure of water pump relief (2) Adjust pressure of relief valve.
11 insufficient pressure of
valve. (3) Check water pump and when
water pump
(3) Damage of water pump. necessary replace.
No lubrication (working (1) Malfunction of hydraulic circuit.
(1) Check hydraulic circuit.
12 failure of lubrication (2) Lubrication time setting malfunction
(2) Reset lubrication time.
pump) of lubrication pump.
(1) Replace lubricating grease

(Generally 0# for summer and 00# for
(1) Inappropriate oil trademark
winter)
13 Lubrication failure (2) Malfunction of distribution valve.
(2) Check distribution valve.
(3) Damage of lubrication pump
(3) Check pressure of lubrication
outlet
48
2. Status Record
49
Chapter VII
Safety Rules
1. Action Table of Solenoid Valves

2. Electric Schematic Diagram
3. Hydraulic Schematic Diagram
50
1. Action Table of Solenoid Valves

Pump Main control Main control High/low
Distribution Distribution Outrigger Reverse Concrete
Electromagn control electrohydra electrohydra Cooler pressure
valve valve switchover mixing return piston
etic ball electric ulic valve ulic valve opening switchover
Action electromagn electromagn solenoid solenoid solenoid
valve proportional electromagn electromagn valve solenoid
et A et B valve valve valve
valve et A et B valve
5DT 6DT 7DT 1DT 10DT 2DT 3DT 8DT 9DT 4DT 11DT
Inching of swing cylinder A + - / / - - - / / / -
Inching of swing cylinder B - + / / - - - / / / -
Inching of main cylinder A (advancement) - - / * - + - / / / -
Inching of main cylinder B (advancement) - - / * - - + / / / -
Start of radiator / / / / - / / + / / -
Stop of radiator / / / / - / / - / / -
Forward mixing / / / / - / / / - / -
Reverse mixing / / / / - / / / + / -
Start of water pump / / / / - / / / / / -
Stop of water pump / / / / - / / / / / -
Accumulator / / + / - / / / / / -
Suction of pumping main cylinder
Low + - + * - + - / / - -
BDischarge of pumping main cylinder A
pressure
pumping Suction of pumping main cylinder
- + + * - - + / / - -
ADischarge of pumping main cylinder B
Low Discharge of pumping main cylinder
- + + * - - + / / - -
pressure ASuction of pumping main cylinder B
reverse Suction of pumping main cylinder
pumping + - + * - + - / / - -
Discharge of pumping main cylinder
High - + + * - - + / / + -
ASuction of pumping main cylinder B
pressure
pumping Suction of pumping main cylinder
+ - + * - + - / / + -
High Discharge of pumping main cylinder
- + + * - + - / / + -
pressure ASuction of pumping main cylinder B
reverse Suction of pumping main cylinder
pumping + - + * - - + / / + -
Telescoping of outriggers / / / / / / / / / -
Concrete return piston A - + + * / + - / / - +
Holding of concrete piston A - + + - / + - / / - +
Restoration of concrete piston A - + + - / + - / / - -
Concrete return piston B + - + * / - + / / - +
Holding of concrete piston B + - + - / - + / / - +
Restoration of concrete piston B + - + - / - + / / - -
51

2. Electric Schematic Diagram
Increased chassis power control circuit
Engine module
J1939 interface
PTO request Keyhole circuit
Pressure Temperature
gauge gauge
Odometer Power switch Remote control/local

signal indicator lamp control switch
Local Remote
Chassis control control
interface
Handbrake
signal
Remote control box assembly

Neutral
gear
signal
Neutral gear Handbrake
signal signal
Remote
Condensing External Remote control Local control
Feedback Engine oil pressure Coolant temperature display Flameout Diesel engine alternator and charging Battery and power Hopper lamp Remote control forward/reverse Reverse Remote control control Remote control
Odometer PTO Driving Transfer case limit solenoid Start solenoid valve and relay Start motor and start control power Clearance lamp Power start and emergency stop control displacement adjustment forward/revers Local control displacement +/-
indicator lamp display and alarm and alarm electromagnet control main switch control pumping mixing emergence stop indicator signal
valve socket +/- e pumping
lamp

Pressure
Oil Remote Forward/ High Return Preheater
Displacement Engine Proximity Proximity Outrigger relay and Start of main Cooling Engine Pressure Temperature Emergency Manual speed Chassis Water Accelerator Inching of swing
Reserved temperature Reserved Reserved Mix control reverse pressure Linear motor and its control Accumulator Reserved Reserved of OFF
up/down speed switch A switch B operations reverse cylinder A/B fan start alarm alarm stop up/down PTO cleaning motor limit cylinder A/B
signal signal pumping switchover piston
mixing
Linear motor controller
Linear motor
Black
Display
White Blue
Grey
Chassis CAN
Low Low High High

Swing Unloading Proportional Bus
pressure pressure Swing Forward Reverse Cooling Accumulat Proportional Outrigger Accelerator pressure pressure High pressure
cylinder Starter relay of main solenoid solenoid valve PWM Direction Bus communication Display power supply and bus communication communic Low pressure pumping Concrete return Water pump valve
main main A
cylinder B mixing mixing valve or valve 1
valve controller ON main main pumping
pump 2 ation
cylinder A cylinder B cylinder A cylinder B

52
3. Hydraulic Schematic Diagram

Front
Main
Main cylinder B
Left Right
cylinder
Mixing motor
Swing
Swing
cylinder A
Water pump cylinder B
motor
Air-cooling
motor
Water cooler

53

L8车载泵说明书 译文

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Loxa Heavy Machinery Truck-Mounted

Beiqi Foton Motor Co., Ltd.

This operation manual describes in details the technical characteristic,

○ Help you understand the structure and performance

○ Prevent the machine malfunctions due to improper operations.

○ Avoid the safety issues arising from mis-operations.

○ Improve the operation reliability of the truck-mounted pump.

○ Prolong the service life of truck-mounted pump.

○ Operate this machine within the specified operation scope and do

○ The operator must be the personnel qualifying the training and

○ Do not ask non-skilled technicians for repair or disassembly of this

○ Fulfill all technical maintenances as per the requirements of this

○ To guarantee the normal running of the machine, please use the

○ In pursuit of advancement and perfection, this product is subject to

1. Exterior Diagram of Truck-Mounted Pump ........................6

2. Basic Parameters and Main Technical Performance

3. Structural Introduction of Truck-Mounted Pump...............9

Chapter II Safety Rules ...................................................................... 11

2. Qualifications and Responsibilities of Truck-Mounted

3. Safety Precautions ................................................................12

Chapter III Electric System and Operations.................................... 17

1. Electric Operating System of Truck-Mounted Pump ......18

2. Electric Operation Specification, Maintenance, and

Chapter IV Operation Instructions.................................................... 29

2. Operation Functional Tests..................................................31

3. Pumping Procedure ..............................................................32

5. Reset of Machine ..................................................................34

Chapter V Safety Rules ...................................................................... 35

1. Maintenance Periods ............................................................36

3. Daily Maintenance ................................................................36

4. First 50h Maintenance ..........................................................36

5. Every 100h Maintenance .....................................................37

6. Every 500h Maintenance .....................................................37

7. Every 1,000h Maintenance ..................................................37

9. Replacement and Adjustment of Wearing Parts ...............38

10. Maintenance of Diesel Engine ..........................................41

11. Technical Data Related to Repair of Equipment ............45

1. Typical Malfunctions ...........................................................47

Chapter VII Safety Rules ................................................................... 50

1. Action Table of Solenoid Valves.........................................51

2. Electric Schematic Diagram ................................................52

3. Hydraulic Schematic Diagram ............................................53

Main Structure and Function Introduction

1. Exterior Diagram of Truck-Mounted Pump

1. Exterior Diagram of Truck-Mounted Pump

Chassis model Auman BJ5133THB-AA Auman BJ5123THB-1

14/9 18/8.7 22.4/11.8 14/9 18/8.7 22.4/11.8

Table 1-2 Parameter Table 2 of Truck-Mounted Pump

Width mm 2490 2490

Chassis model Ollin BJ5139XXY-FD Auman BJ5133THB-AB

Working principle of pumping mechanism:

above-mentioned cycles are repeated to complete the pumping of concrete.

Figure 1-3 Reverse Pumping Diagram

Electric System and Operations

1. Electric Operating System of Truck-Mounted Pump

1. Electric Operating System of Truck-Mounted Pump

Red emergency stop button

Buttons on control box

Figure 3-2 Outrigger Operation Label

Outrigger operation label

1.3 Operations of control board

Beveled seat Interface of wired remote External power socket

Figure 3-4 Operation Panel

L8车载泵说明书译文

L8车载泵说明书译文