Professional Documents
Culture Documents
SYG5283THB 380C-8(R)
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: sanyservice@sany.com.cn
Tel: 0731- 84031888
Fax: 0731- 84031999
Service Hotline: 4008 87 8318
Complaint Hotline: 4008 87 9318
Overseas
Email: crd@sany.com.cn
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.
SYG5283THB 380C-8(R)
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.
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
• Fulfill their promises on after-sales service, and document all maintenance and repair working
done by after-sales service 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.
• 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.
• 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.
• 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
SYG5283THB 380C-8(R)
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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SYG5283THB 380C-8(R)
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 .................................................................................................... 3-7
3.2.1 Boom overview............................................................................................. 3-7
3.2.2 Boom components ....................................................................................... 3-7
3.2.3 Boom control ................................................................................................ 3-8
3.3 Outrigger System ............................................................................................... 3-10
3.3.1 Outrigger overview ....................................................................................... 3-10
3.3.2 Outrigger components.................................................................................. 3-10
3.3.3 Outrigger control........................................................................................... 3-11
3.3.4 Outrigger pads.............................................................................................. 3-12
3.4 Truck Chassis .................................................................................................... 3-13
3.4.1 Truck chassis overview ................................................................................ 3-13
3.4.2 Truck chassis components........................................................................... 3-14
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4 Operation
4.1 Pre-operational Checks ..................................................................................... 4-3
6
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7
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SYG5283THB 380C-8(R)
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
6.1 Routine Maintenance & Mandatory Overhaul .................................................... 6-3
6.2 General Tightening Torques .............................................................................. 6-8
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7 Specifications
7.1 Technical Data ................................................................................................... 7-3
7.2 Dimension .......................................................................................................... 7-5
7.3 Boom Operating Range ..................................................................................... 7-6
8 Appendix
8.1 Hydraulic Basic Diagram ................................................................................... 8-3
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Introduction
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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
SYG5283THB 380C-8(R)
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
SYG5283THB 380C-8(R)
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.
1-3
Introduction
SYG5283THB 380C-8(R)
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
SYG5283THB 380C-8(R)
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.
1.1.8 Appendix
This section provides the hydraulic basic
diagram and the electrical basic diagram.
1-5
Introduction
SYG5283THB 380C-8(R)
Data Plate
Fig.1-2
Fig.1-3
1-6
Introduction
SYG5283THB 380C-8(R)
Our address:
Sany Industry Town, Changsha National
Economic & Technical Development Zone,
Hunan, China
● Service Hotline: 0086 4006098318
● Service E-mail: crd@sany.com.cn
● Web site: http://www.sanygroup.com.cn
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
SYG5283THB 380C-8(R)
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.
1-8
Introduction
SYG5283THB 380C-8(R)
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
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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
2-1
Safety
SYG5283THB 380C-8(R)
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.
2-2
Safety
SYG5283THB 380C-8(R)
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.
2-3
Safety
SYG5283THB 380C-8(R)
2-4
Safety
SYG5283THB 380C-8(R)
2.1.8 Machine
In this safety manual, concrete delivery and
placing machines refer to:
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.
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SYG5283THB 380C-8(R)
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.
2-6
Safety
SYG5283THB 380C-8(R)
2.1.18 Maintenance
Maintenance embraces all measures required
for inspection, servicing and repair of a
machine.
2-7
Safety
SYG5283THB 380C-8(R)
Fig.2-1 Example
Stationary machines
Fig.2-2 Example
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SYG5283THB 380C-8(R)
2-9
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SYG5283THB 380C-8(R)
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-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.
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.
2-10
Safety
SYG5283THB 380C-8(R)
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.
2-11
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SYG5283THB 380C-8(R)
● 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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SYG5283THB 380C-8(R)
2-13
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SYG5283THB 380C-8(R)
2.3.5 Extensions
Extension of the placing boom and end hose
beyond the length specified on the rating
plate is forbidden.
Fig.2-5
2-16
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SYG5283THB 380C-8(R)
2-17
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SYG5283THB 380C-8(R)
2.5 Personnel
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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Safety
SYG5283THB 380C-8(R)
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.
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SYG5283THB 380C-8(R)
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SYG5283THB 380C-8(R)
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
2-21
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SYG5283THB 380C-8(R)
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)
2-22
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SYG5283THB 380C-8(R)
2-23
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SYG5283THB 380C-8(R)
2-24
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SYG5283THB 380C-8(R)
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.
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
2-25
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2-26
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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.
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SYG5283THB 380C-8(R)
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.
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SYG5283THB 380C-8(R)
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.
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
2-33
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2-34
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2-35
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2-36
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Fig.2-24
2-37
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SYG5283THB 380C-8(R)
Fig.2-26
2-38
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2-39
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SYG5283THB 380C-8(R)
2.14.2 Safety
Before switching on the machine, you must
make sure that nobody can be injured by the
running machine.
2-40
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SYG5283THB 380C-8(R)
2-41
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SYG5283THB 380C-8(R)
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.
2-42
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SYG5283THB 380C-8(R)
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.
2-43
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SYG5283THB 380C-8(R)
2-44
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2-45
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2-46
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2-47
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2.17 Welding
2-48
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2-49
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2.20 Software
2-50
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2-51
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2-52
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2.23.1 General
Work on hydraulic systems must only be
carried out by qualified personnel.
2-53
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SYG5283THB 380C-8(R)
2-54
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SYG5283THB 380C-8(R)
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.
Fig.2-29
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System Functions
3 System Functions
3.1 General Overview .............................................................................................3-3
3.2 Boom System ...................................................................................................3-7
3.3 Outrigger System ..............................................................................................3-10
3.4 Truck Chassis ...................................................................................................3-13
3.5 Pumping System ...............................................................................................3-15
3.6 Hydraulic System ..............................................................................................3-18
3.7 Electric Control System ....................................................................................3-24
3.8 Remote Control System ....................................................................................3-48
3-1
System Functions
SYG5283THB 380C-8(R)
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
SYG5283THB 380C-8(R)
3 SYSTEM FUNCTIONS
4 2
[1] Chassis
[2] Boom
[3] Outrigger system
[4] Hydraulic system
[5] Electrical system
[6] Body understructure
[7]Pumping mechanism
1 5 10 6 7 [8] Remote control
3
system (in cab)
[9] Boom & outrigger
backup hydraulics
(in cabinet)
[10] Outrigger control
[11] Maintenance
operation box
[12] Small operation box
12 11 9
3-3
System Functions
SYG5283THB 380C-8(R)
3-4
System Functions
SYG5283THB 380C-8(R)
3-5
System Functions
SYG5283THB 380C-8(R)
3-6
System Functions
SYG5283THB 380C-8(R)
3-7
System Functions
SYG5283THB 380C-8(R)
3-8
System Functions
SYG5283THB 380C-8(R)
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
3-9
System Functions
SYG5283THB 380C-8(R)
3-10
System Functions
SYG5283THB 380C-8(R)
3-11
System Functions
SYG5283THB 380C-8(R)
Fig.3-12
3-12
System Functions
SYG5283THB 380C-8(R)
3-13
System Functions
SYG5283THB 380C-8(R)
Fig.3-13
[1] Vehicle's chassis
[2] Transfer case and oil pump assembly
[3] Platform and accessories
3-14
System Functions
SYG5283THB 380C-8(R)
8 11
3
4 7
1
2
10
9
12
3-15
System Functions
SYG5283THB 380C-8(R)
Fig.3-16
3-16
System Functions
SYG5283THB 380C-8(R)
Fig.3-18
3-17
System Functions
SYG5283THB 380C-8(R)
3-18
System Functions
SYG5283THB 380C-8(R)
Fig.3-20
3-19
System Functions
SYG5283THB 380C-8(R)
3-20
System Functions
SYG5283THB 380C-8(R)
3-21
System Functions
SYG5283THB 380C-8(R)
3-22
System Functions
SYG5283THB 380C-8(R)
3-23
System Functions
SYG5283THB 380C-8(R)
Fig.3-28
3-24
System Functions
SYG5283THB 380C-8(R)
1 3 2
NOTICE
It is prohibited to wash the electric control
cabinet body and elements with water or
make them sprinkled.
SYCD
3-25
System Functions
SYG5283THB 380C-8(R)
3-26
System Functions
SYG5283THB 380C-8(R)
Fig.3-35
(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.
Fig.3-36
3-27
System Functions
SYG5283THB 380C-8(R)
(5)History Faults
This display shows a record for the
preveninet fault for the device,and the
engineers just need to follow the prompts to
carry out the appropriate troubleshooting.
Fig.3-37
Fig.3-38
Force pump
Press F5 button on the home page to go to
the page shown as Fig.3-38. On this page
the display has some notices that pertain to
force pump, force fan and force rotate.
Fig.3-39
3-28
System Functions
SYG5283THB 380C-8(R)
PAR SET
This page contains the following information
(see Fig. 3-40):
● Pump Parameter Set
● Boom Damping Parameter Set
● Boom Parameter Set
● Assistant Function
● Device Info Configure
● Turn on Confirm Fig.3-40
● Intelligent Diagnose System
● 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.
3-29
System Functions
SYG5283THB 380C-8(R)
(1) E-STOP
CAUTION
Failure to sound the horn before resuming
normal operations could result in minor or
major injury.
3-30
System Functions
SYG5283THB 380C-8(R)
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.
3-31
System Functions
SYG5283THB 380C-8(R)
3-32
System Functions
SYG5283THB 380C-8(R)
(6) Preheat
2 AGITATE REVERSE SPEED
4 PISTON 9
STANDBY
EXIT
KEEP
24V 3A RESET
10
Fig.3-50
3-33
System Functions
SYG5283THB 380C-8(R)
Fig.3-53
3-34
System Functions
SYG5283THB 380C-8(R)
Fig.3-54
CAUTION
Failure to sound the horn before resuming
normal operations could result in minor or
major injury.
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.3-56
hydraulic oil to overheat.
3-35
System Functions
SYG5283THB 380C-8(R)
Fig.3-60
3-36
System Functions
SYG5283THB 380C-8(R)
Fig.3-61
3-37
System Functions
SYG5283THB 380C-8(R)
NOTICE
Know the location and function of these
monitoring systems before beginning Fig.3-63
operation. Failure to do so may result in
damage to the machine or a system [1]Main system pressure
[2]Changeover pressure
malfunction.
[3]Agitator pressure
[4]Hydraulic fluid levels
[5]Cleaning water levels
3-38
System Functions
SYG5283THB 380C-8(R)
3000 30
1000
4000
5000
40
3000
2000 30
1000
5000
40
(1,741 psi).
Fig.3-66
3-39
System Functions
SYG5283THB 380C-8(R)
NOTICE Fig.3-67
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.
WARNING
Never use toxic or flammable fluids in the
wash system; use only fresh, clean tap
water. Using toxic or flammable fluids in
Fig.3-68
this system could cause injury or an
explosion resulting in death.
3-40
System Functions
SYG5283THB 380C-8(R)
Fig.3-70
3-41
System Functions
SYG5283THB 380C-8(R)
3.7.7 Light
The lamps and switches of truck-mounted
concrete pump:
Fig.3-73
Fig.3-74
3-42
System Functions
SYG5283THB 380C-8(R)
Fig.3-77
3-43
System Functions
SYG5283THB 380C-8(R)
Fig.3-78
Fig.3-79
Fig.3-80
3-44
System Functions
SYG5283THB 380C-8(R)
Fig.3-81
Fig.3-82
Fig.3-83
3-45
System Functions
SYG5283THB 380C-8(R)
WARNING
All personnel involved with the job — no
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.
E-STOP
UP
DOWN
FORWARD
FORWARD
BACKWARD BACKWARD
PISTON
STANDBY
EXIT
KEEP
24V 3A RESET
Fig.3-84
3-46
System Functions
SYG5283THB 380C-8(R)
Fig.3-85
Fig.3-86
Fig.3-87
3-47
System Functions
SYG5283THB 380C-8(R)
Fig.3-89
Fig.3-90
3-48
System Functions
SYG5283THB 380C-8(R)
Fig.3-91
[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
3-49
System Functions
SYG5283THB 380C-8(R)
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.
Fig.3-93
3-50
System Functions
SYG5283THB 380C-8(R)
It is temporarily unavailable.
Fig.3-95
Fig.3-96
3-51
System Functions
SYG5283THB 380C-8(R)
Fig.3-97
Fig.3-98
3-52
System Functions
SYG5283THB 380C-8(R)
(12)Double-way handle 1#
Fig.3-100
(13)Double-way handle 2#
Fig.3-101
(14)Double-way handle 3#
Fig.3-102
(15)Double-way handle 4#
3-53
System Functions
SYG5283THB 380C-8(R)
(16)Double-way handle 5#
Fig.3-104
(18)Sound button
Fig.3-106
3-54
System Functions
SYG5283THB 380C-8(R)
Fig.3-107
(20)Starting switch
Fig.3-108
Fig.3-109
3-55
System Functions
SYG5283THB 380C-8(R)
Unavailable temporarily..
Fig.3-110
(23)Hard-Wire connector port
Fig.3-112
3-56
System Functions
SYG5283THB 380C-8(R)
Fig.3-113
Fig.3-114
Fig.3-115
3-57
System Functions
SYG5283THB 380C-8(R)
E
G
PA
K
AN
BL
3-58
Operations
SYG5283THB 380C-8(R)
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 Equipment Clean-up .........................................................................................4-54
4.10 Retracting the Boom & Outriggers ...................................................................4-62
4.11 Driving, Towing and Loading ...........................................................................4-63
4.12 Machine Decals .............................................................................................4-68
4-1
Operations
SYG5283THB 380C-8(R)
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
SYG5283THB 380C-8(R)
4 OPERATION
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.
4-3
Operation
SYG5283THB 380C-8(R)
4-4
Operation
SYG5283THB 380C-8(R)
WARNING
Failure to observe and follow these
directives may result in equipment
damage, property damage, personal injury
or even death.
Working clearances
Slab to be poured
Working clearances
Fig.4-2
4-5
Operation
SYG5283THB 380C-8(R)
Surface conditions
Working clearances
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
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
SYG5283THB 380C-8(R)
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.
Releasing position
of hand brake
Indicator lamp is on when
P the hand brake is pulled on
Fig.4-6
4-7
Operation
SYG5283THB 380C-8(R)
H
10
5 15
0 20 5
F
Barometer
Fig.4-7
Fig.4-9
4-8
Operation
SYG5283THB 380C-8(R)
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.
PARKING
BRAKE
Bendin
P E
U
SH AS
E
TO EL
R
Fig.4-11
4-9
Operation
SYG5283THB 380C-8(R)
4-10
Operation
SYG5283THB 380C-8(R)
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.
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.
Fig.4-13
4-11
Operation
SYG5283THB 380C-8(R)
Fig.4-14
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.
a
Fig.4-15
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
SYG5283THB 380C-8(R)
a
Turn the
switch right
O
Fig.4-19
4-13
Operation
SYG5283THB 380C-8(R)
Fig.4-20
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.
Fig.4-21
4-14
Operation
SYG5283THB 380C-8(R)
4.4.4 OSS
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.
4-15
Operation
SYG5283THB 380C-8(R)
Fig.4-24
Fig.4-25
4-16
Operation
SYG5283THB 380C-8(R)
Fig.4-27
CAUTION
Always stand clear from the outrigger
levelling cylinders during set-up. Failure
to do so could result in serious injury.
Fig.4-28
4-17
Operation
SYG5283THB 380C-8(R)
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.
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
SYG5283THB 380C-8(R)
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.
4-19
Operation
SYG5283THB 380C-8(R)
Environmental protection
Comply with the waste disposal regulations in
force for your area when changing the fluid
filter.
4-20
Operation
SYG5283THB 380C-8(R)
4-21
Operation
SYG5283THB 380C-8(R)
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.
WARNING
You must stop work if you open the grille,
but
●the agitator continues to run,
●the S-valve continues to switch,
4-22
Operation
SYG5283THB 380C-8(R)
WARNING Fig.4-32
Fig.4-33
4.6.1 Restrictions on use
4-23
Operation
SYG5283THB 380C-8(R)
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
4-24
Operation
SYG5283THB 380C-8(R)
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.
Fig.4-35
High-voltage lines
A spark can jump across from high-voltage
lines even if you just approach them and this
will energize the machine and the
surrounding area. You must therefore always
maintain the specified safe clearance.
Fig.4-36
4-25
Operation
SYG5283THB 380C-8(R)
Hand signals
Fig.4-37
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.
4-26
Operation
SYG5283THB 380C-8(R)
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.
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
SYG5283THB 380C-8(R)
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.
4-28
Operation
SYG5283THB 380C-8(R)
CAUTION
Always operate the boom slowly and
cautiously. Rapid, jerky movements could
result in loss of control and possible
injury to nearby personnel.
Fig.4-38
Fig.4-39
4-29
Operation
SYG5283THB 380C-8(R)
Fig.4-40
Fig.4-41
Fig.4-42
4-30
Operation
SYG5283THB 380C-8(R)
Fig.4-43
Fig.4-44
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
SYG5283THB 380C-8(R)
Fig.4-47
4-32
Operation
SYG5283THB 380C-8(R)
Fig.4-48
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.
4-33
Operation
SYG5283THB 380C-8(R)
Fig.4-52
4.8 Extending the Boom
4-34
Operation
SYG5283THB 380C-8(R)
Fig.4-54
Fig.4-55
4-35
Operation
SYG5283THB 380C-8(R)
NOTICE
Fig.4-56
Lowering the boom with the hopper in the
open position will result in damage to the
boom, hopper and hopper cover.
NOTICE
NOTICE
When unfolding or folding each boom, it
must provide enough height and space for
boom movement in order to avoid
b u mp . W he n t ur ni n g bo o m op e r a ti o n
handle, don't turn to the dead position
once and move slowly to the maximal
opposition.
4-36
Operation
SYG5283THB 380C-8(R)
WARNING
It should cause bump between oil cylinder
5 and boom 3 if boom 5 is operated before
boom 4 is unfolded to 5°
WARNING
It may cause bump bewteen oil cylinder 5
and boom 3 if boom 4 is folded before
boom 5 is folded completely. The
protective procedure of system will go
into effect so that boom 4 stops at 5° until
boom 5 is fully folded.
Fig.4-60
4-37
Operation
SYG5283THB 380C-8(R)
WARNING
When concrete putting in boom delivery
pipe, the total weight of boom increase
sharply, and the weight distortion of boom
increase, and the distortion is most at the
whole boom horizontal placing state,
a n d t h e b oo m e nd d e sc e n d s h a r pl 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.
C A U T IO N
Fig.4-61
Operation
SYG5283THB 380C-8(R)
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.
CAUTION
Failure to observe and follow these
directives could result in machine tipover,
equipment damage or personal injury.
Pumping Operations
4-39
Operation
SYG5283THB 380C-8(R)
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.
4-40
Operation
SYG5283THB 380C-8(R)
Fig.4-64
Fig.4-65
4-41
Operation
SYG5283THB 380C-8(R)
Fig.4-66
Fig.4-67
Fig.4-68
4-42
Operation
SYG5283THB 380C-8(R)
Fig.4-69
Fig.4-70
Fig.4-71
4-43
Operation
SYG5283THB 380C-8(R)
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.
Fig.4-72
Fig.4-73
4-44
Operation
SYG5283THB 380C-8(R)
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.
4-45
Operation
SYG5283THB 380C-8(R)
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.
4-46
Operation
SYG5283THB 380C-8(R)
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.
NOTICE
Failure to monitor this system may result
in component damage or lock-up.
4.8.8 Pumping
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.
4-47
Operation
SYG5283THB 380C-8(R)
4-48
Operation
SYG5283THB 380C-8(R)
c
NOTE: Always sound the horn with switch (d)
before you start the pump. d
b
Fig.4-80
4-49
Operation
SYG5283THB 380C-8(R)
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
to avo id trap pi ng ai r in the ma te ri al
cylinder openings.
4-50
Operation
SYG5283THB 380C-8(R)
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.4-84
● 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.4-85
4-51
Operation
SYG5283THB 380C-8(R)
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.4-86
layer on the delivery piston rods and
delivery cylinders will be destroyed.
4-52
Operation
SYG5283THB 380C-8(R)
4.8.10Special cases
4-53
Operation
SYG5283THB 380C-8(R)
NOTICE
Failure to thoroughly clean the pumping
system at the completion of pumping
operations will result in equipment
damage.
Fig.4-87
4-54
Operation
SYG5283THB 380C-8(R)
Fig.4-88
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.
Fig.4-89
4-55
Operation
SYG5283THB 380C-8(R)
Fig.4-90
4-56
Operation
SYG5283THB 380C-8(R)
Fig.4-92
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.
4-57
Operation
SYG5283THB 380C-8(R)
CAUTION a
If required, using compressed air to clean
the boom piping or a separate pipeline
should be done only under the Fig.4-94
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.
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.
4-58
Operation
SYG5283THB 380C-8(R)
4-59
Operation
SYG5283THB 380C-8(R)
Fig.4-98
(2) Connect the pressure washer wand hose
to the water pump connection at the left
side rear of the truck below the chassis.
4-60
Operation
SYG5283THB 380C-8(R)
NOTICE
Be careful not to let the pressure washing
system go dry during washing operations.
Damage to the pump may result.
Fig.4-99
NOTICE
Failure to remove all concrete residue may
result in damage to the machine,
especially during later operation.
Water gun
Fig.4-100
4-61
Operation
SYG5283THB 380C-8(R)
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.
4-62
Operation
SYG5283THB 380C-8(R)
4.11.1Driving
Fig.4-103
Fig.4-104
4-63
Operation
SYG5283THB 380C-8(R)
Driving on slopes
Driving on slopes may pose a hazard. In Fig.4-106
order to prevent tipping or losing control of
the machine, it is important to follow some
basic simple rules.
Fig.4-108
4-64
Operation
SYG5283THB 380C-8(R)
Driving in reverse
4-65
Operation
SYG5283THB 380C-8(R)
4.11.2Towing
● 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.
4-109).
Fig.4-109
4-66
Operation
SYG5283THB 380C-8(R)
4.11.3Loading
Fig.4-111
4-67
Operation
SYG5283THB 380C-8(R)
4-68
Operation
SYG5283THB 380C-8 SYG5283THB 380C-8(R)
32 31 9 18 53 38 48 42 57 45 44 7 4 58 6 35 33 19 36 23 27 37 15
Fig.4-112
16 26 40 28 12 10 11 14 41 43 39 59 8 3 20 52 54 2
Fig.4-113
4-69
Operation
SYG5283THB 380C-8(R)
56
24
17
34
警告 WARNING
29 30 35
警告 WARNING
47 50
49
25
46
1 51
21
22
Fig.4-114
4-70
Operation
SYG5283THB 380C-8(R)
12 Mark about Main-system Oil Pressure 36 Prohibition of Using Boom to Lift Loads
Warning Mark for Preventing Boom
13 Mark for forbid working position of boom 37
against Electric Shock
38 Mark for Water Pump Drainage
14 Warning Mark on Stair
Procedure
15 Prohibition for Hopper 39 Information Mark about Placing Range
16 Mark for Caution to Splashing Concrete 40 Mark for End Hose Warning
17 Instruction Mark for Sealing Oil Tank 41 Instruction Mark for Outriggers
18 Mark for Warning of Anti-falling 42 Identification Mark on Water Pump
19 Warning Mark for Outrigger Activation 43 Mark for right One-sided support
20 Smoking Prohibition 44 Mark for left One-sided support
21 Mark 1 on Oil Tank 45 Mark for lubrication points
22 Mark 1 on Oil Tank 46 Mark for butter Filler on turret
47 Mark for Switchover of Driving and
23 Mark of Grease Cup
Pumping
24 Mark at Gear Oil Filler 48 Warning mark for water pump usage
4-71
Operation
SYG5283THB 380C-8(R)
Table 4-1
53 Directive Mark 2
Fig.4-115
Fig.4-116
4-72
Operation
SYG5283THB 380C-8(R)
Fig.4-117
Fig.4-118
4-73
Operation
SYG5283THB 380C-8(R)
Fig.4-119
Fig.4-120
4-74
Operation
SYG5283THB 380C-8(R)
Fig.4-122
4-75
Operation
SYG5283THB 380C-8(R)
Fig.4-123
(10) Mark about Swing Valve System Oil
Pressure (see Fig. 4-124)
Fig.4-124
4-76
Operation
SYG5283THB 380C-8(R)
Fig.4-127
Fig.4-128
4-77
Operation
SYG5283THB 380C-8(R)
Fig.4-129
Fig.4-130
Fig.4-131
4-78
Operation
SYG5283THB 380C-8(R)
Fig.4-132
Fig.4-133
Fig.4-134
4-79
Operation
SYG5283THB 380C-8(R)
Fig.4-138
Fig.4-139
4-80
Operation
SYG5283THB 380C-8(R)
Fig.4-140
Fig.4-142
4-81
Operation
SYG5283THB 380C-8(R)
Fig.4-143
Fig.4-144
(31) Information Mark about Outrigger
Pressure (see Fig. 4-145)
Fig.4-145
4-82
Operation
SYG5283THB 380C-8(R)
Fig.4-146
Fig.4-147
Fig.4-148
4-83
Operation
SYG5283THB 380C-8(R)
Fig.4-149
(36) Prohibition of Using Boom to Lift Loads
(see Fig. 4-150)
Fig.4-150
4-84
Operation
SYG5283THB 380C-8(R)
Fig.4-152
Fig.4-153
4-85
Operation
SYG5283THB 380C-8(R)
Fig.4-154
(41) Instruction Mark for Outriggers (see Fig.
4-155)
Fig.4-155
4-86
Operation
SYG5283THB 380C-8(R)
Fig.4-156
Fig.4-157
4-87
Operation
SYG5283THB 380C-8(R)
Fig.4-158
Fig.4-159
4-88
Operation
SYG5283THB 380C-8(R)
Fig.4-160
Fig.4-161
Fig.4-162
4-89
Operation
SYG5283THB 380C-8(R)
Fig.4-163
Fig.4-165
Fig.4-166
4-90
Operation
SYG5283THB 380C-8(R)
Fig.4-167
Fig.4-168
Fig.4-169
4-91
Operation
SYG5283THB 380C-8(R)
Fig.4-170
(57) Mark for Boom Expansion Sequence (see
Fig. 4-171)
● It indicates the boom expansion sequence.
2.unfold the boom 1 to 3.Unfolding the boom 4 to over 5° 4.unfolding the boom 4 to
1.Initial state about 60°position.Note: position. over 5° position, the boom
Before unfolding boom 1, Note:Make sure unfolding the
5 can be unfolded
folding all booms first. boom 4 to over 5° position, the
boom 5 can be unfolded.
1.Adjust all booms to state 2.Fold boom 2, boom 3 3.Fold boom 4 completely. 4.Fold boom 1 to major
on the display. and boom 5. support .
Note:must be left over 5° Note:Boom 5 is folded
between boom 3and boom 4. completely before folded
boom 4.
Fig.4-171
4-92
Operation
SYG5283THB 380C-8(R)
E
G
PA
K
AN
BL
4-93
Operation
SYG5283THB 380C-8(R)
E
G
PA
K
AN
BL
4-94
Troubleshooting
SYG5283THB 380C-8(R)
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
SYG5283THB 380C-8(R)
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
SYG5283THB 380C-8(R)
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.
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.
5-3
Troubleshooting
SYG5283THB 380C-8(R)
Quick abrasion of Serious abrasion of the spectacle Replace it with a new spectacle
5
cutting ring wear plate wear plate.
5-4
Troubleshooting
SYG5283THB 380C-8(R)
5-5
Troubleshooting
SYG5283THB 380C-8(R)
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.
5-6
Troubleshooting
SYG5283THB 380C-8(R)
5-7
Troubleshooting
SYG5283THB 380C-8(R)
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.
5-8
Troubleshooting
SYG5283THB 380C-8(R)
5-9
Troubleshooting
SYG5283THB 380C-8(R)
5-10
Troubleshooting
SYG5283THB 380C-8(R)
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.
5-11
Troubleshooting
SYG5283THB 380C-8(R)
The transfer case not at the Switch the transfer case to oil
position of oil pump pump position.
5-12
Troubleshooting
SYG5283THB 380C-8(R)
5-13
Troubleshooting
SYG5283THB 380C-8(R)
E
G
PA
K
AN
BL
5-14
Maintenance
SYG5283THB 380C-8(R)
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 ..........................................................................................................6-80
6.12 Hoses ...............................................................................................................6-80
6.13 Electrical System .............................................................................................6-83
6-1
Maintenance
SYG5283THB 380C-8(R)
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
SYG5283THB 380C-8(R)
6 MAINTENANCE
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
SYG5283THB 380C-8(R)
6-4
Maintenance
SYG5283THB 380C-8(R)
6-5
Maintenance
SYG5283THB 380C-8(R)
6-6
Maintenance
SYG5283THB 380C-8(R)
6-7
Maintenance
SYG5283THB 380C-8(R)
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.
6-8
Maintenance
SYG5283THB 380C-8(R)
Preheating Preheating
No Metric Thread No Metric Thread
Torque(N.m) Torque(N.m)
7 M24×1.5 60~88
6-9
Maintenance
SYG5283THB 380C-8(R)
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
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
6-10
Maintenance
SYG5283THB 380C-8(R)
6.3 Lubrication
Automatic lubrication
Through the hydraulic synchronizing
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.
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
6-11
Maintenance
SYG5283THB 380C-8(R)
CAUTION
The hydraulic synchronizing lubrication
pump should be always clean and free of
dust and other foreign matters. In
addition, it should not contact acid or
alkali substances.The adopted grease
Pressure regulating
should comply with specification and overflow valve
must be clean and free of foreign matter.
Failure to do so may result in instability in
Drive oil port II
operating positions or serious damage to
the machine.
Drive oil port I
Circular lubricating
Discharge air in the hydraulic synchronizing grease port
grease pump, as shown in Fig. 6-2. Synchronizing lubricating grease port
Air release valve
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
SYG5283THB 380C-8(R)
6-13
Maintenance
SYG5283THB 380C-8(R)
Fig.6-4
6-14
Maintenance
SYG5283THB 380C-8(R)
Fig.6-5
Grease
6-15
Maintenance
SYG5283THB 380C-8(R)
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.
Engine oil
Under most climatic conditions, the
SAE15W40 engine oil is preferred to water
SANYSPECIAL
pump. GREASENO.00
GENUINEPARTS
6-16
Maintenance
SYG5283THB 380C-8(R)
(2) Viscosity
Fig.6-7
Hydraulic fluid
The recommended hydraulic fluid types for
different ambient temperatures (see Table. 6-
9).
6-17
Maintenance
SYG5283THB 380C-8(R)
6-18
Maintenance
SYG5283THB 380C-8(R)
Adding
No Part to Be Lubricated Lubricating Oil / Grease
Capacity (L)
2 Transfer case 8 SHELL 150 gear oil or MOBIL 629 gear oil
6-19
Maintenance
SYG5283THB 380C-8(R)
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.
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.
6-20
Maintenance
SYG5283THB 380C-8(R)
(50 lbf.ft).
NOTE: See Fig. 6-10 for the location of plug (a). Fig.6-10
6-21
Maintenance
SYG5283THB 380C-8(R)
6-22
Maintenance
SYG5283THB 380C-8(R)
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.
NOTICE
If you will be operating in a cold climate,
you may want use an environmentally
approved antifreeze solution to prevent
the water from freezing. Failure to do so
may cause damage to your machine.
Fig.6-16
6-23
Maintenance
SYG5283THB 380C-8(R)
6-24
Maintenance
SYG5283THB 380C-8(R)
6-25
Maintenance
SYG5283THB 380C-8(R)
6-26
Maintenance
SYG5283THB 380C-8(R)
NOTE: Do not fill the wash box after AGITATE REVERSE SPEED
cleaning. UP
DOWN
BACKWARD BACKWARD
EXIT
shown in illustration until the pumping KEEP
24V 3A RESET
Fig.6-20
6-27
Maintenance
SYG5283THB 380C-8(R)
Replacement procedures
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.
d d
Fig.6-22
6-28
Maintenance
SYG5283THB 380C-8(R)
PISTON
for repair procedures. STANDBY
EXIT
KEEP
24V 3A RESET
Fig.6-24
6-29
Maintenance
SYG5283THB 380C-8(R)
should not be less than 5cm; Fig.6-25 agitator shaft and agitator blade
otherwise the hopper will be worn out.
During installation of left and right
[1] Agitator shaft [6] Flat washer
agitator blades, pay attention to the
[2] Left agitator blade [7] Nut
correct installation direction of agitator
[3] Right agitator blade
blades.
[4] Bolt
[5] Spring pad
6-30
Maintenance
SYG5283THB 380C-8(R)
6-31
Maintenance
SYG5283THB 380C-8(R)
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).
6-32
Maintenance
SYG5283THB 380C-8(R)
6-33
Maintenance
SYG5283THB 380C-8(R)
6-34
Maintenance
SYG5283THB 380C-8(R)
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.
6-35
Maintenance
SYG5283THB 380C-8(R)
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.
6-36
Maintenance
SYG5283THB 380C-8(R)
Fig.6-33
6-37
Maintenance
SYG5283THB 380C-8(R)
6-38
Maintenance
SYG5283THB 380C-8(R)
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
6-39
Maintenance
SYG5283THB 380C-8(R)
4
26
3
25
2
1 24
23
22
16 17
21
15
20
14
13 19
12 18
16
10
11
6-40
Maintenance
SYG5283THB 380C-8(R)
6-41
Maintenance
SYG5283THB 380C-8(R)
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
6-42
Maintenance
SYG5283THB 380C-8(R)
6-43
Maintenance
SYG5283THB 380C-8(R)
6-44
Maintenance
SYG5283THB 380C-8(R)
6-45
Maintenance
SYG5283THB 380C-8(R)
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.
6-46
Maintenance
SYG5283THB 380C-8(R)
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.
6-47
Maintenance
SYG5283THB 380C-8(R)
6-48
Maintenance
SYG5283THB 380C-8(R)
6-49
Maintenance
SYG5283THB 380C-8(R)
6.5.4 Hopper
6-50
Maintenance
SYG5283THB 380C-8(R)
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.
6-51
Maintenance
SYG5283THB 380C-8(R)
(1) Clearance
(2) Elbow
6-52
Maintenance
SYG5283THB 380C-8(R)
6-53
Maintenance
SYG5283THB 380C-8(R)
6-54
Maintenance
SYG5283THB 380C-8(R)
6-55
Maintenance
SYG5283THB 380C-8(R)
6-56
Maintenance
SYG5283THB 380C-8(R)
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.
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
SYG5283THB 380C-8(R)
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.
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.
6-58
Maintenance
SYG5283THB 380C-8(R)
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
SYG5283THB 380C-8(R)
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.
6-60
Maintenance
SYG5283THB 380C-8(R)
6-61
Maintenance
SYG5283THB 380C-8(R)
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.
6-62
Maintenance
SYG5283THB 380C-8(R)
2
3 4
5
7
9
8
10
12 11
14
15
13
16
17
18
19
Fig.6-51Slewing Mechanism
[1] Bolt M10 [10] Oil cup
[2] Baffle [11] Bolt M6
[3] Pin [12] Sealing plate
[4] Axis pin [13] Fixed revolving tower
[5] Copper mat (I) [14] Copper mat (II)
[6] Turntable [15] Dust-proof ring
[7] Slewing bearing [16] Eccentric wheel
[8] Idle pulley [17] Screw M6
[9] Gear [18] Reducer
[19] Bolt M16
6-63
Maintenance
SYG5283THB 380C-8(R)
Overview
The structure of Slewing gear transmission
(see Fig. 6-52), check and maintenance
intervals.
6-64
Maintenance
SYG5283THB 380C-8(R)
Fig.6-54
6-65
Maintenance
SYG5283THB 380C-8(R)
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 ).
5
1
2
4
3
3
4
8
7
6
6-66
Maintenance
SYG5283THB 380C-8(R)
6-67
Maintenance
SYG5283THB 380C-8(R)
6-68
Maintenance
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.
6-69
Maintenance
SYG5283THB 380C-8(R)
6-70
Maintenance
SYG5283THB 380C-8(R)
6.8.1 Overview
1
3
2
4
6-71
Maintenance
SYG5283THB 380C-8(R)
6-72
Maintenance
SYG5283THB 380C-8(R)
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.
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.
6-73
Maintenance
SYG5283THB 380C-8(R)
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.
6-74
Maintenance
SYG5283THB 380C-8(R)
NOTICE
Never use water or toxic liquids to clean
the inside of the tank. These chemicals
could damage the system.
6-75
Maintenance
SYG5283THB 380C-8(R)
6.9 Accumulator
6.9.1 Overview
The accumulator is composed of housing,
1
capsule, oil valve, gas valve, etc. (see Fig. 6-
63). Common sense about the use of
2
accumulator:
6-76
Maintenance
SYG5283THB 380C-8(R)
DANGER
The accumulator should be filled with
nitrogen. Never use other gases. If it is
filled with air, nitrogen, etc., explosion
may occur.
6-77
Maintenance
SYG5283THB 380C-8(R)
6-78
Maintenance
SYG5283THB 380C-8(R)
Fig.6-66
6-79
Maintenance
SYG5283THB 380C-8(R)
NOTICE
Treat the old filter in accordance with the
local regulation to avoid the pollution to
the environment.
Fig.6-67 Metal Breather
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 pressur 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.
6-80
Maintenance
SYG5283THB 380C-8(R)
6-81
Maintenance
SYG5283THB 380C-8(R)
CAUTION
The hydraulic line can not work without
oil. The inner of new house should be
c le an an d f r ee o f d us t . T he c r oo ke d
hydraulic hose is subjected to mechanical
pre-stressing force; therefore, the hose
will rebound when disassembling and lead
to injury.
6-82
Maintenance
SYG5283THB 380C-8(R)
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.
6-83
Maintenance
SYG5283THB 380C-8(R)
3 1 2 6 4 5
6-84
Maintenance
SYG5283THB 380C-8(R)
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
el e ct r i c c on t r ol c ab in e t i s g e ne r al l 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.
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.
6-85
Maintenance
SYG5283THB 380C-8(R)
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.
6-5). UP
DOWN
(1) Periodically check the E-STOP button of MAIN CYLINDER SWING CYLINDER
PISTON
tighten it in time. STANDBY
EXIT
KEEP
6-86
Maintenance
SYG5283THB 380C-8(R)
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.
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.
6-87
Maintenance
SYG5283THB 380C-8(R)
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.
(2) Waterproof seal is used between the Fig.6-72 Control Box for Outriggers
operation box panel and box. If the fixing
screw of panel is loosened, check the seal. [1] E-STOP button
If necessary, replace it and then tighten the [2] Toggle switch
installation screw of panel. [3] Control box
CAUTION
After every construction, the operation
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.
6-88
Maintenance
SYG5283THB 380C-8(R)
6.13.5Mechanical encoder
The mechanical encoder is used to measure
and limit the rotation control angle of boom
(see Fig. 6-73). Check and maintenance
intervals (see Table 6-2 on page 6-5) 1
(1) Apply grease on the slewing part of
2
mechanical encoder every 50 hours of
operation or every week.
3
(2) Periodically check the working condition
of two sensors on the mechanical encoder
and the sensing distance of sensor (less
than 5mm); if the installation nut of sensor is
loosened, re-adjust the measuring distance
of sensor and tighten it.
(3) Periodically check the tightening condition
Fig.6-73 Mechanical Encoder
of plug board of mechanical encoder and
harness for tightness. If not, tighten it timely; [1] Sensor
the plug board should be fixed with the [2] Mechanical encoder
harness to prevent the wire from [3] Rotary reducer
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.
6-89
Maintenance
SYG5283THB 380C-8(R)
NOTICE
Do not put items on the limit switch of
Fig.6-76 Boom Limit Switch
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.
6-90
Maintenance
SYG5283THB 380C-8(R)
6-91
Maintenance
SYG5283THB 380C-8(R)
6.13.11Rocker switch
6-92
Maintenance
SYG5283THB 380C-8(R)
6.13.14Wire
The wire is used to connect different
electrical elements (see Fig. 6-83).
6-93
Maintenance
SYG5283THB 380C-8(R)
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.
6-94
Maintenance
SYG5283THB 380C-8(R)
E
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6-95
Maintenance
SYG5283THB 380C-8(R)
E
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6-96
Specifications
SYG5283THB 380C-8(R)
Specifications
7 Specifications
7.1 Technical Data ..................................................................................................7-3
7.2 Dimension .........................................................................................................7-5
7.3 Boom Operating Range ....................................................................................7-6
7-1
Specifications
SYG5283THB 380C-8(R)
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
SYG5283THB 380C-8(R)
7 SPECIFICATIONS
Overall Parameters
Length 11510mm
Width 2500mm
Height 4000mm
Length 8510 mm
1st section
Articulat ion 89°
Length 7260 mm
2nd section
Articulation 18 0 °
Length 6000 mm
3rd section
Articulation 240°
Length 6100 mm
4th section
Articulation 180°
Length 6100 mm
5th section
Articulation 265°
Rotation ±360°
7-3
Specifications
SYG5283THB 380C-8(R)
Chassis specifications
Output 10.518 L
Pump Specifications
7-4
Specifications
SYG5283THB 380C-8(R)
7.2 Dimension
4000mm
11510mm
Fig.7-1
7-5
Specifications
SYG5283THB 380C-8(R)
Fig.7-2
7-6
Specifications
SYG5283THB 380C-8(R)
E
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7-7
Specifications
SYG5283THB 380C-8(R)
E
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7-8
Appendix
SYG5283THB 380C-8(R)
Appendix
8 Appendix
8.1 Hydraulic Basic Diagram ..................................................................................8-3
8.2 Electrical Basic Diagram ...................................................................................8-5
8.3 Specifications of twin pipes ........................... ....................................................8-18
8-1
Appendix
SYG5283THB 380C-8(R)
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
SYG5283THB 380C-8(R)
8 APPENDIX
8.1 Hydraulic Basic Diagram
8-3
Appendix
SYG5283THB 380C-8(R)
8-4
Appendix
SYG5283THB 380C-8(R)
8-5
Appendix
SYG5283THB 380C-8(R)
8-6
Appendix
SYG5283THB 380C-8(R)
8-7
Appendix
SYG5283THB 380C-8(R)
8-8
Appendix
SYG5283THB 380C-8(R)
8-9
Appendix
SYG5283THB 380C-8(R)
Switch
8-10
Appendix
SYG5283THB 380C-8(R)
8-11
Appendix
SYG5283THB 380C-8(R)
8-12
Fig.8-11 Chassis circuit
Mileage signal
To instrument
SINOTRUCK
SYG5283THB 380C-8(R)
8-13
Appendix
Appendix
SYG5283THB 380C-8(R)
8-14
Appendix
SYG5283THB 380C-8(R)
8-15
Appendix
SYG5283THB 380C-8(R)
8-16
Appendix
SYG5283THB 380C-8(R)
8-17
Appendix
SYG5283THB 380C-8(R)
8.3.1Installation Instructions
angle offset
Fig. 8-16
8-18
Appendix
SYG5283THB 380C-8(R)
WARNING
Fig.8-17
Fig.8-18
WARNING
8-19
Appendix
SYG5283THB 380C-8(R)
Fig. 8-19
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.
NOTICE turn
8-2 0
Appendix
SYG5283THB 380C-8(R)
E
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8-21
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