Quality Changes the World

Trailer-mounted
Concrete Pump
HBT6013C-5S

Operation and Maintenance Manual

 Trailer-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.
 SPECIFIC DECLARATION

The trailer-mounted concrete pump is an equipment installed on a trailer body understructure

and used for concrete pumping by means of pipeline. 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 trailer-
mounted concrete pump correctly. Sany expressly bears no liability for any consequence due to
any use not observing the information on this manual.

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

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

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

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

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

Duty of Sany

• Be responsible for providing qualified products.

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

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

Duty of Owners or Other Authorized Personnel

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

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

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

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

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

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

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

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

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

Duty of all working personnel

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

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

• All personnel should know their working tasks and procedures.

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

Duty of managers

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

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

• Publicize safety consciousness to working personnel, and make them aware of safety
precautions and their related responsibilities.
 Table of Contents
HBT6013C-5S

Table of Contents

1 INTRODUCTION …………………………………………………………………………………… 1-1

1.1 Manual Section Descriptions ………………………………………………………………………… 1-2
1.2 Machine Serial Number & Information ……………………………………………………………… 1-4
1.3 Contact Information …………………………………………………………………………………… 1-5
1.4 Icons and Symbols …………………………………………………………………………………… 1-5

2 SAFETY ………………………………………………………………………………………………… 2-1

2.1 Definition of Terms ……………………………………………………………………………………… 2-2
2.1.1 Concrete pump ………………………………………………………………………………… 2-2
2.1.2 Boom pedestal ………………………………………………………………………………… 2-2
2.1.3 Arm assembly …………………………………………………………………………………… 2-2
2.1.4 Placing boom …………………………………………………………………………………… 2-2
2.1.5 Base structure ………………………………………………………………………………… 2-2
2.1.6 Truck mixer ……………………………………………………………………………………… 2-2
2.1.7 Delivery line systems ………………………………………………………………………… 2-3
2.1.8 Machine ………………………………………………………………………………………… 2-3
2.1.9 Operator ………………………………………………………………………………………… 2-3
2.1.10 Machine operator ……………………………………………………………………………… 2-3
2.1.11 Hoseman ……………………………………………………………………………………… 2-4
2.1.12 Signaller and other auxiliary personnel …………………………………………………… 2-4
2.1.13 Truck mixer driver …………………………………………………………………………… 2-4
2.1.14 Authorized inspector ………………………………………………………………………… 2-4
2.1.15 Subject expert ………………………………………………………………………………… 2-5
2.1.16 Qualified personnel …………………………………………………………………………… 2-5
2.1.17 After Sales Service personnel ……………………………………………………………… 2-5
2.1.18 Maintenance …………………………………………………………………………………… 2-5
2.1.19 Place of work, working area, danger zone ………………………………………………… 2-6
2.2 Designated Use ………………………………………………………………………………………… 2-11
2.2.1 Inspection intervals …………………………………………………………………………… 2-12
2.3 Use Contrary to Designated Use ……………………………………………………………………… 2-13
2.3.1 Transporting goods …………………………………………………………………………… 2-13
2.3.2 Lifting loads ……………………………………………………………………………………… 2-13
2.3.3 Removing obstacles …………………………………………………………………………… 2-13
2.3.4 Extending the reach …………………………………………………………………………… 2-14
2.3.5 Extensions ……………………………………………………………………………………… 2-14
2.3.6 Impermissible end hose ……………………………………………………………………… 2-14
2.3.7 Impermissible working area …………………………………………………………………… 2-14
2.3.8 Climbing the placing boom …………………………………………………………………… 2-15
2.3.9 High-pressure delivery ………………………………………………………………………… 2-15
2.3.10 Accessories and attachments ……………………………………………………………… 2-15
2.4 Exclusion of Liability …………………………………………………………………………………… 2-15

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2.5 Personnel ……………………………………………………………………………………………… 2-16

2.5.1 Requirements …………………………………………………………………………………… 2-16
2.5.2 Qualifications …………………………………………………………………………………… 2-17
2.5.3 Responsibility of the machine operator ……………………………………………………… 2-17
2.6 Operating Instructions, Operating Procedures and Other Regulations …………………………… 2-17
2.6.1 Operating instructions ………………………………………………………………………… 2-17
2.6.2 Operating procedures ………………………………………………………………………… 2-18
2.6.3 Other regulations ……………………………………………………………………………… 2-19
2.7 Personal Protective Equipment ……………………………………………………………………… 2-19
2.8 Before Starting Work …………………………………………………………………………………… 2-21
2.8.1 Checking that the machine is ready for operation ………………………………………… 2-21
2.8.2 Rendering the machine ready for operation ………………………………………………… 2-21
2.9 Danger Due to High-voltage ………………………………………………………………………… 2-22
2.9.1 High-voltage lines ……………………………………………………………………………… 2-22
2.9.2 Discharge voltage pattern …………………………………………………………………… 2-22
2.9.3 Clearances ……………………………………………………………………………………… 2-23
2.9.4 High-voltage warning devices ………………………………………………………………… 2-24
2.9.5 Procedure in the event of a flash over ……………………………………………………… 2-24
2.9.6 Earthing in the event of electrostatic charging ……………………………………………… 2-25
2.10 Stationary Machines ………………………………………………………………………………… 2-25
2.10.1 Set-up site …………………………………………………………………………………… 2-25
2.10.2 Stationary booms ……………………………………………………………………………… 2-26
2.10.3 Lifting machines and components ………………………………………………………… 2-26
2.10.4 Loading and transporting …………………………………………………………………… 2-26
2.11 Mobile Machines ……………………………………………………………………………………… 2-27
2.11.1 Set-up site …………………………………………………………………………………… 2-27
2.11.2 Supporting ground …………………………………………………………………………… 2-27
2.11.3 Corner bearing loads ………………………………………………………………………… 2-28
2.11.4 Supports ……………………………………………………………………………………… 2-29
2.11.5 Driving ………………………………………………………………………………………… 2-30
2.11.6 Towing ………………………………………………………………………………………… 2-31
2.11.7 Loading ………………………………………………………………………………………… 2-31
2.12 Placing Booms ………………………………………………………………………………………… 2-32
2.12.1 Unfolding the placing boom ………………………………………………………………… 2-32
2.12.2 End hose ……………………………………………………………………………………… 2-33
2.12.3 Procedure in storms ………………………………………………………………………… 2-34
2.12.4 Concreting in cold weather …………………………………………………………………… 2-35
2.13 Delivery Line Systems ……………………………………………………………………………… 2-35
2.13.1 Suitable delivery lines ………………………………………………………………………… 2-35
2.13.2 Securing delivery lines ……………………………………………………………………… 2-35
2.13.3 Tightness and blockages …………………………………………………………………… 2-36
2.13.4 Opening delivery lines ……………………………………………………………………… 2-36
2.13.5 Clearance to delivery lines …………………………………………………………………… 2-36
2.13.6 Fastening delivery lines ……………………………………………………………………… 2-37
2.13.7 Continuation delivery lines …………………………………………………………………… 2-37
2.14 Pumping Operations ………………………………………………………………………………… 2-37
2.14.1 Place of work ………………………………………………………………………………… 2-37

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2.14.2 Safety ………………………………………………………………………………………… 2-38

2.14.3 Remote control ………………………………………………………………………………… 2-38
2.14.4 Moving machine components and hot surfaces …………………………………………… 2-39
2.14.5 Constant observation of the machine ……………………………………………………… 2-39
2.14.6 Truck mixer …………………………………………………………………………………… 2-40
2.15 Cleaning ……………………………………………………………………………………………… 2-40
2.15.1 General ………………………………………………………………………………………… 2-40
2.15.2 Cleaning agents ……………………………………………………………………………… 2-41
2.15.3 Hazards ………………………………………………………………………………………… 2-41
2.15.4 Cleaning with compressed air ……………………………………………………………… 2-41
2.15.5 Protection against water ……………………………………………………………………… 2-43
2.15.6 Post-cleaning procedure …………………………………………………………………… 2-44
2.16 Maintenance and Special Work ……………………………………………………………………… 2-44
2.16.1 Requirements for special work ……………………………………………………………… 2-44
2.17 Welding ………………………………………………………………………………………………… 2-46
2.18 Working on the Placing Boom ……………………………………………………………………… 2-47
2.19 Safety-relevant Components ……………………………………………………………………… 2-48
2.20 Software ……………………………………………………………………………………………… 2-48
2.21 Protective and Safety ………………………………………………………………………………… 2-49
2.22 Electrical Power ……………………………………………………………………………………… 2-49
2.22.1 General ………………………………………………………………………………………… 2-49
2.22.2 Electrical components ………………………………………………………………………… 2-50
2.22.3 Power at the construction site ……………………………………………………………… 2-50
2.23 Hydraulic Systems …………………………………………………………………………………… 2-51
2.23.1 General ………………………………………………………………………………………… 2-51
2.23.2 Replacing hydraulic hoses …………………………………………………………………… 2-52
2.23.3 Noise emissions ……………………………………………………………………………… 2-52
2.24 Exhaust Fumes ……………………………………………………………………………………… 2-53
2.25 Functional Fluids ……………………………………………………………………………………… 2-53

3 SYSTEM FUNCTIONS …………………………………………………………………………… 3-1

3.1 General Overview ……………………………………………………………………………………… 3-1
3.1.1 Main component locations …………………………………………………………………… 3-1
3.1.2 Main characteristics …………………………………………………………………………… 3-2
3.2 Mechanical System …………………………………………………………………………………… 3-4
3.2.1 Pumping system (S-valve) …………………………………………………………………… 3-4
3.2.2 Main power system …………………………………………………………………………… 3-7
3.2.3 Hydraulic oil tank ……………………………………………………………………………… 3-9
3.2.4 Supporting and moving mechanism ………………………………………………………… 3-10
3.3 Cooling System ………………………………………………………………………………………… 3-13
3.3.1 Air cooling system ……………………………………………………………………………… 3-13
3.3.2 Water cooling system (Optional) ……………………………………………………………… 3-14
3.4 Lubrication System …………………………………………………………………………………… 3-14
3.4.1 Manual lubrication system …………………………………………………………………… 3-15
3.4.2 Automatic lubrication system ………………………………………………………………… 3-15
3.5 Hydraulic System ……………………………………………………………………………………… 3-17
3.5.1 Operation device of outriggers ………………………………………………………………… 3-17

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3.5.2 Agitating device ………………………………………………………………………………… 3-18

3.5.3 Accumulator …………………………………………………………………………………… 3-19
3.5.4 Self-sealing device of main oil pump oil suction …………………………………………… 3-20
3.5.5 water pump(optional) ………………………………………………………………………… 3-20
3.6 Electrical Control System ……………………………………………………………………………… 3-21
3.6.1 Electrical cabinet control device ……………………………………………………………… 3-22
3.6.2 Remote control device ………………………………………………………………………… 3-29
3.6.3 SYCD operation and instruction ……………………………………………………………… 3-30
3.6.4 E-STOP buttons ……………………………………………………………………………… 3-33
3.6.5 Functions of the symbols ……………………………………………………………………… 3-34

4 OPERATION ………………………………………………………………………………………… 4-1

4.1 The Requirement of Concrete ………………………………………………………………………… 4-1
4.1.1 Materials of concrete …………………………………………………………………………… 4-1
4.1.2 Material and mix proportion of pumping concrete …………………………………………… 4-2
4.2 Pipe Disposal …………………………………………………………………………………………… 4-6
4.2.1 Selection of concrete delivery pipe …………………………………………………………… 4-6
4.2.2 Disposal ………………………………………………………………………………………… 4-6
4.2.3 Operation after blockage ……………………………………………………………………… 4-9
4.3 Pre-operational Checks ……………………………………………………………………………… 4-11
4.4 Set-up Site ……………………………………………………………………………………………… 4-14
4.5 Starting Up ……………………………………………………………………………………………… 4-15
4.5.1 Engine starting ………………………………………………………………………………… 4-15
4.5.2 Engine racing …………………………………………………………………………………… 4-16
4.6 Outrigger Set-up ……………………………………………………………………………………… 4-18
4.6.1 Load-bearing surface ………………………………………………………………………… 4-18
4.6.2 Operation of outriggers ………………………………………………………………………… 4-21
4.7 Function Check ………………………………………………………………………………………… 4-22
4.7.1 Pump functions ………………………………………………………………………………… 4-22
4.7.2 Filter functions ………………………………………………………………………………… 4-23
4.7.3 E-STOP function ……………………………………………………………………………… 4-24
4.7.4 Function check on the agitator safety cutout ………………………………………………… 4-25
4.8 Pumping Operation Hand Signals …………………………………………………………………… 4-26
4.9 Pumping Operation …………………………………………………………………………………… 4-30
4.9.1 Safety precautions ……………………………………………………………………………… 4-30
4.9.2 Notes on correct pumping …………………………………………………………………… 4-34
4.9.3 Pre-operational checks ……………………………………………………………………… 4-35
4.9.4 Pumping ………………………………………………………………………………………… 4-36
4.9.5 Possible faults ………………………………………………………………………………… 4-39
4.10 Equipment Clean-up ………………………………………………………………………………… 4-41
4.10.1 Cleaning the delivery pipe …………………………………………………………………… 4-41
4.10.2 Clean the machine …………………………………………………………………………… 4-43
4.11 Retracting the Outriggers …………………………………………………………………………… 4-44
4.12 Towing and Loading ………………………………………………………………………………… 4-45
4.13 Machine Decals ……………………………………………………………………………………… 4-48
4.13.1 Locations of safety decals on the complete vehicle ……………………………………… 4-49
4.13.2 Decal descriptions …………………………………………………………………………… 4-50
4.13.3 Detailed explanations ………………………………………………………………………… 4-51

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HBT6013C-5S

5 MAINTENANCE ……………………………………………………………………………………… 5-1

5.1 Routine Maintenance & Mandatory Overhaul ……………………………………………………… 5-1
5.2 General Tightening Torques ………………………………………………………………………… 5-12
5.3 Lubrication ……………………………………………………………………………………………… 5-15
5.4 Working Media ………………………………………………………………………………………… 5-17
5.4.1 Lubricating grease ……………………………………………………………………………… 5-18
5.4.2 Hydraulic oil …………………………………………………………………………………… 5-19
5.5 Visual Check …………………………………………………………………………………………… 5-22
5.5.1 General check ………………………………………………………………………………… 5-22
5.5.2 Check the hydraulic system …………………………………………………………………… 5-23
5.5.3 Check the electrical system …………………………………………………………………… 5-23
5.6 Pumping System ……………………………………………………………………………………… 5-23
5.6.1 Concrete piston ………………………………………………………………………………… 5-24
5.6.2 Glasses plate and cutting ring maintenance ………………………………………………… 5-29
5.6.3 Mixing shaft and mixing blade maintenance ………………………………………………… 5-32
5.6.4 S-tube …………………………………………………………………………………………… 5-33
5.6.5 Hopper …………………………………………………………………………………………… 5-47
5.6.6 Delivery cylinder ………………………………………………………………………………… 5-48
5.6.7 Delivery pipe …………………………………………………………………………………… 5-48
5.6.8 Main oil cylinder maintenance ………………………………………………………………… 5-52
5.7 Hydraulic System ……………………………………………………………………………………… 5-56
5.7.1 Replacement of hydraulic oil ………………………………………………………………… 5-57
5.7.2 Water drainage of hydraulic oil tank maintenance ………………………………………… 5-59
5.7.3 Rubber hose …………………………………………………………………………………… 5-59
5.8 Accumulator …………………………………………………………………………………………… 5-62
5.9 Oil Filter ………………………………………………………………………………………………… 5-65
5.10 Air Filter ………………………………………………………………………………………………… 5-66
5.11 Electrical System ……………………………………………………………………………………… 5-66
5.11.1 Electrical control cabinet ……………………………………………………………………… 5-67
5.11.2 Remote control box …………………………………………………………………………… 5-68
5.12 Power System ………………………………………………………………………………………… 5-68

6 TROUBLESHOOTING …………………………………………………………………………… 6-1

6.1 Troubleshooting Mechanical System ………………………………………………………………… 6-2
6.2 Troubleshooting Hydraulic System …………………………………………………………………… 6-2
6.3 Troubleshooting Lubrication System ………………………………………………………………… 6-4
6.4 Troubleshooting Electric System ……………………………………………………………………… 6-4
6.5 Troubleshooting of Diesel Engine …………………………………………………………………… 6-6

7 SPECIFICATIONS …………………………………………………………………………………… 7-1

7.1 Overall Technical Data ………………………………………………………………………………… 7-1
7.2 Pumping System Technical Data …………………………………………………………………… 7-2
7.3 Pumping Curve ………………………………………………………………………………………… 7-3

8 APPENDIX …………………………………………………………………………………………… 8-1

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8.1 Hydraulic Basic Diagram ……………………………………………………………………………… 8-1

8.2 Electrical Basic Diagram ……………………………………………………………………………… 8-2

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 INTRODUCTION
HBT6013C-5S

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

This manual provides safety, technical

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

Items addressed in this manual are designed

to help you:

● Understand the structure and performance

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

Always keep this manual nearby and have all

personnel involved with any work operations
read it periodically.

If this manual is damaged and any part of it is

unreadable, you must immediately request a
replacement copy from your SANY distributor.

If a copy of the manual i s not with the

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

1-1
1
INTRODUCTION
HBT6013C-5S

If you sell the equipment, be sure to give this

manual to the new owner.

NOTE:Continuing improvements in the design

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

1.1 Manual Section Descriptions

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

NOTE:Due to improvement and updating of

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

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

Safety
This section covers basic safety information
relating to this equipment. Make sure you
fully understand all the precautions described
in this manual.

1-2
 INTRODUCTION
HBT6013C-5S

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

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.

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

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

Specifications
This information provides overall required
operating parameters for the equipment you
are using.

NOTE:Some information presented in this

manual may vary from your machine
due to design changes.

1-3
INTRODUCTION
HBT6013C-5S

1.2 Machine Serial Number & Information

The serial numbers and model numbers on

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

Data Plate
See Fig. 1-2 for the Data Plate.

Fig.1-2

Data Plate Location

On the side of the base structure is the data
plate (a).

Fig.1-3

1-4
 INTRODUCTION
HBT6013C-5S

1.3 Contact Information

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

Our address:
Sany Industry Town, Economic and
Technological Development Zone, Changsha,
Hunan, China

● Service Hotline: 0086 4006098318

● Service E-mail: crd@sany.com.cn
● Web site: http://www.sanygroup.com

1.4 Icons and Symbols

Most accidents are usually caused by the
failure to follow fundamental safety rules for
the operation and maintenance of the
machine. To avoid accidents it is important to
read and understand all information outlined
in this manual before operating or performing
maintenance on this machine.
The following (ANSI/ISO) signal words are
used to inform you that there is a potentially
hazardous situation that may lead to damage,
personal injury or even death. In this manual
and on the machine decals, different signal
words or illustrations are used to express the
potential level of hazard.

DANGER
High level of rick, it indicates a hazard with a
high level of risk which, if not avoided, will
result in death or serious injury.

WARNING
Medium level of risk, it indicates a hazard
with a medium level of risk which, if not
avoided, could result in death or serious
injury.

1-5
INTRODUCTION
HBT6013C-5S

CAUTION
Low level of risk, it indicates a hazard with
a low level of risk which, if not avoid,
could result in minor or major injury.

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

This is the general warning sign. It is

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

This symbol indicates that the operation

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

This symbol indicates that the operation

is in conformity to the safety regulations.

SANY cannot predict every circumstance that

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

If any procedures or actions not specified,

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

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 INTRODUCTION
HBT6013C-5S

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 h e e q u ip m e n t f o r r ef e r e n c 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.

1-7
HBT6013C-5S

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1-8
 SAFETY
HBT6013C-5S

2 SAFETY

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

This section corresponds to the contents of

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

Here you will find a summary of the most

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

NOTE:Special safety regulations may be

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

2-1
SAFETY
HBT6013C-5S

2.1 Definition of Terms

The terms used in this safety manual are

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

2.1.1 Concrete pump

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

2.1.2 Boom pedestal

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

2.1.3 Arm assembly

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

2.1.4 Placing boom

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

2.1.5 Base structure

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

2.1.6 Truck mixer

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

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 SAFETY
HBT6013C-5S

2.1.7 Delivery line systems

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

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

– Truck-mounted concrete pumps (ensemble

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

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

2.1.10 Machine operator

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

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SAFETY
HBT6013C-5S

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

2.1.12 Signaller and other auxiliary

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

2.1.13 Truck mixer driver

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

2.1.14 Authorized inspector

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

– To have completed a higher education

course in engineering or similar.

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 SAFETY
HBT6013C-5S

– To have at least 5 years’ professional

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

2.1.15 Subject expert

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

2.1.16 Qualified personnel

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

2.1.17 After Sales Service personnel

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

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

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SAFETY
HBT6013C-5S

2.1.19 Place of work, working area, danger zone

Mobile machines

Fig.2-1 Example

Stationary machines

Fig.2-2 Example

2-6
 SAFETY
HBT6013C-5S

NO. Designation Explanation

1 Machine operator In normal operation, with the remote control

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

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SAFETY
HBT6013C-5S

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

● Place of work-machine operator

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

The operator’s place of work is with the

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

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

● Place of work- truck mixer driver

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

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

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 SAFETY
HBT6013C-5S

The working area must be secured and

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

● Impermissible working area

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

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

The danger zone varies within the working

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

Depending on the working situation,

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

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SAFETY
HBT6013C-5S

The machine operator is responsible for

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

The machine operator must stop work

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

● Supporting legs and support feet

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

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

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

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

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

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 SAFETY
HBT6013C-5S

● Delivery line systems

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

2.2 Designated Use

The machine must only be operated as

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

The machine is constructed in accordance

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

The machine is designed exclusively for the

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

Designated use also includes observing the

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

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SAFETY
HBT6013C-5S

2.2.1 Inspection intervals

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

In anticipation of the change to the standard

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

Machines of up to and including 5 years old:

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

Machines more than 5 years old:

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

Machines more than 10 years old:

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

The day of initial commissioning in

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

2-12
 SAFETY
HBT6013C-5S

The operator is responsible for commissioning

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

Notwithstanding national legislation, the

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

2.3 Use Contrary to Designated Use

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

2.3.1 Transporting goods

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

2.3.2 Lifting loads

The placing boom must never be used for
lifting loads.

2.3.3 Removing obstacles

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

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SAFETY
HBT6013C-5S

2.3.4 Extending the reach

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

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

2.3.6 Impermissible end hose Fig.2-4

The end hose must not be fitted with any

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

2.3.7 Impermissible working area

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

Fig.2-5

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 SAFETY
HBT6013C-5S

2.3.8 Climbing the placing boom

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

2.3.9 High-pressure delivery

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

2.3.10 Accessories and attachments

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

2.4 Exclusion of Liability

Where the manufacturer’s delivery conditions

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

Unless the responsibility of the manufacturer,

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

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SAFETY
HBT6013C-5S

– adjustment of safety pressures, speeds of

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

2.5 Personnel

The operator must ensure that only persons

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

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

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 SAFETY
HBT6013C-5S

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

If you do not have qualified personnel,

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

2.5.3 Responsibility of the machine

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

2.6 Operating Instructions, Operating

Procedures and Other Regulations

2.6.1 Operating instructions

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

The Operating Instructions must always be

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

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SAFETY
HBT6013C-5S

As the operator, you must always make sure

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

Personnel entrusted with work on the

machine must observe all safety notes and
hazard warnings.

Personnel entrusted with work on the

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

2.6.2 Operating procedures

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

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 SAFETY
HBT6013C-5S

Furthermore, reference must be made to

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

2.6.3 Other regulations

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

2.7 Personal protective equipment

In order to reduce risks to personnel,

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

Personal protective equipment must, as a

minimum, comply with the requirements of
the specified standards.

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

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SAFETY
HBT6013C-5S

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

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

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

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

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 SAFETY
HBT6013C-5S

Face mask and respiratory protection

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

2.8 Before Starting Work

2.8.1 Checking that the machine is

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

2.8.2 Rendering the machine ready

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

Set all the control and monitoring devices to

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

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SAFETY
HBT6013C-5S

Never put the remote control down when the

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

Never leave the machine when the engine is

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

2.9 Danger Due to High-voltage

2.9.1 High-voltage lines

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

2.9.2 Discharge voltage pattern

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

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

Rated voltage [V] Minimum clearance [m]

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

The specified clearances are minimum

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

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2.9.4 High-voltage warning devices

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

2.9.5 Procedure in the event of a flash

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

You should only move and rescue injured

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

A radio remote control system only protects

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

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2.9.6 Earthing in the event of

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

Machines in use in the vicinity of transmitters

must be earthed. Secure the earthing cable
(at least 16 mm2) to an extra pre-prepared,
bright metal point of the machine (e.g. not to
a piston rod) and to a conductive metal rod in
the ground (minimum insertion depth of 1.5
m). Thoroughly dampen the earth around the
metal rod to make it more conductive.

Even when the machine is earthed, the safe

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

If you have any further questions about

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

2.10 Stationary Machines

2.10.1 Set-up site

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

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When selecting the set-up site, remember

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

2.10.2 Stationary booms

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

2.10.3 Lifting machines and components

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

2.10.4 Loading and transporting

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

If there are fixtures provided for transport of the

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

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2.11 Mobile Machines

2.11.1 Set-up site

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

As machine operator, you must familiarise

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

You must also check the approach route to

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

You must always ask for a signaller if you

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

2.11.2 Supporting ground

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

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The supporting ground must be level and

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

The support area must be enlarged as

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

Check the stability of the machine regularly

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

2.11.3 Corner bearing loads

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

The force transferred to the ground by each

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

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However, for undisturbed, compacted ground,

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

For loose or back-filled ground, the safe

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

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

Swing out and telescope the support legs to

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

Lock all supports mechanically, if this is

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

The machine must be made level in all

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

Check stability regularly during operation. The

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

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

Maintain a clearance of at least 1 m from the

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

Always make sure that there is sufficient

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

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Do not drive across uphill or downhill

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

Observe national road traffic regulations. If

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

Persons accompanying the driver must be

seated on the passenger seats provided for
this purpose.

Whilst the truck is in motion, the mixer drum

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

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

You must comply with the prescribed driving

position, permitted speed and itinerary when
towing.

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

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Use only appropriate means of transport and

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

Use only stable loading ramps of adequate

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

Secure the machine against rolling, slipping

and toppling over on the transport vehicle.

2.12 Placing Booms

2.12.1 Unfolding the placing boom

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

Only raise the placing boom in the sequence

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

Always ask the site management to supply

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

Only slew the placing boom over persons

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

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Press the EMERGENCY STOP button

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

Placing booms with placing boom hinges

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

2.12.2 End hose

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

There is a risk of injury to the hoseman if the

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

Never bend the end hose over. Never

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

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The concrete may also spray from the end

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

The end hose must be secured against falling.

2.12.3 Procedure in storms

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

A lightning strike poses a lethal danger to

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

Tower cranes on construction sites generally have

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

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– In winds of force 7 and greater, green

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

2.12.4 Concreting in cold weather

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

In addition, such minus temperatures should

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

2.13 Delivery Line Systems

2.13.1 Suitable delivery lines

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

2.13.2 Securing delivery lines

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

Fig.2-24

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2.13.3 Tightness and blockages

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

A properly-cleaned delivery line is the best

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

2.13.4 Opening delivery lines

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

2.13.5 Clearance to delivery lines

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

Fig.2-26

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2.13.6 Fastening delivery lines

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

2.13.7 Continuation delivery lines

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

Devices for shutting- off, diverting or cleaning

delivery lines

During operation there is a risk of being

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

Use only suitable, perfectly functioning

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

2.14 Pumping Operations

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

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In the case of stationary placing booms,

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

It is forbidden to climb onto the machine

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

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

Refrain from any procedures that may impair

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

2.14.3 Remote control

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

You must carry the remote control in such a

way that no control element is actuated
unintentionally.

During breaks in pumping, interruptions,

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

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2.14.4 Moving machine components

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

Never start work unless the grille is closed

and bolted down or otherwise secured.

Do not touch moving parts of the machine,

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

Never poke any objects (e.g. a shovel

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

2.14.5 Constant observation of the

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

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2.14.6 Truck mixer

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

Make sure that no-one stands between the

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

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

The machine must not be driven with the

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

The preferred methods for cleaning the

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

Never spray remote controls or control

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

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2.15.2 Cleaning agents

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

Do not use sea water or other water

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

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

Do not reach into the hopper or any other moving

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

Only point the water jet into the hopper or

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

2.15.4 Cleaning with compressed air

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

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Compressed air should only be used for

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

The manufacturer accepts no liability for

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

2-42
 SAFETY
HBT6013C-5S

– The pressure gauge must be kept under

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

2.15.5 Protection against water

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

You must close/seal all openings into which

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

2-43
SAFETY
HBT6013C-5S

2.15.6 Post-cleaning procedure

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

Look out for leaks, loose connections, chafe

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

2.16 Maintenance and Special

Work

2.16.1 Requirements for special work

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

Carry out the maintenance and inspection

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

Workshop equipment appropriate to the task

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

Secure a wide area around the maintenance

area as far as is necessary.

A machine completely shut down for

maintenance and repair work must be
secured against being restarted inadvertently:

2-44
 SAFETY
HBT6013C-5S

– Lock the main control devices and

remove the key.
– Fix a warning plate to the main switch.
Only carry out maintenance work if the
machine is parked on level and sufficiently
supporting ground and is secured against
rolling away.

Use specially designed or otherwise safety-

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

Carefully secure individual parts and large

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

The fastening of loads and instruction of

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

Observe national regulations when working

with lifting gear.

Work on chassis, braking and steering

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

Clean the machine, especially connections

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

2-45
SAFETY
HBT6013C-5S

Bolted connections that you have loosened

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

Do not open gas-filled spring elements, as

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

Be aware of hot functional fluids and surfaces

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

Ensure that all functional fluids, consumables

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

2.17 Welding

Only qualified personnel commissioned by

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

Always attach the earth cable of the welding

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

Electronic components can be destroyed by

stray voltage during arc welding processes.
For this reason:
– Disconnect the remote control cable from
the control console.

2-46
 SAFETY
HBT6013C-5S

– Disconnect all cables leading to the

receiver of the radio remote control
system.
– Close connector sockets with caps.
– Disconnect the positive and negative
leads from the battery.
Only carry out welding, flame cutting and
grinding operations on the machine if this is
expressly approved by the manufacturer.

Clean the machine and its surroundings of

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

Only qualified personnel should carry out welding

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

2.18 Working on the Placing Boom

Only carry out maintenance and repair work

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

Support the plac ing boom arms before

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

The delivery line was installed without tension

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

Do not remove the whole delivery line but

exchange the delivery arm, e.g boom arm by

2-47
SAFETY
HBT6013C-5S

boom arm. Otherwise, the pivot points of the

new delivery line will have to be redetermined
using special equipment.

Following substantial changes, placing booms

must be inspected by an authorized inspector
before recommissioning.

2.19 Safety-relevant Components

Some of the manufacturer’s spare parts, such

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

Parts relevant to safety and adjustable

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

2.20 Software

If a machine is equipped with software, the

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

Only persons authorized by the machine

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

Unauthorized interventions in the machine’s

software may lead to severe damage and
accidents.

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 SAFETY
HBT6013C-5S

2.21 Protective and Safety

Any safety devices removed for maintenance

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

All equipment required for safety and

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

Keep all warning signs and information plates

on the machine complete and in a perfectly
legible condition.

It is your responsibility as operator to ensure

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

2.22 Electrical Power

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

The power supply to machine components on

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

2-49
SAFETY
HBT6013C-5S

Before starting work on high-voltage

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

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

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

2.22.2 Electrical components

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

2.22.3 Power at the construction site

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

Only qualified personnel may work on

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

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 SAFETY
HBT6013C-5S

An electric shock (possibly with fatal

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

2.23 Hydraulic Systems

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

Always wear your personal protective

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

Injection through the skin is a major medical

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

Parts of the system and pressure lines which

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

Work only on depressurized systems. Switch

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

2-51
SAFETY
HBT6013C-5S

residual pressure. Modifications to the

hydraulic accumulator are prohibited.

Be aware that enclosed hydraulic fluid can

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

Route and install hydraulic lines in accordance

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

You must carefully bleed the hydraulic

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

Damaged hydraulic lines must be replaced

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

2-52
 SAFETY
HBT6013C-5S

the sound pressure level and sound power

level from the machine Operating Instructions.

Wear suitable personal protective equipment

in the vicinity of the machine.

As the operator, you must instruct your

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

All soundproofing equipment must be fitted

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

2.24 Exhaust Fumes

Vehicle exhaust gases contain constituents

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

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

2.25 Functional Fluids

When handling oils, greases and other

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

2-53
SAFETY
HBT6013C-5S

Oils, fuel and other functional fluids may be

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

Take care when handling toxic and caustic

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

Cleaning agents, concrete release agents, Fig.2-29

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

Frequent injuries are eye injuries caused by

concrete spatter, water glass or other
chemical substances.

Take care when handling hot functional fluids

and consumables (risk of burning or
scalding).

Have used operating equipment and

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

2-54
 HBT6013C-5S

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HBT6013C-5S

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 SYSTEM FUNCTIONS
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3 SYSTEM FUNCTIONS

3.1 General Overview

This section of the manual provides detailed

information regarding the basic description
and overview of all the controls, alerts and
operating systems on your equipment. It is
important to study and become familiar with
all systems before proceeding with any
pumping operations.

3.1.1 Main component locations

The SANY trailer-mounted concrete pump
consists of the following main components
(see Fig. 3-1).

1 2 3

4 5

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

Table 3-1

No. Designation Index

1 Mechanical system P3 - 4
2 Cooling system P3-12
3 Lubrication system P3-13 P5-15
4 Hydraulic system P3-16 P5-56
5 Electrical control system P3-20 P5-66

3-1
SYSTEM FUNCTIONS
HBT6013C-5S

3.1.2 Main characteristics

(1) Energy-saving technology of diesel engine

In the construction process, the computer control
system automatically adjusts diesel engine
speed or variable output pump according to the
pumping load so as to reduce the diesel engine
fuel consumption, improve the fuel economy,
decrease the exhaust emission and achieve the
energy-saving and environmental protection goal
under the condition that the construction
requirements are met.

(2) New technology for wearing parts

In contrast to the traditional concrete pistons
employing normal polyurethane or wrapped rubber,
the new concrete piston is made of the enhanced
polyurethane material with top-secret formula and
can be used for pumping 20000 m3 of concrete or
above averagely within its service life; patented
super-hard carbide glasses plate and cutting ring
are more wear resistant and have longer service
life, furthermore, the cutting ring employs a floating
structure and automatically compensates for the
wear clearance to completely eliminate the
pressure relief due to wear.

(3) Domestically pioneered streamlined hopper

technology
It is designed by use of fluid mechanics, with
small mixing dead angle, better suction and
more convenient cleaning.

(4) SYMC special control system

It has electronic monitor and alarm system with
CAN-bus communication. This system is featured
by simple wiring which enhances integral reliability
and maintenance convenience, user-friendly control
interface, strong anti-interference ability, high
operational speed, adaptability to working
temperature of -20°C ~ +70°C, strong waterproof &
dust-proof ability, IP67 protection level and a
malfunction rate reduced by 80%.

3-2
 SYSTEM FUNCTIONS
HBT6013C-5S

(5) Water-proof sealing technology for main

oil cylinder
A high-pressure cushion area set around the
piston rod may prevent the piston rod from
taking water into the hydraulic system, and in
this way, to effectively prevent hydraulic oil
emulsion, prolong the service life of hydraulic
elements and reduce the cost.

(6) Automatic protection

There are six protection functions for SANY
trailer-mounted concrete pump to avoid
damage to the machine: diesel engine start
protection, electrical system malfunction and
short-circuit protection, automatic protection
for motor overload, automatic protection for
too high diesel engine water temperature and
too low oil pressure, speed limit protection of
diesel engine and emergency stopping
button.

(7) Automatic concrete piston retraction

technology
This technology not only facilitates the
removal and installation of concrete piston,
and also makes you easily check the
concrete piston for wear and lubrication, clear
away the impurities on the concrete piston,
and better maintain the concrete piston to
extend its service life. The concrete piston
can be replaced most quickly in 15min, which
improves the working efficiency.

(8) Patented high-low pressure switch-over

technology
Only in one second, the switching between
high and low pressures can be realized by
pulling the electrical control switch without
l e ak a g e a n d p ol l u t i o n t o e l i m i n a t e t h e
blockage of pipe.

3-3
SYSTEM FUNCTIONS
HBT6013C-5S

3.2 Mechanical System

The mechanical system is made up of pumping
system, main power system, hydraulic oil tank,
base structure, machine body, axle, guiding
wheel, etc.

Table 3-2

No. Designation Index

1 Pumping system (S-valve) P3-4 P4-31 P5-23
2 Main power system P3-7
3 Hydraulic oil tank P3-8 P5-57 P5-59 P5-66
4 Supporting and moving mechanism P3-9 P4-18 P4-45
3.2.1 Pumping system (S-valve)
Pumping system components
The S-valve pumping system is made up of main
oil cylinder, water tamk, delivery cylinder, concre-
te piston, swing mechanism, agitating mechanism,
hopper, S-tube, (see Fig. 3-2).

Fig.3-2 Basic Diagram of S-valve Pumping Mechanism

1. Left main oil cylinder 7. Right concrete piston
2. Right main oil cylinder 8. Agitating system
3. Water tank 9. S-tube
4. Left delivery cylinder 10. swing mechanism
5. Right delivery cylinder 11.Hopper
12. Material outlet
6. Left concrete piston
3-4
 SYSTEM FUNCTIONS
HBT6013C-5S

Pumping system operation

The following occurs when the pump is
energized. The item numbers used here are
the same as used in Fig. 3-2 on P3-4.

(1) Main oil cylinder (1) and (2) force

concrete piston (7) forward (towards the
hopper) while the other piston (6) retrac
ting. At the same time, swing cylinder (9)
is in the extending state while the swing
cylinder (8) at the retracting state.

(2) The swing mechanism positions the S-

tube (12) to align delivery cylinder (5)
with concrete piston (7).

(3) Suction created by the retracting concrete

piston (6) pulls concrete from the hopper
(11) to fill that piston’s delivery cylinder (4).

(4) When the two concrete pistons have reached

the limit of their travel, control system sends a
signal to make swing cylinder (8) extend and
swing cylinder (9) retract.

(5) Then control system sends a signal to make

main oil cylinder (1) and (2) moving to the
contrary direction. Concrete piston (6) is
forced forwards while piston (7) retracting.

(6) The concrete sucked in the delivery 1

cylinder (4) is pushed to the S-tube (12)
then to the delivery pipe. At the same
time, delivery cylinder (5) sucked.

(7) The actions are repeated to complete

pumping operation.

(8) In case of reverse pumping, the concrete 2

cylinder in suction stroke is connected with
the S-valve, while the concrete cylinder in Fig.3-3 Working State of Pumping System
pushing stroke be connected with the hopper,
1. Forward pumping state
so as to pump the concrete in delivery pipe
2. Reverse pumping state
back into the hopper (see Fig. 3-3).

3-5
SYSTEM FUNCTIONS
HBT6013C-5S

Pumping control
Pumping operation can be controlled by the
switch on the electrical cabinet and the
remote control box.

(1) Fig. 3-4 shows the pumping direction

toggle switch (8), the pumping output
toggle switch (10) and the pumping Electrical Control
Box 

pressure toggle switch (9) are on the

electrical control panel. See "Electrical
cabinet control device" on page 3-21 for I O
+ -

details. RPM+ RPM-

I O I O

The item numbers used here are the

same as used in Fig. 3-25 on P3-21.
8 9 10

Fig.3-4

(2) Fig. 3-5 shows the pumping direction

toggle switch (2) and the pumping output
toggle switch (3) on the remote control 2 3
box. See "Remote control device" on
page 3-28 for details.
The item numbers used here are the
same as used in Fig. 3-41 on P3-28.

Fig.3-5

3-6
 SYSTEM FUNCTIONS
HBT6013C-5S

3.2.2 Main power system

Main power system components
Main power system is made up by diesel
engine, automatic throttle adjusting device,
diesel tank and attached accessories of
diesel engine.

(1) The diesel engine adopted in SANY

trailer-mounted concrete pump is SANY 1 2 3 4
diesel engine, which consists of gear
pump, main oil pump, pump seat, Fig.3-6a Power System
coupling, etc. (see Fig. 3-6a).
1. Gear pump 3. Pump seat
2. Main oil pump 4. Coupling

(2) The thermal insulation cover between diesel

engine and Electric Control Cabinet, in order
to protect the cabinet from heated.(optional)
(see Fig. 3-6b).

(2) The automatic throttle adjusting device Fig.3-6bThermal insulation cover

consists of DC motor, softshaft, draw,
plate, supporting plate,etc. (see Fig. 3-7).

4
(3) The attached accessories of diesel 1

engine include diesel filter, exhaust pipe,

muffler, manual pump, etc.
Fig.3-7 Automatic Throttle Adjusting Device
1. Draw plate 2. Soft shaft
3. DC motor 4. Supporting plate

3-7
SYSTEM FUNCTIONS
HBT6013C-5S

Main power system operation

(1) Diesel engine is the power source of the

trailer-mounted concrete pump. The diesel
engine drives the oil pump running at a
high speed via coupling to provide
pressure oil to the hydraulic system.
(2) The axial plunger variable pump is
adopted in diesel engine, whose output
flow is in direct proportion with the driving
rotation speed and displacement, and
can be adjusted steplessly between zero
and maximum, with functions of constant-
power control, pressure cut-off and
electrical proportional flow adjustment.
(3) The computer can identify different work
conditions, and send electric signals by
SYMC controller to switch the rotation
movement of the step motor to the linear
movement of the throttle. Therefore, the
diesel engine speed, torque and oil
injection volume can be adjusted on real-
time to achieve the automatic power
matching.
(4) The automatic throttle adjusting device is
used to control the diesel engine speed.
Power control
Power system can be controlled by the
switches on the electrical cabinet.

Fig. 3-8 shows the diesel engine start switch

(6), diesel engine stop switch (7) and the
rotate speed toggle switch (17) on the Electrical Control
Box 

electrical control panel. See "Electrical 7

cabinet control device" on page 3-22 for
6
details. I O
+ -

17 RPM+ RPM-
I O I O

The item numbers used here are the same

as used in Fig. 3-25 on P3-22.

Fig.3-8

3-8
 SYSTEM FUNCTIONS
HBT6013C-5S

3.2.3 Hydraulic oil tank

NOTICE
To keep the hydraulic oil free of foreign
substances, it is forbidden to uncover the
hydraulic oil tank at random.

Hydraulic oil tank components

Hydraulic oil tank consists of tank body, 5 4 6
drainage valve, self-sealing device of oil
suction, temperature sensor, oil level meter,
air filter, etc. (see Fig. 3-9).

Hydraulic oil tank operation

The hydraulic oil tank is a specially made 4

container which has functions of eliminating

heat and depositing oil dirt besides storing
hydraulic oil.

The functions of each component are as

follows: 3
2
1
(1) Drainage valve: It is used for draining dirty
oil in case of cleaning the oil tank. Mostly,
it is closed.
Fig.3-9 Hydraulic Oil Tank
(2) Tank body: It is used to store hydraulic oil.
1. Drainage valve
(3) Self-sealing device of oil suction: It is 2. Tank body
used to prevent the hydraulic oil from 3. Self-sealing device of oil suction
4. Temperature sensor
leaking from oil tank when the main oil-
5. Oil level meter
suction pipe is removed. 6. Air filter
(4) Temperature sensor: It is used to
measure the hydraulic oil temperature.

(5) Oil level meter: It is used to indicate the oil

level in oil tank. When the trailer-mounted
concrete pump is working, the oil level
should be above the middle level.

(6) Air filter: It is used to block foreign

substances and filter air.

3-9
SYSTEM FUNCTIONS
HBT6013C-5S

3.2.4 Supporting and moving mechanism

Base structure assembly
Fig. 3-10 shows the components of the base 2
structure assembly.
5

The base structure assembly is the basic part

1
for the connecting and supporting of each 3
5
part of the trailer-mounted concrete pump.
4
It is connected with the hopper in the front
with towing ring in the rear to transfer the
trailer-mounted concrete pump from one
worksite to another. Fig.3-10 Base Structure

1. Left free outrigger

2. Left fixed outrigger
3. Right fixed outrigger
4. Right free outrigger
5. Cross pin

Machine body
The machine body (covering parts) is
installed on the base structure and mainly
used to protect the internal parts (see Fig. 3- 4
11).

1 2

Fig.3-11 Machine Body

1. Side door 4. Top cover
2. Door lock 5. Tail cover
3. Framework

3-10
 SYSTEM FUNCTIONS
HBT6013C-5S

Axle assembly
The axle of trailer-mounted concrete pump
mainly works as the traveling mechanism
1 2
when the trailer-mounted concrete pump is
being towed with guiding wheel and outrigger
retracted (see Fig. 3-12).

When the machine is towed, the speed

should not exceed 15 km/h on Class 2 road 3 4 5
and 8 km/h on Class 3 road.

Fig.3-12 Axle Assembly

1. Tyre cover 4. Mounting seat

2. Tyre rim 5. Wheel hub
3. Axle
Guiding wheel

NOTICE
When the trailer-mounted concrete pump
is towed, its guiding wheel should be
completely retracted and should not
contact the ground or the machine may be
damaged.
1

The guide wheel is the auxiliary device for

8
the short-distance traveling and supporting of 2

trailer-mounted concrete pump (see Fig. 3-

7
13a). 3
4

When the trailer-mounted concrete pump is 5 6

towed, its guide wheel should be completely

retracted and should not contact the ground.
The method of retracting the guide wheel: Fig.3-13a Guiding Wheel
rotate the handle 1 in clockwise to retracting 1. Handle
the threaded rod. Pull out bolt 3, rotate the 2. Barrel
movable support 5 to make the pinhole (2) 3. bolt
coincide with pinhole (1), insert bolt 3 to 4. Pinhole 1
pinhole (1), and then, use bayonet lock to fix 5. Movable support
bolt 3. 6. Wheel
7. Pinhole 2
8. Mounting seat

3-11
SYSTEM FUNCTIONS
HBT6013C-5S

For the extended and retracted state of guide

wheel(see Fig. 3-13b).

Fig.3-13b Guiding Wheel Extended and

Retracted State

3-12
 SYSTEM FUNCTIONS
HBT6013C-5S

3.3 Cooling System

There are two cooling methods to cool of

hydraulic oil: water cooling and air cooling.
Select the proper cooling system according to
the local climate and construction conditions.

3.3.1 Air cooling system

Air cooling system components
1
The air cooling system is composed of
radiator, hydraulic motor, fan, rubber hose,
etc. (see Fig. 3-14).
3
Air cooling system operation 2

(1) Air cooling system can adjust the hydraulic

oil temperature.

(2) When the oil temperature is higher than

55°C, the contactor of temperature switch Fig.3-14 Air Cooling System
will close automatically and give out
1. Radiator
command to make the electromagnet of 2. Hydraulic motor
hydraulic motor move. 3. Rubber hose

(3) The hydraulic motor starts to work and

cool the hydraulic oil under the effect of
radiator.

(4) When the oil temperature is lower than

38°C, the contactor of temperature switch
will open automatically, so the hydraulic
motor stops working and the cooling is
stopped.

(5) The adoption of great-performance

radiator and hydraulic motor in this cooler
makes it be able to work in adverse
condition for a long time.

3-13
SYSTEM FUNCTIONS
HBT6013C-5S

3.3.2 Water cooling system (Optional)

Water cooling system components
The water cooling system is composed of
water-in/out connecting tube, valve, oil-return
tube, radiator, oil-in tube, etc. (see Fig. 3-15).

5 3
4

2
Water cooling system operation 1
Water cooling system is installed under the
base structure generally, featuring convenient
use, simple structure, fast cooling and low Fig.3-15 Water Cooling System
cost. It is applicable when the cooling water
is available easily. 1. Water inlet/outlet
2. Valve
When the oil temperature ≥ 50°C, open the 3. Oil-return tube
water cooler valve, and the water will flow in 4. Radiator
the water inlet and flow out the water outlet 5. Oil-in tube
after passing through the cooler. At this time,
heat exchange is conducted between the
hydraulic oil and the water in the cooler, so
that the hydraulic oil is cooled.

3.4 Lubrication System

Table 3-3

No. Designation Index

1 Manual lubrication system P5-16
2 Automatic lubrication system P5-15

The mainly function of this system is

lubricating mechanical moving parts.

The lubrication system of the trailer-mounted

concrete pump includes two parts, i.e. the
manual lubrication system and the automatic
lubrication system.

3-14
 SYSTEM FUNCTIONS
HBT6013C-5S

3.4.1 Manual lubrication system

A lubri c at in g o i l c up of sc r ew c ov er i s Oil cup on one side
equipped on each of the two swing valve
cylinder seats (see Fig. 3-16).

Before pumping, fill the oil cup with

lubricating grease and press the grease onto
the friction surface by the pressure
engendered from tightening oil cup cover.
The oil cup cover, during pumping, should be
lubricated once per four hours so as to keep
the spherical friction surface in a good
lubrication status.

3.4.2 Automatic lubrication system

Fig.3-16 Position of The Oil Cup
Automatic lubrication system components
The automatic lubrication system is
c o m p o s e d o f d o u b l e p o w e r lubrication
pump, sheet oil separator, etc.
(see Fig. 3-17).

1
Pressrue oil

3 4 5 6 7 8 9

Fig.3-17 Automatic Lubrication System

1. Double power 5. Small bearing seat of S-valve
lubrication pump 6. Small bearing seat of S-valve
2. Sheet oil separator 7. Mixing bearing seat
3. Big bearing seat of S-valve 8. Big bearing seat of S-valve
4. Mixing bearing seat 9. Concrete piston

3-15
SYSTEM FUNCTIONS
HBT6013C-5S

Fig.3-18 shows the structure of double

power lubrication pump..

NOTE:In summer, use #00 semifluid non-

extreme-pressure lithium-based handle
lubricating grease; in winter, use #000
semifluid non-extreme-pressure
Synchronizing lubricating Pressure regulating
lithium-based lubricating grease. grease port
overflow valve

Automatic lubrication system operation

(1) Check and add lubricant to the automatic

lubrication system every time before start
the machine.
Circular lubricating grease port Drive oil port

(2) If the oil pressure is too low, please clean Air-bleed valve

the pressure adjustment relief valve, oil-

outlet check valve or exhaust air.

(3) If the double power lubrication Fig.3-18 Double power lubrication pump
pump is used for the first time, or the
lubricant is exhausted, the pump may
suck air and can’t pumping lubricant for
along time. Loosen two air-bleed valves
by screwing them half circle until the air
exhausting and the lubricant comes out
continuously with no air pocket. Then
lock the two valves.

NOTICE
Double power lubrication pump
should keep clean. Prevent dust and other
impurity entering. It is forbidden to
contact with the acid and alkali materials.

Lubricant should be according with the

requirement and clean without impurity.
Calcium base grease (butter) is not
commendatory for its conglutination feature
may cause block of the lubrication line.

3-16
 SYSTEM FUNCTIONS
HBT6013C-5S

3.5 Hydraulic System

Table 3-4

No. Designation Index

1 Operation device of outriggers P3-16 P4-21
2 Agitating device P3-17
3 Accumulator P3-18 P5-62
4 Self-sealing device of main oil pump oil suction P3-19

3.5.1 Operation device of outriggers

When the pump has hydraulic outriggers,
follow the operation below.

Outriggers operation is manipulated by manual

change valve control and mechanical limit.

The control of manual change valve is

realized by manual control valve group, which
includes overlapped one-way valve and
1 2 3
manual change valve (see Fig. 3-20).
Fig.3-20 Manual control valve group

1. Manual control valve block

2. Overlapped type one-way valve
3. Manual change valve

The mechanical limit is mainly achieved by

outrigger cross pin as shown in Fig. 3-21.

Outriggers operation
Pull the handle leftwards or rightwards the
outriggers will extend or retract. The manual
change valve can automatically return to zero
position after released, at this moment the
outriggers stop action. Cross pin
of outrigger

Fig.3-21

3-17
SYSTEM FUNCTIONS
HBT6013C-5S

3.5.2 Agitating device

The auxiliary valve block equipped with
agitating control valve is installed on the left
side of oil tank (taking the hopper as front).
1

2 3
Make the agitator switch between the two
rotation directions by controlling the reverse
agitating solenoid valve. During forward
agitating (when the electromagnet is Fig.3-21
deenergized), the agitator “feeds” the delivery 1. Hopper
cylinder with concrete; during reverse 2. Agitating motor
agitating (the electromagnet is energized), the 3. Agitating ball valve
agitator pushes the concrete out from the
delivery cylinder.

The agitating solenoid valve installed on the

auxiliary valve block (item 1 in the Fig. 3-22)
is used to adjust the operating pressure of
agitating motor; while the pressure relay is 1
used to ensure that when the agitating
2
pressure is excessive, let the agitating
solenoid valve reverse to make the agitating 3
motor reverse.

Fig.3-22

1. Agitating solenoid valve

2. Agitating overflow valve
3. Pressure relay

3-18
 SYSTEM FUNCTIONS
HBT6013C-5S

3.5.3 Accumulator
Accumulator installed on the right side of oil
tank of trailer-mounted concrete pump (taking
the hopper as front), is used to supply the
reversing circuit with auxiliary energy and
reduce system impact.

Unloading cut-off valve is installed beside the

main valve block. When this cut-off valve is 2 4
opened, the pressure oil of accumulator is
unloaded for the convenience of inspection
1 3
and repair (see Fig. 3-23).

Fig.3-23

1. Main valve block 3. Accumulator

2. Unloading ball valve 4. Oil tank

NOTE:The machine may still run when the

accumulator is unloaded, and the S-
valve may still move. You must stop
the machine before inspection to
prevent your fingers from danger of
crushing or cutting.
If the machine is still running, do not
access to the hopper from the
discharge port at the lower of hopper
or the screen at the upper of hopper
and do not throw sundries into the
hopper either.

3-19
SYSTEM FUNCTIONS
HBT6013C-5S

3.5.4 Self-sealing device of main oil

pump oil suction
An oil circuit sealing device is installed in the
oil suction pipeline of oil pump, which is
mainly used to seal the oil suction pipeline of
pump during the inspection and repair of 1

hydraulic system to prevent the hydraulic oil

in the oil tank from leaking outwards. What
adopted for the oil suction sealing device of
main oil pump is “self-sealing device of oil 2
suction”, see Fig. 3-24; while the gear pump
directly takes oil from the oil-suction tube of
main oil pump.
3

Fig.3-24

1. Oil tank
NOTE:To prevent the pump from sucking air, 2. Self-sealing device of oil suction
the self-sealing device must be often 3. Oil-suction tube of main oil pump
opened to ensure smooth oil suction.
The oil suction is adjusted by the
adjusting threaded rod. Screw it down
to open the oil circuit, while screw off it
to seal the oil circuit (the thread of
threaded rod must be screwed off
completely).
Do remember to mount and screw
down the adjusting threaded rod after
system inspection.

3.5.5 water pump(Optional)

The water pump is mainly consist of water

1 2 3 4
pump motor,mouthpiece of water gun and
water pipe,water pump and Pressure gauge
Fig 3-24-2
of water pump (see Fig. 3-24-2).
1. Water pump motor
2. Mouthpiece of water gun and water pipe
3. water pump
4. Pressure gauge of water pump

3-20
 SYSTEM FUNCTIONS
HBT6013C-5S

3.6 Electrical Control System

(1) This electrical control system adopts DC

24 power supply and silicone rectifying
generator to supply power. The SANY
SYMC controller is adopted in the control
system which has two control modes, local
control and remote control. After the
control mode is selected by operation on
the electrical control cabinet panel, the
pumping operation can only be conducted
under the selected mode. Each control
circuit is set with short circuit and overload
protection.

(2) The display is the SANY-made SYCD

with pages for original parameters setup
and parameter modification. See "SYCD
operation and instruction" on page 3-30
for details.

(3) This control system is composed of

power supply start circuit, diesel engine
start and control circuit, air cooler control
circuit, automatic speed adjustment
control circuit, SYMC control circuit,
meter indication circuit, SYMC control
power supply and SYCD communication
circuit, CAN bus diesel engine control
circuit and remote control box control
circuit.

3-21
SYSTEM FUNCTIONS
HBT6013C-5S

3.6.1 Electrical cabinet control device

Introduction of electrical cabinet control device

(1) Electrical control cabinet panel

The electrical control cabinet panel is as
shown in Fig. 3-25. Table. 3-5 shows the
designation of each element.

18 5
4

2
Electrical Control
Box 

6 7 8 9 10 11

I O
+ -

RPM+ RPM-
I O I O

17 16 15 14 13 12

Fig.3-25 Electrical control cabinet panel

3-22
 SYSTEM FUNCTIONS
HBT6013C-5S

Table 3-5

No. Designation
1 Power supply button
2 Malfunction indicator light
3 Operation indicator light
4 Power supply indicator light
5 E-STOP (emergency stop) button
6 Diesel engine start toggle switch
7 Diesel engine stop toggle switch
8 Pumping direction toggle switch
9 High/low pressure toggle switch
10 Output adjust toggle switch
11 Control mode toggle switch
12 Outrigger movement toggle switch
13 Pre-heating control toggle switch
14 Piston adjust toggle switch
15 Swing cylinder movement toggle switch
16 Main cylinder movement toggle switch
17 Rotating speed control toggle switch
18 SYCD display

3-23
SYSTEM FUNCTIONS
HBT6013C-5S

(2) Elements of Electrical Control Cabinet

Fig. 3-26 and Table. 3-6 shows the elements of electrical control cabinet.

5 4 3 2
Fig.3-26

Table 3-6

No. Designation No. Designation

1 SYMC controller 4 Truck pump electric plate Assembly SYMCEB
2 Intermediate Relay 5 Circuit board assembly SYEB

3 monopole Breaker

The cabinet is mainly used for installing the

elements required by the trailer-mounted
concrete pump. When checking and replacing
the elements, the main power supply must be
cut off and switches should be reset in order
to prevent damage of the electrical elements
or getting an electric shock.

3-24
 SYSTEM FUNCTIONS
HBT6013C-5S

NOTICE
It is prohibited to flush the electrical
control cabinet and electric appliance
elements with water or expose them to
water, or short cut will damage the
electrical elements.

Function and operation instructions of

electrical control cabinet panel

(1) Power supply button (see Fig. 3-27)

This button is at the right side of the
electrical control cabinet (item 1 in Fig. 3-
25). Set the button to the “On” position to
supply power to the device.
Fig.3-27
(2) Indicator lights (see Fig. 3-28)
Malfunction indicator light (item 1 in Fig.
3-28): this red light indicates the machine
3
have some malfunctions.
Operation indicator light (item 2 in Fig. 3- 2

28): this orange light indicat es the

1
machine is operating. 

Power supply indicator light (item 3 in Fig.3-28

Fig. 3-28): this green light indicates the
power supply status.

(3) E-STOP (emergency stop) button (see Fig.

3-29)
This large, red, round button is used for
only emergency stopping. Pressing this
button stops all operations immediately. It
locks in the STOP position until released
by rotating it clockwise, as indicated by
the arrows on the button. All functions will
resume normal operations after the E-
STOP button is released.
When restarting the device to work again
Fig.3-29
after every abnormal condition eliminated,
reset the E-STOP button to prevent of
affection the starting of the engine.

3-25
SYSTEM FUNCTIONS
HBT6013C-5S

(4) Engine start/stop toggle switches (see Fig.

3-30)
These two switches are always set in the
left position. Switch the item 1 in Fig. 3- 1 2
start stop
30 rightward to start the diesel engine.
Switch the item 2 in Fig. 3-30 rightward
to stop the diesel engine.
I O
The two switches will reset themselves to
the left position after operation. Fig.3-30

(5) Pumping direction switch (see Fig. 3-31)

In the left position, concrete flows is in
the normal forward flow direction. forward reverse
In the right position, all flow is reversed.
No pumping action occurs when the
switch is in the center position.

Fig.3-31
(6) High/low pressure toggle switch (see Fig.
3-32)
Low position and the High position can’t
be used at the same time. This switch is high low
pressure pressure
used to switch the pumping pressure.
In the left position, the device will pump
in high pressure.
In the right position which is the default,
Fig.3-32
the device will pump in low pressure.

(7) Output adjust toggle switch (see Fig. 3-

33) output output
increase decrease
Turn the switch to the right to decrease
the output, while turn the switch to the
left to increase the output. When the
equipment is pumping, adjust the output + -
according to the condition. Fig.3-33

3-26
 SYSTEM FUNCTIONS
HBT6013C-5S

(8) Control mode toggle switch (see Fig. 3-34)

In the right position, the machine can be remote local
only operated by the electrical control
cabinet.
In the left position, the remote control box
can be used.
It always set in the local position. Fig.3-34

(9) Outrigger movement toggle switch

This switch can be used to control the outriggers outriggers
extend retract
h y d r a u l i c o ut r i g g e r s e x t e n di ng a n d
retracting.
The outriggers will extend when the I O
switch is in the left position.
Fig.3-35
The outriggers will retract when the
switch is in the right position.

(10)Pre-heating toggle switch (see Fig. 3-36)

This switch controls the pre-heating pre-heating pre-heating
operation of the machine. start stop

Pre-heating operation will start when the

switch is in the left position. O
I
It always set in the right position (pre-
heating stop). Fig.3-36

(11)Piston adjust toggle switch (see Fig. 3-37)

This three-position button is used during exit reset
maintenance procedures.
Middle position used for normal operation keep
which function is “Keep”.
Left position to draw the pump piston into
the wash box for service. Fig.3-37

Right position to reset the piston

automatically.

3-27
SYSTEM FUNCTIONS
HBT6013C-5S

(12)Swing cylinder movement toggle switch

(see Fig. 3-38)
extend retract
Left position controls the swing cylinder
extending.
Right position controls the swing cylinder
retracting. This feature is used during
maintenance or clean-up operations. Fig.3-38

(13)Main cylinder movement toggle switch

(see Fig. 3-39)
The switch is used in case the pumping
cylinders require service. extend retract
Left position controls the main cylinder
extending.
Right position controls the main cylinder
retracting.
Fig.3-39

(14)Rotate speed control toggle switch (see Fig.

3-40)
When the switch is in the left position
(“RPM+” position) engine speed is
increase decrease
increased.
When the switch is in the right position
(“RPM-” position) engine speed is
RPM+ RPM-
decreased.

Fig.3-40

(15)SYCD display (item 18 in Fig. 3-25)

SYCD display shows the operating conditions
and data as well as parameter selection and
modification.

3-28
 SYSTEM FUNCTIONS
HBT6013C-5S

3.6.2 Remote control device 1 2 3 4 5

The trailer-mounted concrete pump can be

operated by the remote control box when the
control model switch on the electrical cabinet
in the Remote position.

Fig. 3-41 shows the panel of the remote

control box.shows the designation of each
element. Fig.3-41

Table 3-7

No. Designation
1 E-STOP button
2 Pumping direction switch
3 Output adjustment switch
4 Agitate reverse
5 Indicator light

E-STOP button (item 1 in Fig. 3-41)

E-STOP is used for only emergency stopping
purposes.

Pumping switch (item (a) in Fig. 3-42)

The up position is pumping forward, while the
down position is pumping reverse.

Output adjust switch (item (b) in Fig. 3-42)

The up position is to increase output, while (a) (b) (c)
the down position is to reduce.

Agitate reverse (item (c) in Fig. 3-42) Fig.3-42

Up position allows the agitator rotate reverse,

centre position allows agitator run in normal
direction and no effect in the down position

Indicator light (item 5 in Fig. 3-41)

It will be light when the machine is in the
remote control mode.

3-29
SYSTEM FUNCTIONS
HBT6013C-5S

3.6.3 SYCD operation and instruction

SYCD only can be used in monitoring the
operating condition and original parameters
setup. If the parameters should be modified,
you’d better ask for after-sale service.
Home page (see Fig. 3-43)

10 5 1 2 11 12

9 HBT60C-1816DIII V2.6 F1
Remote Fan mode Low-P
F2
8 0 125 0 10
Lang
Oil Pre 0.0 bar
uage
F3
0 Speed:0 rpm
30 3
Force F4
fan

0 15 -30 90
Ene-
Oil Posi:57 L Oil Temp:18 F5
7 sel

Flux 74%
Emergerncy Stop! Batter 24.0V Menu F6

6 4

Fig.3-43
1. Type of the machine 7. Oil position
2. Version number of SYCD 8. Water temperature
3. Function buttons 9. Control mode of the machine
4. Oil temperature 10.Cooling mode
5. Diesel engine rotating speed 11.High/Low pressure
6. Error information 12.Oil pressure

Functions of the buttons in Fig. 3-43 are as

follows:

● F1 and F2: no function.

● F3: language selection.
● F4: force fan.
● F5: chose the engine saving mode.
● F6: turn to the “System Function Menu”.

3-30
 SYSTEM FUNCTIONS
HBT6013C-5S

System function menu

Press F6 in the home page to enter the
“System Function Menu” (see Fig. 3-44). System Function Menu
Home
Page F1
This page contains the following information: I/O Test
F2
● I/O Test Modify Parameters

Working Stat. Info

● Modify Parameters F3
Fault Diagnose
● Working Stat. info Information Query
F4

● Fault Diagnose Current Faults F5

● Information Query History Faults
OK F6
● Current Faults
● History Faults
Fig.3-44
Function of the buttons are as follow:
● F1: return to the home page.
● F2 to F3: no function.
● F4: choose the up item.
● F5: choose the below item.
● F6: to confirm the item chosen.

NOTE:Some of the pages downwards need

password when accessing. You should
ask for after-sale service before modify
the parameter in these pages.

(1) I/O Test

This page displays all of the input and output
port information for the device (see Fig. 3-45).
The State of Input 1
Home F1
● F1: return to the Home page.
Forward Pumping--A116 Page
Reverse Pumping--A117

● F2: return to the “System Function Menu”. Local Control--A114 Menu F2

Remote Control--B208

● F3 and F6: no function. Delivery Volume Increase--B116 F3

Delivery Volume Decrease--B117
● F4: turn to the next page. High Pressure--B114
Next
Page
F4

● F5: go to IO-OUT/IN menu.

Temperature Switch--A220
IO-
Main Cylinder Forward--A112 OUT F5

This page is mainly used for service Main Cylinder Backward--A113

Swinging Cylinder Forward--A208 F6
engineers to eliminate the fault codes.

(2) Modify parameters

Fig.3-45
In this page parameters can be set to adapt
different conditions. Each parameter has
been set up before sale. If you want to
modify the parameters, ask for after-sale
service firstly.

3-31
SYSTEM FUNCTIONS
HBT6013C-5S

(3) Working status information (see Fig. 3-46)

This page contains the following information:
Working Stat. Info
● Pump time Home
Page
F1
1. Pump Time 10.4 H
● Diesel engine run time Menu F2
2. Diesel Runned 14.4 H

F3
Function of the buttons are as follow:
● F1: turn to home page F4

● F2: turn to “System Function Menu”. F5

● F3 to F6: no function. F6

Fig.3-46

(4) Information Query (see Fig. 3-47)

This page contains the following information:
● Control Program Version
● Display Program Version
● Double Power
● Power System
● Hydraulic Selection
● Distribution Selection
● System Model Selection

Function of the buttons are as follow:

● F1: turn to home page Fig.3-47
● F2: turn to “System Function Menu”.
● F3: turn to next page.
● F4 to F6: no function.

(5) Current faults

This page will display current fault codes
which have occurred.

(6) History faults

This display shows a record for the fault of
the device before.

3-32
 SYSTEM FUNCTIONS
HBT6013C-5S

3.6.4 E-STOP buttons

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.

There are E-STOP (emergency stop) buttons

at various locations on the trailer-mounted
concrete pump, with one more on the remote
control box.

After pressing one of these buttons, all the

actions of the trailer-mounted concrete pump
will be stopped in spite of any operation.

Rotating the pressed button as directed by

the arrow on the button while pressing it Electrical Control
Box 

again, the button will automatically bounce to

the original position to make the operation
available again. I O
+ -

RPM+ RPM-
I O I O

Fig. 3-48 shows the E-STOP button on the

electric control cabinet of the trailer-mounted
concrete pump. Fig.3-48

Fig. 3-49 shows E-STOP button on the

remote control box of the trailer-mounted
concrete pump.

Fig.3-49

3-33
SYSTEM FUNCTIONS
HBT6013C-5S

3.6.5 Functions of the symbols

Details of the symbols on the electrical
cabinet and remote control box are shown in
Table. 3-8.

Table 3-8

Function Symbol Function Symbol

Engine Outrigger
start/stop I O extend/retract I O

Diesel engine Piston

start/stop I O exit/keep/restore

Pumping
Washing
forward/reverse

Output
Pre-heating
increase/decrease + - I O

Rotate speed High/low

RPM+ RPM-
increase/decrease pressure

Swing cylinder Power supply

extend/retract indicator

Local/remote Running
control indicator

Malfunction
Reverse agitate
indicator 
Main cylinder
extend/retract

3-34
 HBT6013C-5S

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AN

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BL

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3-35
HBT6013C-5S

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3-36
 OPERATION
HBT6013C-5S

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.

4.1 The Requirement of Concrete

Concrete is a material formed by mixing
cement, coarse and fine aggregate and
water, with or without the incorporation of
admixtures and additions. It develops its
properties by hydration of the cement.

Besides strength and durability, the pumping

concrete mixture should also meet the
requirement of the pipeline. Therefore,
material and mixing proportion of the
pumping concrete are different from
traditional concrete.

4.1.1 Materials of concrete

Cement
Cement is a kind of finely ground inorganic
material. When mixed with water, it forms a
paste that sets a hardens by means of
hydration reactions and processes. After
hardening, cement retains its strength and
stability even under water.

Admixture
Admixture is material added during the mixing
process of concrete in small quantities related
to the mass of cement to modify the
properties of fresh or hardened concrete.

Aggregate
Aggregate is a kind of granular mineral material
suitable for use in concrete. Aggregates may be
natural, artificial or recycled from material
previously used in construction.

4-1
OPERATION
HBT6013C-5S

Addition
Addition is finely divided material used in
concrete in order to improve certain properties
or to achieve special properties.

4.1.2 Material and mix proportion of

pumping concrete
Properly choosing the material and mix
proportion is an important method to
guarantee good quality of pumping concrete.

Coarse aggregate
(1) Variety and quality of coarse aggregate
Gravel, macadam and combined aggregate
of gravel and macadam can be adopted for
pumping concrete. The pumpable capacity
of gravel aggregate concrete is the best, that
of combined aggregate ranks the second,
and that of macadam aggregate is a little bit
poor. Acicular aggregate in macadam, and
macadam with relatively great porosity (such
as vesuvianite and porous aggregate)
should be under strict control for the frequent
occurrence of pipe blockage due to their
relatively poor pumpable capacity.

(2) Maximal grain size of coarse aggregate

The maximal size of coarse aggregate
depends on the minimal diameter of
delivery pipe. It is allowed that a small
amount of aggregate in size of one grade
higher coarse, but with the proportion no
more than 2% (see Table. 4-1).

Table 4-1 Comparison of Sizes of

Aggregates in Delivery Pipe

Minimal Maximal Size of Coarse

Diameter of Aggregate (mm)
Delivery Pipe
(mm) Gravel Macadam

100 30 25

125 40 30

150 50 40

4-2
 OPERATION
HBT6013C-5S

(3) Gradation of coarse aggregate

Refer to Table. 4-2 for details of
gradation of coarse aggregate.

Table 4-2 Gradation of Coarse Aggregate

Nominal Size of Sieve Pore (mm)
Aggregate Size
50 40 30 25 20 15 10 5 2.5
(mm)
Weight percentage of aggregates passing through sieve (%)
Below
100 100-95 - - 75-35 - 30-10 5-0
40
Gravel
Below
100 100-95 - 75-40 10-0 5-0
30
Below
- - 100 100-90 90-60 - 50-20 10-0 5-0
25
Macadam
Below
- - - 100-90 100-90 (86-55) 55-20 10-0 5-0
20

Fine aggregate
Fine aggregate influences concrete pumpable
capacity more than coarse aggregate. It is
required to get a good gradation of fine
aggregate. Refer to Table. 4-3 for the weight
percentage of fine aggregate passing through
the sieve:

Table 4-3 Gradation of Fine Aggregate

Fine Nominal Size of Sieve Pore (mm)

Aggregate 10 5 2.5 1.2 0.6 0.3 0.15
Sand 100 100-90 100-80 90-50 60-25 30-10 10-2

NOTE:The fine aggregates passing through

sieve pore of 0.3 mm play an
important role, so generally the
content of such aggregates should be
not less than 15%.

4-3
OPERATION
HBT6013C-5S

Cement proportion
The minimum cement proportion is required to be
300 kg / m3.

But it should be noted that an excessively

large cement proportion will increase the
cohesiveness of concrete, thus increase the
pumping resistance. The propo rtion of
admixed cement can be reduced accordingly
when fly ash is being added, but the total
amount of fly ash should depend on the
cement grade (see Table. 4-4).

Table 4-4 Proportion of Fly Ash in Case of Different Cement Grades

Cement Type and
5~25 ordinary 425 slag Portland
Grade Class of 5~25 Portland cement
Portland cement cement
Concrete Strength
≤C25 30% 20% 15%

Determination of sand ratio

The optimum sand ratio is the one with
minimum cement proportion on the premise
of ensuring good concrete strength and
pumpable capacity. The sand ratio of pumped
concrete is greater than that of non-pumping
concrete by 2~5%. The recommended sand
ratio is shown in the table below:

Table 4-5 Recommended Sand Ratio (%)

Max. Aggregate Concrete with Additive Concrete Without Additive

Size (mm) Gravel Macadam Gravel Macadam
15 48 53 52 54
20 45 50 49 54
25 42 44 44 49
40 38 42 40 45

Water cement ratio

The water cement ratio refers to the ratio of
water to cement, the value of which directly
influences the slump. The optimum water
cement ratio for pumped concrete is 0.4 ~ 0.6.

4-4
 OPERATION
HBT6013C-5S

Additive for concrete

Adoption of additive is a relatively economical
method for improving workability of concrete.
Please consult the adoption of the additive
w i t h th e c on s t r u c t or s a c c or d i n g t o t h e
experiment results in order to ensure smooth
pumping. You must follow the local regulation
for pumped concrete.

Mix proportion of pumped concrete

In determining the mix proportion of pumped
concrete, the method for the ordinary
concrete can still be adopted. But special
treatment should be considered in respect of
cement proportion, slump, sand ratio, etc.

(1) The slump range of pumped concrete is

generally controlled between 10 ~ 23 cm.
For the pumping with a long distance and
a great height, it is generally controlled at
about 18 cm.
(2) Strict control of the mix proportion of
concrete.
Precautions
● It is generally required to finish pumping
within 90 min after mixing.
● The rapid setting concrete is forbidden for
pumping.
● It is forbidden to add water into the
hopper.
● It is forbidden to put the concrete with too
much deviation of slump or obvious
quality problems into the hopper.
● You must adopt the cement according to
the local standards during working.

4-5
OPERATION
HBT6013C-5S

4.2 Pipe Disposal

4.2.1 Selection of concrete delivery pipe
Concrete delivery pipe includes tapered pipe,
elbow bend pipe, spigot tube, straight tube,
hose, pipe connector etc. Generally, a set of
standard pipes is equipped with the machine.
At the same time, customers can choose other
kind of pipes according to the local situation.

The commonly used 2-gradation pipes diameter

is 125 mm or 150 mm. The basic requirements
for selection are as follows:

Table 4-6

125 mm delivery 150 mm delivery 205 mm 3-gradation

Concrete pipe
pipe pipe delivery pipe

Aggregate size
40 mm / 30 mm 50 mm / 40 mm 80 mm / 70 mm
(gravel/ macadam)

4.2.2 Disposal
Preparation of Pipe
Prepare pipes and pipe connectors according
1 2 3 4 5
to the 2-gradation pipes list (see Fig. 4-1).

Requirement of Concrete Delivery Pipe

● Pay attention to the wall thickness where
are easily worn out. Never use the pipes
which are damaged, cracked or thin-wall.
● Shorten the distance as much as
possible and reduce use of the elbow
pipes to reduce the delivery resistance.
But you must ensure smooth pumping Fig.4-1
and normal delivery.
● It is suggested that the hose in the end of 1. Discharge outlet 4. Spigot
2. Tapered tube 5. 125A straight tube
front should be vertical. If horizontal
3. 45° elbow
placement is required, too much bending
is forbidden.
● Ensure that the connections are firm. Fixed
devices must set at the elbows, and the
horizontal pipeline must be fixed with firm
supports instead of being suspended.

4-6
 OPERATION
HBT6013C-5S

● All the pipe clamps should be tightened to

ensure pipe connectors are sealed properly
without leakage, especially during water
pumping. The contact of the pipe clamps
with the ground or supports is forbidden.
● It is suggested to wrap the delivery pipes with
heat preservation materials in cold winter to
keep the concrete from cold exposure. It is
suggested to cover the delivery pipes with
wet grass sacks, etc. in summer to avoid
slump loss which causes pipe blockage.
Upward vertical pipe disposal
In upward vertical pipe disposal, try to
overcome the refluent pressure caused by
gravity of the concrete.
(1) When the vertical height is relatively small.
Set a certain length of horizontal pipe
between the lower end of the vertical pipe
and the trailer-mounted concrete pump.
Generally, the length ratio of vertical pipe to
horizontal pipe is 3:1, and the length of the
horizontal pipe should generally not be less
than 15 m.
(2) When the vertical height is relatively large
or confined by the site.
Set a spigot between the tapered tube
and the straight tube. Seal the spigot to
prevent the concrete from back flowing at
the time of pumping stopped.

NOTE:When the upward vertical pumping

height exceeds 30 m, set a new pipe
without any wear or with a thick wall at
the beginning of the pipeline so as to
avoid excessively high pressure inside
the pipe which will lead to accidents.
When necessary, inspect the wall
thickness. If the wear of the pipe after
long-time use is relatively great, new
pipes should be changed.

4-7
OPERATION
HBT6013C-5S

The fixation of elbows, vertical pipes and etc.

are shown in Fig. 4-2.
11 12

1 2 3 4 5 6 7 9
10

Fig.4-2
1. trailer-mounted concrete pump 5. 45° elbow 9. 90° elbow with R=1000
2. Hopper 6. Spigot 10. Vertical pipe support
3. Discharge outlet 7. Straight tube 11.90° elbow with R=1000
4. Tapered tube 8. Base 12.Horizontal support

Downward vertical pipe disposal

(1) When the inclination of the pipe is over 4°~7°
A horizontal pipe should be set at the upper
end of the downward inclined pipe, with a 4°~7°
•+

length more than 5 times of the fall height

H Concrete flowing direction
“H” (or 3H long pipe plus a hose) to prevent
the concrete from gravity flow by the friction
resistance in the horizontal pipe.
Fig.4-3
(2) When the inclination of the piping is over 7°~12°
Besides the horizontal tube referred upward,
an air release valve should also be set at the
upper end of the inclined pipe. During
pumping, open the air release valve to
discharge air until the mortar starts to flow out.
Inclined pipe is filled with concrete. Close the
air release valve to conduct normal pumping.

4-8
 OPERATION
HBT6013C-5S

NOTE:If there is no enough space for laying

a horizontal pipe, hoses, elbows or
ring pipes can be use.
Set sponge rubber balls in the pipeline
at the beginning of pumping for the
downward concrete delivery at a large
angle.

Practical delivery length

Practical delivery length is different according
to pipeline forms, quantities, and landforms.
Reference can be made to Table. 4-7.

Table 4-7 Horizontal Conversion Length for Different Pipe Disposal

Horizontal Conversion Length
Delivery Pipe
Type Unit Slump (mm) Slump (mm) Slump (mm)
Specification
50~120 137~170 190~230
Upward
meter 125A 3.5 4 4.5
vertical pipe
Tapered tube piece 150A~125A 6 6 6
Elbow piece 90° 6 6 6
Hose piece 2 2 2
For downward pipeline, calculation is carried out according to the actual length.

4.2.3 Operation after blockage

Precaution of Blockage
(1) Improve the quality of the concrete to
prevent blockage.
(2) Prevent leakage of the connectors. Never
use elbows with too small bent radius.
Use uniform pipes connected well.
(3) Adjust the parameters of the hydraulic
system properly. Prevent unauthorized
persons operate the adjustment.
(4) If the pumping has to be stopped for a
long time, start the pump once every
15~30 min to carry out reverse pumping
for 1-2 strokes and then forward pumping
for 1-2 strokes.

4-9
OPERATION
HBT6013C-5S

Judgement and Solution of Blockage

WARNING
Before remove the connectors, screw off
the bolts of the connectors and shake the
pipe to reduce the inner pressure to 0. It
is to prevent injury of the concrete splash.

(1) If the pumping circle stops automatically

after the peak value raising to the setting
pressure (32MPa) rapidly with the
alternation of the strokes, blockage occurs.
(2) Under normal situations, operate 1~2 circles
of reverse pumping will eliminate blockage.
If it doesn’t work, stop themachine to clean
the pipelines after locating the blocked point.
NOTE:Never operate reverse pumping too
frequently, or the blockage will be
more serious.
Wooden Hammer
(3) During reverse pumping operation, there
will be strong vibration on the pipe from the
outlet of the pump to the blocked point.
After the blocking point the pipes are still.
(4) Knocking the blocked pipes with wooden
harmer, the pipeline will recover
sometimes. If it doesn’t work remove the
blocked pipes and clean them.
(5) If the judgement of the blockage is not
precise, clean the pipeline in sections. If Fig.4-4
d i s c o v e r t h e c on c r e t e b e g i n n i n g t o
coagulate, open all of the connectors
immediately and clean the pipes rapidly
in order. At the same time, clean the
trailer-mounted concrete pump.

4-10
 OPERATION
HBT6013C-5S

General Rules of Blockage

WARNING
Air will enter the pipeline at the time of
blockage elimination. When restarting
pumping, prevent the concrete jetting out
from the pipe end to injure people.

(1) During upward pumping, reverse

pumping is easy, so blockage seldom
occurs. But the blockage of distribution
valve, tapered tube or elbow in horizontal
section easily occurs. Fig.4-5
(2) During horizontal long-distance pumping
or downward inclined pumping, reverse
pumping is hard. Blockage mainly occurs
in elbows and horizontal pipes at the
lower end.

4.3 Pre-operational Checks

When preparing to operate this equipment, it is
importa n t t o be a war e of you r wo r k in g
conditions and hazards involved. Always study
the job carefully before starting any operations.
Be sure you and others involved with
operations understand all of the rules. Operate
the machine within the operating parameters
specified in this manual (see "Specifications" on
page 7-1). Never use the work equipment for
something it was not intended, otherwise
damage to the equipment or injury to personnel
may result. Keep in mind you are responsible
for the safe operation of your equipment.

Before starting your machine or preceding with

any work operations, it is important to be sure
your equipment is safe to operate. Below is a
list of basic items to check before any work is
to begin. If any problems are found during this
check, have them repaired immediately.

4-11
OPERATION
HBT6013C-5S

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

Before operating this equipment read and

understand the following:
● Look for any obviously missing or
damaged items and immediately replace
or repair them.
● Be sure all safety and work-related
equipment necessary for the job is in
place and properly secured for travel.
● Inspect the outriggers for damage or
missing components. Be sure the
outrigger locks are functional and that the
outriggers are properly retracted and
locked in place before you travel.
● Inspect the hopper area for loose,
missing or damaged items. Be sure this
area is clean and functional.
● Check the condition of all visible
hydraulic hoses. Look for worn or leaking
fittings and cuts, scuffed or cracked hose
surfaces. Have worn, cracked or leaking
hoses repaired or replaced immediately.
● Check whether the delivery pipes are
disposed correctly. Guarantee the
concrete delivery, feeding mode and
capacity. Inspect the delivery pipe for
damage, excessive wear, dents, loose
clamps or mountings. Never use a worn
hose or damaged piping.
● Inspect the hydraulic cylinders for damage
or leak s. Have damaged or leaking
hydraulic cylinders repaired immediately.

4-12
 OPERATION
HBT6013C-5S

● Be sure all safety decals are in place and

are not damaged. Be sure they are clean
and visible to all personnel.
● Check the hydraulic tank and cooler. Be
sure they are not damaged, loose,
leaking or blocked with debris. Ensure
the coolant is sufficient.
● Check that all fluid levels are at correct
levels (hydraulic, water, fuel). Ensure the
grease in the lubricating grease pump is
sufficient. Pull the handle of grease pump
and turn the oil cup cover for well
lubrication of each point.
● Set all switches on the electrical control
cabinet panel and the remote control box
at “OFF” position. Disconnection, wire off,
looseness of contact screws and short
circuit of electrical elements are
impermissible.
● Check the engine battery and circuit.
Make sure the voltage is 24±2V, and
there is no disconnection, wire off and
looseness in the circuit.
● Check that the power and water supply
meet the demand of normal operation,
and make sure the electrical, hydraulic
and mechanical systems are in good
condition.

4-13
OPERATION
HBT6013C-5S

4.4 Set-up Site

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

The machine operator takes responsibility for

setting up the machine safely. He must inspect
the proposed set-up site and refuse to set the
machine up at the site of operations if he has
any doubts regarding safety.
The machine operator must be familiar with
the working area and surroundings before
working. The working area and surroundings
include obstacles in the work and travelling
areas, the load bearing capacity of the
supporting ground and any barriers separating
the construction site from public roads.
The machine operator must also check the
approach route to the site where the machine
will be set up. If you are unsure the suitable
approach route, prepare the route before
working. It is necessary to walk the approach
route once in darkness and at dusk or dawn.
You should repeat this exercise again before
leaving the construction site.
The machine operator must always ask for a
signaller if you have to reverse into the site
where the machine will be set up. If necessary,
have the approach route closed off or secured
by signallers. Have any materials or equipment
that hinder your approach removed.
You must always ask for a signaller if you
have to reverse into the site where the
machine will be set up. If necessary, have the
approach route closed off or secured by
signallers. Have any materials or equipment
that hinder your approach removed.

4-14
 OPERATION
HBT6013C-5S

4.5 Starting Up
The operator can start the trailer-mounted
concrete pump after having conducted all the
inspection work.

4.5.1 Engine starting

CAUTION
Make sure all the switches and buttons
are at the position of stopping forward
pumping and reverse pumping. Or
damage of the machine and injury of
personnel may occur.

(1) Keep the engine rotate without load.

(2) Turn on the power supply button (a) in
Fig. 4-6 (“Power supply button”) on the (d)
left side of electrical control cabinet, and
the indicator light (d) goes on and the Electrical Control
Box

SYCD displays the current state. (a)

(b) (c)
(3) Set switch (b) to the right side in Fig. 4-6
(“Engine start” switch). After the diesel
I O
+ -

RPM+ RPM-
I O I O

engine starts, SYCD display the current

working state of the diesel engine. The
interval between two adjacent starts
should be 2~3 min.
(4) Once the engine is started, observe
SYCD used to measure engine oil
pressure, voltage, fuel level, water Fig.4-6
temperature and rotation speed of diesel
engine. Only after everything goes well,
can the engine work with load.
(5) In winter, use winter engine oil and diesel.
Under the temperature lower than -20°C,
often remove the startup motor, and
lubricate the ring gear of flywheel using
cold-resistant grease through the mounting
hole of the startup motor. This will make
the startup gears mesh properly.

4-15
OPERATION
HBT6013C-5S

(6) Check whether there is abnormal noise

on the machine and wether the oil filter is
blocked.
(7) Set the switch (c) in Fig. 4-6 (“Pumping
direction” switch) in the “Forward” position
(left position), and then the concrete piston
begins to move. Check the whether the
main oil cylinder and swing valve cylinder
change over normally. Check whether each
pipe clamp looses, and each pipe
connector leaks.
NOTE:When the reverse pumping is required
at the time of blockage, just keep the
“Pumping direction” switch on the
electrical control cabinet in the
“Reverse” position (right position). But
do not conduct reverse pumping too
frequently, otherwise more serious
blockage could be caused.

4.5.2 Engine racing

(1) After starting the diesel engine, operate it

with a rotation speed of 800~1000 r/min
for 3~5 min.
(2) Conduct idling for 10 min to check
whether the indication of the pressure
gauges are normal, whether the agitating
device can achieve reverse agitating and
whether the reverse pumping is normal.
The pressure gauges are on the side of the
trailer-mounted concrete pump (see Fig. 4- Fig.4-7
7).
1. Main system oil pressure gauge
2. Change-over pressure gauge
3. Agitating oil pressure gauge

4-16
 OPERATION
HBT6013C-5S

● Main system oil pressure gauge is used

to monitor the hydraulic oil pressure
produced by the hydraulic pump during
20

operation (see Fig. 4-8).

3000
30
10 2000 S 4000

1000 5000

psi
5800
MPa

0 40

Oil pressure of main system

Fig.4-8

● Change-over pressure gauge is used to

monitor the S-tube shift cylinder hydraulic
operating pressure during operation. The
change-over pressure is the accumulator 20

pressure and it is always active (see Fig. 10 2000

3000
S 4000
30

4-9). 1000 5000

psi
5800
MPa

0 40

Change-over pressure

Fig.4-9

● Agitating oil pressure gauge is used to

monitor the hydraulic pressure of the
agitators in the concrete hopper (see Fig. 10 15

4-10). 1500 2000

1000
S 2500
5 20
3000
500
psi 3500
MPa
0 25
(3) A period of idling is necessary if the
temperature is low. Only after the
temperature of the hydraulic oil rises up
to 20°C, can the concrete be fed for Agitating oil pressure

pumping.
Fig.4-10

4-17
OPERATION
HBT6013C-5S

4.6 Outrigger Set-up

When preparing to extend the outriggers for
the job set-up, ensure there is no explosive
gas and substance around, and the load-
bearing surfaces should satisfy the working
conditions.

4.6.1 Load-bearing surface

It is important to ensure that the load-bearing
surface (area the outrigger will be resting on)
will support the weight of the machine before
operation.

The following are conditions to avoid during

set-up:

● Very green grass in a circular shape

● Pipes extending from the ground
● Signs of recent excavation
● Sprinkler heads
● Backfill ditches
● Ditches with water (indicating recent rain)
● Loose soil
● Underground cavities/voids

Check the position of the trailer-mounted

concrete pump. The trailer-mounted concrete
pump should be installed on even and solid
ground. To avoid slide, the trailer-mounted
concrete pump cannot be set on a slope more than 3°
more than 3°.

This following information gives you a basic

idea of how well your outrigger may be
supported with different soil types and
cribbing timbers.
more than 3°

Fig.4-11

4-18
 OPERATION
HBT6013C-5S

The trailer-mounted concrete pump should be

set at the ground which has a load-bearing
capacity of 45kN. Before proceeding, you
must kn ow i f onl y t he f act or y su p p lie d
outrigger pads are sufficient before
completing outrigger setup or if auxiliary
cribbing timbers are required (see Fig. 4-12).

Note the downward pressure value of each

outrigger of your machine. Note the
“Allowable Soil Pressure” for the ground
surface type where the machine will be
stationed to check if pads are necessary.
Fig.4-12

● Never place the outriggers in an uneven

position. Be sure all sides of the outrigger
pad (a) is level and square with the
surface.
a

Fig.4-13

● Never set the outriggers up on a slope or

hill. Be sure the outrigger pad (a) is
sitting on flat level ground.

Fig.4-14

4-19
OPERATION
HBT6013C-5S

● Never set the outriggers up on areas with

voids. Be sure the surface is flat (a) and
stable and without voids.

Fig.4-15

● When using cribbing support, be sure the

support pad that came with the machine
is also used between the outrigger pad
(a) and cribbing (b). a
b

Other details about placement of the Fig.4-16

outriggers:

● If this pump is needed to set a place for

a long time, a reinforced concrete level
ground is advised in order to clean it
conveniently.
● During high-pressure and large-output
pumping, anchor the pump completely. If
the pump is set on the pads, this should
be treated as temporary placement.
● If the pump is set on the sinkage or a
h o l e , r e l e v a n t m ea s u r e s s h o u l d b e
adopted.
● Ensure enough illumination on the worksite.
● At least 1m space around the pump
should be left, to make maintenance
convenient.

4-20
 OPERATION
HBT6013C-5S

4.6.2 Operation of outriggers

CAUTION
Take care to prevent your feet from being
injured by outriggers during operation
(see Fig. 4-17).

The trailer-mounted concrete pump is

supported by the outriggers (see Fig. 4-18).
Before start-up the equipment, you should
set-up the outriggers as follows:
Fig.4-17

Rear Front Guiding

outriggers outriggers wheel

Fig.4-18

(1) If the guide wheel is retracted in position

1, pull out the locking pin to extend it to
locking pin
the limit position and then insert the pin
to fix it (see Fig. 4-19).

position 2

position 1

Fig.4-19

4-21
OPERATION
HBT6013C-5S

(2) Pull out the rear free outriggers, insert

the locking pins of rear outriggers and
lock the anti-l ooseness mec hanism
(see Fig. 4-20).
(3) Pull out the front free outriggers, insert
the locking pins of front outriggers and
lock the anti-looseness mechanism.
(4) Retract the outriggers in the reverse insert the
order. lock pin

4.7 Function Check

Fig.4-20
You should check the following functions
before you begin using the machine on the
construction site.

4.7.1 Pump functions

The fundamental prerequisite for problem-
free use is a fully functional pump.

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

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.

4-22
 OPERATION
HBT6013C-5S

● Measure the stroke time in a minute for

three times, get the average. The value
must match the data of maximal pumping
times.
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.

4.7.2 Filter functions

The hydraulic system of trailer-mounted concrete
pump has a high pressure oil filter, which shall
be subject to the same requirements on use and
maintenance. The oil filter is mounted beside the
oil tank (see Fig. 4-23).
The checking processes of the filter is as
following:
● Bring the hydraulic fluid up to operating
temperature (122° F (50° C)).
● Set the maximum pumping rate. Fig.4-23 High-pressure Oil Filter
● Press in the red button on the filter if it is
sticking out.
NOTE:If the indicator at the top of oil filter
turns green, it indicates that the oil
filter is in good condition, without any
blockage; if it turns red, in indicates
that the filter core is seriously blocked
and the operation is stopped, and the
filter core must be replaced.

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

4-23
OPERATION
HBT6013C-5S

4.7.3 E-STOP function

It is only possible to intervene rapidly in the
event of danger if all the E-STOP buttons are
functioning.

The machine is no longer safe in operation if

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

There are E-STOP (emergency stop) buttons

at various locations on the trailer-mounted
concrete pump, with one more on the remote
control box.

Pressing any button stop all operations

immediately. The button locks in the STOP
position until it is released by rotating it
clockwise, as indicated by the arrows on the
button. All functions will resume normal
op e ra t i o ns a f te r t h e E - S TO P b ut t on i s Fig.4-24
released (see Fig. 4-24).

When restarting the device to work again

after every abnormal condition eliminated,
make sure that all the switches on the
electrical control cabinet panel and the
remote control box are set at “OFF” state,
and then reset the E-STOP button to prevent
of affection the starting of the engine
Electrical Control
Box 

Fig. 4-25 shows the E-STOP button on the

electrical control cabinet of the trailer- I O
+ -

mounted concrete pump. RPM+ RPM-

I O I O

Fig.4-25

4-24
 OPERATION
HBT6013C-5S

Fig. 4-25 shows E-STOP button on the

remote control box of the trailer-mounted
concrete pump.

The way of checking the function of E-STOP

buttons is as following:

● Switch the pump on.

● Operate a boom function.
● Press one of the E-STOP buttons. The
pump must come to a halt immediately.
● Check all E-STOP buttons on the machine Fig.4-25
and on the remote control in the same way.

4.7.4 Function check on the agitator

safety cutout
This machine is fitted with an agitator safety
cutout. A pressure roller switch is acted on as
soon as you open the grille. This causes the
agitator to halt and the pressure to be
dumped from the accumulator, i.e. the S-
valve will no longer be able to switch over. In
addition, the delivery pistons return to the end
position and the concrete pump halts.

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

● Open the grille with the concrete pump

running.

4-25
OPERATION
HBT6013C-5S

● The switching cam acts on the pressure

roller switch.
● The agitator must come to a halt
immediately.
● The S-valve must no longer switch over.
● The concrete pump must run to the end
position and halt.

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

NOTE:You must switch the concrete pump

off and back on again to restart it.

4.8 Pumping Operation Hand Signals

CAUTION
Failure to observe and follow this directive
may result in loss of control, a possible
rollover and personal injury.

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).

NOTE:If nonstandard signals are used, be

sure the operator and signal person
agree on them before operations are
to begin.

4-26
 OPERATION
HBT6013C-5S

Never begin operations until all signals are

clearly understood. The operator shall
respond to operating signals from the proper
signal person only, but shall obey a stop
signal at any time from anybody. The signal
person shall be in a clearly visible or lighted
location.

If signal communications are interrupted at

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

START OR SPEED UP PUMPING

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

Move the forearm in and out at a faster pace

to indicate an increase in pumping speed. Fig.4-25

SLOW DOWN PUMPING

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

Fig.4-26

4-27
OPERATION
HBT6013C-5S

CHANGE PUMPING SPEED SLIGHTLY

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

Fig.4-27

RELIEVE PRESSURE IN PUMP SYSTEM

Use the right hand or left hand to tap twice
on your hard hat to indi cate to put the
pumping system in the reverse mode to
relieve pressure on the piping system.

CAUTION
Stop pumping in the forward mode and
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.

Fig.4-28

4-28
 OPERATION
HBT6013C-5S

ADD WATER TO HOPPER

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

Use this signal to indicate the concrete mix is

too thick and needs to be thinned out for
better flow.

Fig.4-29

STOP THE PUMP

Use the right or left hand with a closed fist
and extended index finger moving the hand
across the base of the throat (slashing
motion) to signal the operator to stop all
pumping operations.

CAUTION
This signal may be used by other
personnel in an emergency. The operator
shall obey a STOP signal at any time from
anybody.

Fig.4-30

4-29
OPERATION
HBT6013C-5S

PUMPING OPERATIONS COMPLETED

Using both hands with thumbs up motion
indicates to the operator that all pumping
operations are completed.

4.9 Pumping Operation

This section describes common pumping Fig.4-33
operation during working and maintenance.

4.9.1 Safety precautions

WARNING
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 and oil pump run switch (a)
normally, the outriggers are supported
well and all the examinations are carried 

out. Failure to do so may result in serious

damage to the pumping system, or
personal injury.
I O
+ -

RPM+ RPM-
I O I O

(1) Before pumping concrete, fill the hopper

with fresh water. Set switch (a) on the
electrical cabinet panel to the “Forward”
Fig.4-34
position (left position) to pump the water.
During pumping, check each clamp to
make sure it is sealed well without leak.

4-30
 OPERATION
HBT6013C-5S

NOTICE
When the trailer-mounted concrete pump
is running, the level of the mixed concrete
must be higher than the mixing shaft to
avoid air pumping (Fig. 4-35).

Fig.4-35

(2) Inform the front hose operator before

starting or stopping pumping. The bend
radius of the front hose should be more
than 1 m. The operator is not permitted
to stand at the outlet of the hose to avoid
injury caused by the suddenly jetting
concrete.

L1

L2

Fig.4-36

(3) When the trailer-mounted concrete pump

is running, it is forbidden to put your
hands into the hopper or the water tank
(see Fig. 4-37).

Fig.4-37

4-31
OPERATION
HBT6013C-5S

(4) The delivery pipe must be fastened and

padded firmly. Never bend the delivery
hose or add another delivery at the end
of the delivery hose to avoid hose burst
(see Fig. 4-38).

Fig.4-38

(5) The end of hose may swing violently

while pumping starts after solving the
blockage, thus causing sudden concrete
jetting, so the operator is not permitted to
approach the hose (see Fig. 4-39).

(6) It is prohibited to stand on the edge or at

the corner of a building, with the end
hose held in the hands, as the operator
may fall due to the swing of the end hose Fig.4-39
or jetting of concrete (see Fig. 4-40).

Fig.4-40

4-32
 OPERATION
HBT6013C-5S

(7) The hopper screen should be closed

when the pumping system is running, and
it is strictly prohibited to stretch the hands
into the hopper or water tank and touch
the swing mechanism (see Fig. 4-41 and
Fig. 4-42).

Fig.4-41

Fig.4-42

(8) When the pressure is applied, it is

prohibited to open or remove the delivery
pipes, and it is necessary to decompress
the concrete inside the pipe by the
reverse pumping. Beware of the
wounding by the instant ejection of
concrete (see Fig. 4-43).

Fig.4-43

4-33
OPERATION
HBT6013C-5S

(9) Never allow personnel to stand between

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

Fig.4-44

(10)It is forbidden to climb onto the machine

during operation.

Fig.4-45

(11)Make sure that nobody can be injured by the

running machine before switching on the
machine.

4.9.2 Notes on correct pumping

Before pumping, the pipeline should be
lubricated firstly (mortar generally or cement
grout). In case of mortar, the used amount
should be 0.5 m3/200 m, and the mix
proportion (cement: sand) should be 1:2 for Fig.4-46
pipeline with a length less than 150 m, or 1:1
for pipeline with a length more than 150 m.

4-34
 OPERATION
HBT6013C-5S

Pour mortar into the hopper for pumping.

When mortar pumping is coming to end, pour
the required concrete into the hopper for
normal pumping.

If the mortar pumping is blocked, dismount

the first section of piping, and take out the
dehydrated block. Start normal pumping so
long as piping is reinstalled well.

NOTE:The slump of pumped concrete should

not vary greatly, and the variation
scope should be controlled within
100~230 mm. Mix the concrete in the
mixing drum of the truck mixer for
several minutes at first.

4.9.3 Pre-operational checks

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

Before starting any pumping operations,

confirm that:

● All personnel involved are ready for the

concrete placing process and that they
understand all rules and procedures and
know where all E-STOP buttons are
located.
● All personnel have an unobstructed view
and are able to communicate with the
operator.
● All hand signals are understood.
● The auto-grease system is full and
operating. It is important that the operator
monitor this system during operation.

4-35
OPERATION
HBT6013C-5S

4.9.4 Pumping
Control mode selection

(1) Turn on the control power supply, select

“Local control” mode (right position) Remote Local

through the “Control mode” switch on the

electrical control cabinet panel (see Fig.

4-47).
NOTE:Under local control mode, the
operation switches on the remote
control box are ineffective. I O
+ -

RPM+ RPM-
I O I O

Fig.4-47

(2) If remote control is required by the

system, connect the ten-pin plug at the Electrical control cabinet
end of the remote control box with the
ten-pin socket on the side of electrical
Remote controller
control cabinet (see Fig. 4-48).
+

Set remote control mode through the -

“Control mode” switch (left position) on the

panel of electrical control cabinet (see Fig. 6

1
7

2
8

3
9

4
10

ten-pin socket
4-47). At this time, the power indicator light
on the remote control box goes on, which ten-pin plug

in dica t es t h e r emot e cont r ol b o x is

operable.
Fig.4-48
NOTE:Under remote control mode, the
switches for forward and reverse
pumping on the electrical control box
panel are ineffective, but the switches
for automatic reverse mixing and E-
STOP button are still operable.

Pumping direction selection

(1) Use switch (a) in Fig. 4-34 to control the

pumping direction. In the normal operation,
“Forward” is the normal flow direction.

4-36
 OPERATION
HBT6013C-5S

(2) In remote control mode, use switch (a) to

switch (a)
control the pumping direction. Up position
is normal forward flow direction, and the
down position is pumping reverse.
(3) If the pumping has to be stopped for a
comparatively long time, start the pump
once every 15~30 min to carry out
reverse pumping for 1-2 strokes and then
forward pumping for 1-2 strokes to avoid
+
concrete setting inside the pipes.
-

Fig.4-49
Output adjustment
There are two ways of adjusting output.

(1) Use the “Output adjust” switch on the

electrical control cabinet to control output
increase/decrease (see Fig. 4-50): Increase Decrease

● Output will be increased when held the

switch in “Increased” position (left  + -

position).
● Output will be decreased when held the
switch in “Decreased” position (right I O
+ -

RPM+ RPM-

position).
I O I O

Fig.4-50

(2) Use “Output adjust” switch on the remote

control box to carry out pumping forward/
reverse (see Fig. 4-51):
● Up position: output will be increased
when held the switch in this position.
● Down position: output will be decreased
+
when held the switch in this position.
-

Fig.4-51

4-37
OPERATION
HBT6013C-5S

Engine rotating speed adjustment

Use the “Rotate speed control” switch on the
electrical control cabinet to control engine
rotate speed (see Fig. 4-52):

● To increase engine speed, hold the switch

in the “Increased” position (left position) Increase Decrease

until desired engine speed is reached.

● To decrease engine speed, hold the RPM+ RPM-
switch in the “Decreased” position (right
position) until the desired engine speed is
reached. I O
+ -

RPM+ RPM-
I O I O

NOTE:The output and the engine speed can

be monitored in the SYCD.
Fig.4-52
Agitate reverse
During normal operation, the agitator system
is used to continually mix the concrete slurry
in the hopper and to keep it over the pumping
mechanism spectacle ports.

If the agitator paddles become jammed,

rotation stops. Agitator should rotate in the
opposite direction to correct any jamming
problems. Operate as follows:

(1) Use the control mode switch on the

electrical control cabinet to enter the
“Remote” mode.
+

(2) Turn up the “Agitate reverse” switch to

-
start reverse agitating (see Fig. 4-53).

Fig.4-53

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

4-38
 OPERATION
HBT6013C-5S

4.9.5 Possible faults

Pumping stoppages
Due to the setting characteristics of concrete
in the delivery piping, the pumping process
must continue until completion of the
particular job at hand. This is especially true
of concrete with a low water mix. Also,
stationary concrete slurry in the delivery line
may separate into individual components.

NOTE:If setting has occurred, a blockage in

the delivery line could result before
pumping can resume.

CAUTION
Failure to observe and follow this caution
could result in equipment damage and
minor or major injury if a blockage is
ejected from the end hose under extreme
pressure or if an end hose whipping
situation occurs.

NOTE:If concrete components separate inside

the delivery piping, the resulting output
will be defective and of substandard
quality; this could prove to be tragic if the
concrete structure is a load-bearing item.

WARNING
Failure to observe and follow this warning
could result in injury or possibly death if
the resulting concrete structure fails.


Follow these directives if a pump stoppage is

unavoidable.
I O
+ -

(1) Set the “Control mode” switch (a) on the RPM+ RPM-
I O I O

electrical control cabinet panel to the “Local”

position (right position) and “Pumping
(b) (a)
direction” switch (b) to the “Backward”
position (right position) to empty the delivery
Fig.4-54
piping as much as possible.

4-39
OPERATION
HBT6013C-5S

(2) When no concrete exits the delivery

piping, move the “Pumping direction”
switch (item b in Fig. 4-54) to the center
position to stop the reverse pumping
operation.
Other operations

(1) Always observe the hydraulic oil

temperature during pumping. When it
rises up to 55°C, it is required to start the
cooling system; if it continues rising up
and exceeds 80°C, stop the machine for
check.
(2) During pumping, do not empty the
hopper, as the remaining concrete may
jet from the hopper to damage the
machine and injure the people around.
(3) In the event of too low concrete slump,
do not add water into the hopper for
mixing; instead, add cement mortar (with
the same proportion of water and cement
as the pumped concrete) into a truck
mixer or mixer, mix it evenly and then
pour it into the hopper.
(4) Don’t pile concrete on the hopper screen.
In addition, control the concrete feeding
flow and clear away the over-diameter
aggregates and foreign substances in time.
(5) Stop pumping and do troubleshooting in
time when the mixing shaft is seized.
(6) In case of concrete segregation in the
hopper, stop pumping temporarily, and
mix the concrete evenly before pumping
again. In case of serious aggregate
segregation and obviously insufficient
mortar in the hopper, remove some
aggregates and add mortar for remixing.

4-40
 OPERATION
HBT6013C-5S

(7) For re-pumping after short break in

vertically upward pumping, carry out
reverse pumping at first to suck the
concrete back into the hopper from the
distribution valve.
In the event of working pause, if there is a
spigot in the pipeline, fit the plug-in board well
to protect the concrete in the vertical or up
tilting pipes against back flow.

4.10Equipment Clean-up
Remove and clean all concrete material
residue from the machine after all pumping
operations are completed.

NOTICE
Failure to thoroughly clean the pumping
system at the completion of pumping
operations will result in equipment
damage.

4.10.1Cleaning the delivery pipe

Clean the delivery piping before cleaning any
other parts of the concrete pump unit.

Timing is very important during this operation

because concrete can set and harden very
quickly.

(1) Use either the electrical cabinet panel or

the remote control box as described
earlier to begin reverse pumping
operation to empty the delivery piping as
much as possible.
(2) Stop the reverse pumping operation when
no concrete exits the delivery piping.
(3) Set a plug-in board in the spigot, dismount
the hose at the front end.

4-41
OPERATION
HBT6013C-5S

(4) Dismount the pipe connector from the

1 5 0A ~ 1 2 5 A t a p e r e d t u b e , p ou r t h e
concrete in this tapered tube out.
(5) Mount cleaning tools which are different
tapered tube
according to delivery pipe length.
For the delivery pipe of a length below 100
m, the cleaning tools include one sponge
plug and one cleaning piston;

For the deliv ery pi pe of a length of

100~500 m, the cleaning tools include one Fig.4-52
paper cement sack, one sponge plug and
one cleaning piston;

For the delivery pipe of a length over 500

m, the cleaning tools include two cement
sacks, two sponge plugs, and one cleaning
piston (the cement sacks and sponge plugs
should be dunked fully in water before
setting into pipeline).

Above 500m
100~500m 3
Below 100m 1 1
1 2 2
2 3 3
Pu
Pu

Pu

mp
mp

mp

in
ing

ing

gD
Dir

Di

ire
rec
ec

cti
tio
tio

on
n
n

Fig.4-53

1. Sponge plug 2. Cleaning piston 3. Cement sack

4-42
 OPERATION
HBT6013C-5S

(6) Later, reconnect the tapered tube with

tube clamp fixed. Fill the hopper with
water and connect it with a water source.
(7) Pull out the plug-in board, cover the lid,
start the pump (see Fig. 4-54).
(8) Start pumping water to push the cleaning
tools to advance along the pipeline until
the sponge plugs, cleaning pistons, and
cement paper come out from the front
end. Pump water repeatedly until no
concrete residues flow out. At this time,
the cleaning of delivery pipe is finished.

4.10.2Clean the machine

Set the output of the main oil pump to the Fig.4-54
minimum, running for 3~4 strokes without
load to discharge the residual concrete. Stop
the no-load running.

● Dismount the tapered tube to remove the

residual concrete in the hopper and S-
valve with such auxiliary tools as shovels
and scratching stick fittings.
● Open the lower hopper gate, wash the
hopper inside and outside with water, and
close the gate after cleaning.
● Fill the hopper with water. Then run for 3
~ 4 strokes to make the residual concrete
be discharged with the water. Run for 20
min without load when the water is
drained. In this step, keep on supplying
lubricating grease.
● If the trailer-mounted concrete pump will
not be used for a period, it should be put
into the warehouse with maintenance
cleaning.
● Stop engine and cut off the power supply.

4-43
OPERATION
HBT6013C-5S

● Draw back the concrete piston to drain

the water tank. Dismount the piston to
clean it, and remount it after being
lubricated with lubricating grease.
● Clean all parts of the machine body, dry
them up, and spray engine oil. The
standard for cleanliness is: no concrete
block, mortar or muddy water on any part
of the machine body.

4.11Retracting the Outriggers

WARNING
Clear the work area of all personnel and
equipment before proceeding. Never
retract the outriggers before all operation
completed. Loss of control may occur,
resulting in equipment damage, personal
injury or death.

(1) Ensure that all clean-up operations are

complete.
(2) Unlock the hydraulic outriggers, and
operate the valve to retract them to make
the whole machine bent to the front and
the wheels touch the ground.
(3) Chock all wheels on both side of the
machine.
(4) Unlock the mechanical outriggers which
are leaving the ground, and retract them
back.
(5) When the wheels bearing the machine,
you can tow the trailer-mounted concrete
pump out of the worksite after moving off
the chocks.

Fig.4-55

4-44
 OPERATION
HBT6013C-5S

4.12Towing and Loading

The trailer-mounted concrete pump should be
transported and stored in accordance with
ISO 6749-1984. In addition, the following
precautions should be taken:

(1) Release the accumulator oil pressure

completely;
(2) Drain the water (including the oil water
cooler);
(3) Set all switches and operating handles at
the OFF position;
(4) Close and lock the doors and covers of
the control cabinet.

CAUTION
When the equipment is moving, prevent
the guiding wheel or the wheels from
pressing on your feet (see Fig. 4-8).

Fig.4-56

In case of site transition, the trailer-mounted

concrete pump should be loaded and
transported as follows:

4-45
OPERATION
HBT6013C-5S

(1) If the distance between the two worksites

is not more than 1000 m, fold and fix the
four outriggers before towing the
equipment away with a trailer at a speed
not more than 8 km/h (see Fig. 4-7).

trailer velocity (v”NPK)

Fig.4-57

(2) If the distance between the two worksites

is more than 1000 m, use a crane to load
the trailer-mounted concrete pump onto a
truck.
● Check whether the hook of the trailer-
mounted concrete pump (see Fig. 4-58)
and the sling of the crane are in good
condition;
● Check whether the lifting method is
correct (see Fig. 4-59). During lifting, no
person should stand under the trailer-
mounted concrete pump in case the sling
breaks abruptly and thereby hurts people.

Fig.4-58

4-46
 OPERATION
HBT6013C-5S

Fig.4-59

● The gravity center positions on the trailer-

mounted concrete pump and truck should
be the same in general.
● The truck should not carry things
irrelevant to the transportation of the
trailer-mounted concrete pump.
● The height, width and length of the load
should not exceed the values specified in
the local road traffic law.
● Since the gravity center of the trailer-
mounted concrete pump is relatively high,
keep traveling at a proper speed, and
decelerate at the time of turning to avoid
overturn. When passing through
underpasses, bridges, tunnels, or overhead
pipelines or cables, it is required to ensure
there is enough space and distance.
NOTE:It is forbidden towing the machine on
the road. This machine can only be
towed on the worksite. Please abide
by the local traffic code during
transportation and working.

4-47
OPERATION
HBT6013C-5S

4.13Machine Decals
It is important that all safety, alert and
warning decals are in place, not damaged,
covered or removed. It is also important for
the operator and all personnel involved to be
aware of the decal content and locations on
the equipment.

● Your SANY dealer can supply you with

new replacement decals if the ones on
the machine are damaged or missing.
Never modify or change existing decal
information unless authorized by your
SANY distributor.
● When replacing damaged or missing
decals, be sure they are placed in the
proper locations.
● Additional safety or warning decals may
be added to your machine if necessary.
Please see the decals on the machine for
details.

4-48
 OPERATION
HBT6013C-5S

4.13.1Locations of Safety Decals on The Complete Vehicle

1 8 9 13 12 11 10 14 15 16 17 18 25

24 20 19 7 6 5 4
26 23 22 21

2
A

27 A B
water box electrical box

28
30 35 31 32 29 33 34

Fig.4-59

4-49
OPERATION
HBT6013C-5S

4.13.2Decal Descriptions
Table 4-8 Decal Descriptions

No. Decal Callout

1 Caution of Loosened Bolt

2 Mark for Forbidden Operation on Hopper
3 Logo of Earcaps
4 Mark for Warning of Breakage of Oil Tube
5 Mark about Emission
6 Warning Mark for Danger of Splashing Concrete
7 Protective Mark on Swing Mechanism
8 Logo for Remote plug seat
9 Symbol of Emergency Stop Button
10 Mark for Oil Pressure of Main System
11 Mark for Agitating Oil Pressure
12 Mark for Oil Pressure of Swing Valve System
13 Indication of Oil Tank Lifting Point
14 Indication of total machine Lifting Point
15 Mark for Caution to Working on Equipment
16 Warning Mark for Hand Scald
17 Mark for Drawing in and Drawing out of Outriggers
18 Warning Mark for Outrigger Activation
19 Caution mark for Hand Injury
20 Caution Mark for Safety
21 Mark for Cooling Water Requirements
22 Namemark of Trailer-mounted Concrete Pump
23 Sign of Drainage valve
24 Caution of Loosened Bolt
25 Caution Mark for Delivery Pipe Breakage
26 Warning Mark for Feet Injury Due to guide wheel Pressing
27 Prohibition for Grip into the Water Box
28 Mark for Checking Piston Head

4-50
 OPERATION
HBT6013C-5S

Table 4-8 Decal Descriptions

No. Decal Callout

29 Smoking Prohibition
30 Sign of Rating Voltage of Plug
31 Mark for Self-sealing Device of Oil Tank
32 Warning Mark for Accumulator
33 Identification Mark on Hydraulic Oil Tank
34 Mark for Towing Bracket
35 Mark of main switch

4-51
OPERATION
HBT6013C-5S

4.13.3Detailed explanations

(1) Caution of Loosened Bolt I (see Fig. 4-60)

● It asks personnel to check the fastening

parts and screw down the bolts before it
works!

(2) Mark for Forbidden Operation on Hopper

(see Fig. 4-61)
● It indicates that it is forbidden to put Fig.4-60
hands into the hopper, touch the running
mixing device, step on the hopper, or to
open the grille during pumping.

Fig.4-61

(3) Logo of Earcaps (see Fig. 4-62)

● It reminds personnel to wear protective
articles such as earcaps during pumping
and comply with the safety regulations in
construction site.

11558272

Fig.4-62

4-52
 OPERATION
HBT6013C-5S

(4) Mark for Warning of Breakage of Oil

Tube (see Fig. 4-63)

● It warns personnel not to touch the

leaking hydraulic oil. Get medical
examination immediately if oil splashing
on skin.

Fig.4-63

(5) Mark about Emission (see Fig. 4-64)

● It indicates that cement dust is toxic, and

the lung protection should be used when
exposed to the dust.

Fig.4-64

(6) Warning Mark for Danger of Splashing

Concrete (see Fig. 4-65)

● It warns people to beware of the

splashing concrete during pumping to
avoid physical injury.

Fig.4-65

4-53
OPERATION
HBT6013C-5S

(7) Protective Mark on Swing Mechanism

(see Fig. 4-66)

● It prohibits personnel to touch the swing

mechanism when pumping.

Fig.4-66

(8) Logo for Remote plug seat (see Fig. 4-67)

● It indicates the plug seat for Remote
controller connecting.

Fig.4-67

(9) Symbol of Emergency Stop Button

ergen
(see Fig. 4-68)

● It is used to identify the button for

Em

cy

emergency stop.

Fig.4-68

(10)Mark for Oil Pressure of Main System

(see Fig. 4-69)
● It indicates the value displayed on the
corresponding instrument is the oil
pressure of main system.

Fig.4-69

4-54
 OPERATION
HBT6013C-5S

(11)Mark for Agitating Oil Pressure (see Fig.

4-70)

● It indicates the value displayed on the

corresponding instrument is the agitating
oil pressure.

Fig.4-70

(12)Mark for Oil Pressure of Swing Valve

System (see Fig. 4-71)

● It indicates the value displayed on the

corresponding instrument is the change-
over pressure.

Fig.4-71

(13)Indication of Oil Tank Lifting Point

(see Fig. 4-72)
● It indicates the corresponding position is
for hooking the Oil Tank.

Fig.4-72

4-55
OPERATION
HBT6013C-5S

(14)Indication of total machine Lifting Point

(see Fig. 4-73)
● It indicates the corresponding position is
for hooking the total machine.

Fig.4-73

(15)Mark for Caution to Working on

Equipment (see Fig. 4-74)
● It indicates that this equipment is remote
controlled and may start at any time.
Always stop engine before working on
equipment.

Fig.4-74

(16) Warning Mark for Hand Scald (see Fig. 4-

75)

● It warns personnel to beware of scald

caused by engine, oil tank or others.

Fig.4-75

4-56
 OPERATION
HBT6013C-5S

(17)Mark for Drawing in and Drawing out of

Outriggers (see Fig. 4-76)

● It indicates the operation for drawing in

and drawing out of outriggers.

Fig.4-76

(18)Warning Mark for Outrigger Activation

(see Fig. 4-77)

● It warns the personnel to clear area when

activating outriggers and take caution to
crushing hazard.

Fig.4-77

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OPERATION
HBT6013C-5S

(19)Caution mark for Hand Injury (see Fig. 4-

78)

● It warns personnel to beware of hand

injury when closing the electric control
cabinet door.

12379614

(20)Caution Mark for Safety (see Fig. 4-79)

● To use the trailer-mounted concrete Fig.4-78
pump, it is necessary to carefully read
the precautions shown on this mark.

Fig.4-79

4-58
 OPERATION
HBT6013C-5S

(21)Mark for Cooling Water Requirements

(see Fig. 4-80)
● It indicates the precautions for water
cooling of trailer-mounted concrete pump
which should be observed strictly.

Fig.4-80

(22)Namemark of Trailer-mounted Concrete

Pump (see Fig. 4-81)

● Such basic specifications for the trailer-

mounted concrete pump are shown on
the namemark: product type, brand, max.
theoretical displacement, max. theoretical
output pressure, engine rated power,
complete vehicle gross mass, overall
dimension, date of production, and
number.

Fig.4-81

(23)Sign of Drainage valve (see Fig. 4-82)

● It indicates the corresponding position

about the drainage valve.

Fig.4-82

4-59
OPERATION
HBT6013C-5S

(24)Caution of Loosened Bolt (see Fig. 4-83)

● It asks personnel to check the fastening
parts and screw down the bolts before it
works!

Fig.4-83

(25)Caution Mark for Delivery Pipe Breakage

(see Fig. 4-84)

● It instructs personnel to only use pipes

bearable for the max. delivery pressure of
the concrete pump, there is a risk of
injury from cracked pipes under a
pressure too high.

Fig.4-84

(26)Warning Mark for Feet Injury Due to

guide wheel Pressing (see Fig. 4-85)

● It calls attention to potential hand injury

caused by guide wheel crush.

Fig.4-85

4-60
 OPERATION
HBT6013C-5S

(27)Prohibition for Grip into the Water Box

(see Fig. 4-86)

● It prohibits personnel from griping into the

water box when the machine is working.

Fig.4-86

(28)Mark for Checking Piston Head (see Fig.

4-87)

● It reminds personnel to check piston

head before pumping each time and
when water is getting turbid.

Fig.4-87

(29)Smoking Prohibition (see Fig. 4-88)

● It is used to prohibit smoking near the
machine.

Fig.4-88

4-61
OPERATION
HBT6013C-5S

(30)Sign of Rating Voltage of Plug (see Fig.

4-89)

● It shows the rates of plug: the rating 24V 3A

voltage is 24 V and the rating current is
3A.
Fig.4-89

(31)Mark for Self-sealing Device of Oil Tank

(see Fig. 4-90)

● It indicates how to seal the hydraulic oil

to keep its cleanliness when checking
and repairing the trailer-mounted
concrete pump.

Fig.4-90

(32)Warning Mark for Accumulator (see Fig.

4-91)

● It indicates that, to avoid explosion, the

accumulator can be charged only with
nitrogen rather than other gases, and
specifies the nitrogen inflation pressure
should be 7 MPa~8 Mpa.

Fig.4-91

4-62
 OPERATION
HBT6013C-5S

(33)Identification Mark on Hydraulic Oil Tank

(see Fig. 4-92)

● It is used to identify the hydraulic oil tank.

Fig.4-92

(34)Mark for Towing Bracket (see Fig. 4-93)

● Towing force of the machine is below 60
kN.

Fig.4-93

(35)Mark of main switch (see Fig. 4-94)

● It indicates the main switch.

Fig.4-94

4-63
OPERATION
HBT6013C-5S

E
G
PA
K
AN
BL

4-64
 MAINTENANCE
HBT6013C-5S

5 MAINTENANCE
In order to guarantee normal operation of the
machine and avoid malfunctions affecting
construction, all inspection and maintenance
work should be earnestly carried out. Only in
this way, can the failure rate of product be
decreased, the service life of the machine be
prolonged, and the repair cost be reduced,
thus greater profits be achieved.

Fill the inspection card for future reference,

when carrying out maintenance work.

5.1 Routine Maintenance & Mandatory

Overhaul
Precautions for equipment overhaul as bellow
should be follow through the process of the
maintenance and inspection.

(1) Cleaning of Equipment

The equipment should be cleaned
completely before being delivered to
maintenance factory, to prevent the parts
of the machine from pollution and
damage due to the dirt on the equipment.

(2) Check of Machine

It is necessary to fully understand the
disassembly and assembly procedures to
prevent injury of personnel or damage of
the machine due to improper disassembly
and assembly of parts.

(3) Preparation of Cleaning Tools and

Disassembly & Assembly Site
(4) Precautions for Disassembly
a) Plug up the dismounted hydraulic
elements such as pipeline, pump and
valve in time to avoid entering of dirt.

5-1
MAINTENANCE
HBT6013C-5S

b) Before disassembling parts, clean them

at first and then disassemble them on the
workbench.
c) Before disassembling the hydraulic parts,
discharge the oil in them and collect the
oil with proper containers.
d) Do use special tools if required.
e) Place the dismounted parts in order and
mark them properly.
f) Carefully check each dismounted part for
damage, serious wear, etc, especially the
matching surface.
g) Measure and record the wear degree and
clearance.
(5) Precautions for Assembly
a) Clean all parts before assembly.
b) Check each part for damage. Any burr
should be removed.
c) Keep the contact surfaces or moving
surfaces clean.
d) The dismounted O-rings and seal rings
must be replaced, and new O-rings and
seal rings must be coated with
lubricating oil (grease) before being
mounted.
(6) Precautions for Maintenance Safety
a) Shut down the engine, release pressure
and cut off the power supply before
maintenance. Never allow unauthorized
person to carry out maintenance.
b) When lifting any part, please confirm the
lifting capacities of the equipment and
cable.
c) The maintenance must be carried out at
a special worksite by maintenance
personnel worn safety helmets.

5-2
 MAINTENANCE
HBT6013C-5S

d) If the top of the equipment needs

maintenance, an anti-slip ladder and a
mobile workbench must be prepared
according to EN14122 Safety Standard.
NOTE:This safety standard is of Europe
standard. If there are special
standards of local, please adopt the
local standards.

e) In case of overhaul, the equipment

should be operated only after being
checked by professional maintenance
personnel.
The routine maintenance and inspection is of
great importance for the normal operation of
the pump. Follow the Safety Inspection
Intervals (Table. 5-1), Maintenance Intervals
(Table. 5-2) and Mandatory Overhaul (Table.
5-3) during the maintenance process.

WARNING
You must follow the Safety Inspection
Intervals (Table. 5-1), Maintenance
Interv als (T able. 5-2) and M anda to ry
Overhaul (Table. 5-3) during the
maintenance process. The Manufacturer
accepts no liability for any safety accident
arising from the failure to perform due
mandatory overhaul.

5-3
MAINTENANCE
HBT6013C-5S

Table 5-1 Safety Inspection Intervals

Every...Hours of Operation
Assembly Action
Daily 100 500

Check main system pressure (28~32

Q
MPa)
Hydraulic
Check switching pressure (8~16 MPa) Q
system
Check agitator overflowing pressure
Q
(12 MPa)
Functional check on emergency stop
Q
Electrical button
system Check hopper grill limit switch for
Q
abnormity

5-4
 MAINTENANCE
HBT6013C-5S

Table 5-2 Maintenance Intervals

Every...Hours of Operation
Assembly Action
Daily 50 100 250 500 1000

Check air pressure of tyre, it is

Q
normally at 0.7~0.8MPa
Tyre
Check the installation bolt of tyre
Q
looseness
Wear check of concrete piston and
Q
guide ring

Check water tank for water level,

mortar leakage and solidly Q
eyewinker.Check water for
superfluous hydraulic oil
Check agitator motor for oil leakage
and agitator shaft for mortar leakage, Q
and agitator blade for wear
Pumping Check swing valve cylinder to the
mechanism end once
Q

Wear check of spectacle wear plate and

Q
cutting ring
Check clearance between cutting
Q
ring and end face of S-tube (≤ 4mm)
Check delivery cylinder for abnormal
Q
wear
Wear check of transitional bushing
Q
(not lower than delivery cylinder)
Check grease level in lubricating
Q
grease pump
Lubrication
system Check oil distributor for abnormity Q

Check lubrication of delivery cylinder Q

5-5
MAINTENANCE
HBT6013C-5S

Table 5-2 Maintenance Intervals

Every...Hours of Operation
Assembly Action
Daily 50 100 250 500 1000

Check hydraulic oil level and oil

Q
quality
Check indicator on hydraulic oil filter Q

Check hydraulic elements for oil

Q
leakage
Drain off accumulated water in
Q
hydraulic oil tank
Check and clean radiator blade Q

Q
or when
the
Hydraulic Replace hydraulic oil filter element indicator
system
turns
red
Clean oil suction filter element(new
Q
oil tank)
Replace oil suction filter
Q
element(new oil tank)
Q
Replace oil return filter element(new First Q
oil tank) time
Full hydraulic oil change Q

Clean oil tank Q

Check such threaded connectors as

Q
toggle switch for looseness
Check such connectors as fuse and
Q
relay for looseness
Electrical
system Check water tightness of remote
Q
control box
Check wiring for damage Q

Check solenoid valve for abnormity Q

5-6
 MAINTENANCE
HBT6013C-5S

Table 5-3 Motor Maintenance Intervals

Every...of Operation
Action
daily 50 125 250 500 1000 1500 2000

Check oil level of engine oil and

Q
pressure gauge reading(or alarm)
Check liquid level of coolant Q

Drain off accumulated water in fuel

Q
system(include oil-water separator)
Check oil/dry type air filter Q

Check for leakage Q

Q
Replace primary filter of diesel oil First Q
time
Q
Replace filter of diesel oil First Q
time
Q
Replace engine oil First Q
time
Q
Replace filter of engine oil First Q
time
Q
Check injector oil-return First
pipe(change it if necessary) time
Q
Check air valve clearance(adjust it First Q
if necessary) time
Q
Check engine suspension First Q
time
Q
Check V-belt First Q
time
Q
Check alarm equipment First
time
Q
Check fixed component First Q
time
Check Battery and wire Q

5-7
MAINTENANCE
HBT6013C-5S

Table 5-3 Motor Maintenance Intervals

Every...of Operation
Action
daily 50 125 250 500 1000 1500 2000

Check cooling system(wash it if

Q Q Q Q Q
necessary)
Replace filter of air Q

Chean radiator surface Q

Drain off water in diesel oil tank Q

Check coolant for Additive

Q
concentration
Check cooling medium for Additive
concentration(change it if Q

necessary)
Check hose connector,tube
Q
collar,air intake and inter-cooler
Check preheater plug Q

Q
Replace injector oil-return pipe or two
years
Q
Replace coolant or two
years

CAUTION
The running time during maintenance of
engine refers to the running time of
engine.
For the new or overhauled machine, the
o i l l e ve l o f e n gi n e m u st b e c h e ck e d
everyday and twice everyday during
wearing period.

5-8
 MAINTENANCE
HBT6013C-5S

CAUTION
When used in China, it suggests to
replace the engine oil, reduce the filtrating
time by half and use the cleaning diesel
oil when the working condition is bad, the
oil is dirty or the quality of oil doesn’t
meet the standard of SANY.

Table 5-4 Mandatory Overhaul

Every...of Operation
Assembly Action
1 Year 2 Years 5 Years

In accordance with the maintenance

Motor specifications specified by motor
manufacturer

Pumping
Replace seal of main oil cylinder
mechanism

Check and adjust main oil pump pressure

Check accumulator pressure and charge

nitrogen

Hydraulic system Replace seals of all oil cylinders (main oil

cylinder excluded)

Replace all hoses

Replace all O-rings

Electrical system Check wiring

NOTE:The actions in Mandatory Overhaul

shall be carried out by professional
maintenance personnel in workshops
or 6S shops authorized by SANY
Heavy Industry Co., Ltd.

5-9
MAINTENANCE
HBT6013C-5S

WARNING
For any safety accident caused by not
performing obliged overhaul in
time,manufacturer doesn’t take for any
responsibility.

5-10
 MAINTENANCE
HBT6013C-5S

In case of the following malfunctions (see

Table. 5-13), you should send the truck-
mounted concrete pump to the repair shop or
6S Shop appointed by SANY Heavy Industry
Co., Ltd. for overhaul.

Table 5-13 Overhaul Conditions

No. Item Overhaul Condition Remarks

When the main stressed members such as base structure

Main stressed is subject to destructive malfunctions and cannot be
1
members repaired by means of adjustment, repair welding or
reinforcement, over haul should be performed.
When the capabilities of placing, pumping and safety
2 Performance protection are reduced and cannot be recovered by such
means as adjustment, overhaul should be performed.

When the whole control system needs to be repaired

because the action of each mechanism is unavailable or
the performance parameters and technical indices are
3 Control system unacceptable due to the aging of hydraulic pipelines and
electric lines as well as the failure of hydraulic and
electrical elements after long-term use, overhaul should
be performed.

In case of traffic accidents, structure malfunctions,

contact with any fixed object or electric wire or overload of
4 Special events boom, if it is confirmed to be repairable after expert's
examination and safety assessment, overhaul should be
performed.

NOTE:In case of the above malfunctions, the

trailer-mounted concrete pump should
be repaired in time.

Every time after hydraulic element

replacement or repair, it is necessary to test
the pressure of each valve group and verify
the concrete suction efficiency (or named
mechanical control efficiency) η. If η ≥ 85%, it
is normal; otherwise, you should recheck the
working condition of each hydraulic element.

5-11
MAINTENANCE
HBT6013C-5S

The calculation is as follows:

The actual concrete output each stroke is
Q’=W/n
W-- total concrete output;
n -- strokes per minute.

The theoretical concrete output each stroke is

Q = πD2L/4
D -- bore of delivery cylinder;
L -- stroke of concrete piston.

Both of these parameter table in the section

Specifications.

The concrete suction efficiency is

η = Q’/Q=4w/πnD2L

5.2 General Tightening Torques

NOTICE
Looseness or breakage could occur if
fasteners, hose or line couplings are not
torqued to the specified value. If you will
be doing any repairs or service
procedures on this machine, always refer
to this table if the tightening torque value
is not listed or specified in the procedure.
Failure to do so could damage the
machine, shorten machine life or cause
premature system failure.

(1) Table. 5-13 gives the pretightening

torques of bolts with lubrication.

Table 5-13 Pretightening Torques of Bolts (with lubrication)

Strength Grade(8.8) Strength Grade(10.9) Strength Grade (12.9)

Thread
Specification Pretightening torque T Pretightening torque T Pretightening torque T
(N·m) (N·m) (N·m)

M8 23±2 34±2 39±2

M10 45±5 67±5 78±5

5-12
 MAINTENANCE
HBT6013C-5S

Table 5-13 Pretightening Torques of Bolts (with lubrication)

Strength Grade(8.8) Strength Grade(10.9) Strength Grade (12.9)

Thread
Specification Pretightening torque T Pretightening torque T Pretightening torque T
(N·m) (N·m) (N·m)

M12 85±5 118±8 137±8

M16 210±10 290±10 339±15

M20 408±15 568±18 666±18

M24 710±18 984±20 1147±25

M30 1410±25 1956±25 2280±25

M36 2470±30 3412±30 3988±30

(2) Table. 5-14 gives the pretightening

torques of bolts without lubrication.

Table 5-14 Pretightening Torques of Bolts (without lubrication)

Strength Grade(8.8) Strength Grade(10.9) Strength Grade(12.9)

Thread
Specification Pretightening torque T Pretightening torque T Pretightening torque T
(N·m) (N·m) (N·m)

M8×1 27±2 39±2 46±5

M10×1.25 52±5 76±5 90±5

M12×1.25 93±5 135±8 160±10

M12×1.5 89±5 130±8 155±10

M14×1.5 215±15 215±15 255±15

M16×1.5 225±15 330±18 390±18

M18×1.5 340±18 485±18 570±20

M20×1.5 475±20 680±25 790±25

M22×1.5 630±20 900±25 1050±30

M24×2 800±25 1150±30 1350±30

M27×2 1150±30 1650±30 1950±30

M30×2 1650±30 2350±30 2750±30

NOTE:Replace with a new bolt of the same

size and grade.
The above pretightening torques for
bolt connection are not applicable to
hydraulic pipe connectors.

5-13
MAINTENANCE
HBT6013C-5S

(3) Don't apply excessive force when

disassembling pipe connectors. When
tightening pipe connector, the pretightening
torques should be moderate, and just ensure
there is no leakage.
Table. 5-15 gives the pretightening torques of
common pipe connectors (rubber hose and
steel pipe).

Table 5-15 Pretightening Torques of Pipe Connectors

Pretightening Torque Pretightening Torque

No. Metric Thread No. Metric Thread
(N·m) (N·m)

1 M12×1.5 15~25 7 M24×1.5 60~88

2 M14×1.5 30~45 8 M26×1.5 85~125

3 M16×1.5 38~52 9 M30×2 115~155

4 M17×1.5 43~85 10 M36×2 140~192

5 M20×1.5 50~65 11 M42×2 210~270

6 M22×1.5 60~88 12 M45×2 255~325

Table. 5-16 gives the pretightening torques of

common pipe connectors (oil port).

Table 5-16 Pretightening Torques of Pipe Connectors (close to oil port)

Type B Seal
Type A Seal Type E Seal Type F Seal
(Metal Plain
(Metal Washer) (Elastic-ED) (O-ring)
Series Thread G Washer)

Pretightening Pretightening Pretightening Pretightening

Torque (N·m) Torque (N·m) Torque (N·m) Torque (N·m)
M10×1.0 9 18 18 15
M12×1.5 20 30 25 25
M14×1.5 35 45 45 35
M16×1.5 45 65 55 40
L M18×1.5 55 80 70 45
M20×1.5 65 140 125 60
M27×2 90 190 180 100
M33×2 150 340 310 160
M42×2 240 500 450 210

5-14
 MAINTENANCE
HBT6013C-5S

Table 5-16 Pretightening Torques of Pipe Connectors (close to oil port)

Type B Seal
Type A Seal Type E Seal Type F Seal
(Metal Plain
(Metal Washer) (Elastic-ED) (O-ring)
Series Thread G Washer)

Pretightening Pretightening Pretightening Pretightening

Torque (N·m) Torque (N·m) Torque (N·m) Torque (N·m)
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 70
S M20×1.5 55 150 125 80
M22×1.5 65 170 135 100
M27×2 90 270 180 170
M33×2 150 410 310 310
M42×2 240 540 450 330

NOTE: The allowable tolerance for the pretighting

torques in the two tables above is ± 10%.
L refers to light low-pressure pipe connec-
tor ; and S refers to heavy high-pressure
pipe cinnector.

5.3 Lubrication
The lubrication sustem comprises automatic and
manual lubrication.
handle
Autom atic lubricati o n
(1 ) Check and add lubricant to oil storage of Synchronizing lubricating Pressure regulating
grease port
overflow valve
double power lubrication pump (se e Fig. 5-1)
every time before start the machi ne.

(2 ) I f t he oil pressure is too low, please clean

t he pressure adjust ment reli ef valve , oil-
Circular lubricating grease port Drive oil port
outlet check valv e or exhaust air . Air-bleed valve

(3 ) I f t he double power lubric at ion pump is

used for the first time, or the lubricant is
Fi g. 5-1
exhausted . The pump may

5-15
MAINTENANCE
HBT6013C-5S

suck air and can’t pumping lubricant for along

time.
Loosen two air-bleed valves by screwing them
half circle ulnttihe air exhausting and the lubri-
cant comes out continuously with no air pocket.
Then lock the two valves.

NOTICE
Double power lubrication pump
should keep clean. Prevent dust and other
impurity entering. It is forbidden to
contact with the acid and alkali materials.

NOTE: Lubricant shoule be according with the

requirment and clean without impurity.
Calcium base grease (butter) is not com-
mendatory for its conglutination feature
may cause block of the lubrication line.

Manual lubrication

One lubricating oil cup (see Fig. 5-2) is adopted on

each of the two swing valve cylinder seats. Before
pumping, it is necessary to fill the oil cups with
grease and remove the cover should be turned
once every 4 hours for lubrication so as to keep
the spherical friction surface in good lubricating
condition.

NOTE: Calcium-based grease / butter is not

recommended for the lubrication sys-
tem, as it is easily cohered, leading
to blockage of lubrication pipeline.

Fi g. 5-2

5-16
 MAINTENANCE
HBT6013C-5S

5.4 Working Media

NOTICE
Collect the used functional fluids
carefully, and deal with the fluids properly
to prevent pollution of the environment.
Deal with the abandoned working media
according to the local regulations.

NOTE:If there are special standards of local,

please adopt the local standards.
5.4.1 Lubricating grease
NOTICE
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.

(1) Selection of lubricating oil

Adopt lubricating oil according to DIN51
825. Use lubricating oil according to
DIN51 502. For the trailer-mounted
concrete pump, the SANY special lithium-
based lubricating grease is adopted.

The NLGI grade requirement should

comply with DIN51 818. Customers can
select lubricating oil from the following
varieties recommended for this trailer-
mounted concrete pump according to
specific season.

● The “00” lithium-based lubricating grease

is used when the temperature of the
surroundings above 10°C;
● The “000” lithium-based lubricating
grease is used when the temperature of
the surroundings below 10°C.

5-17
MAINTENANCE
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NOTE:If there are special standards of local,

please adopt the local standards.

5.4.1 Lubricating grease

NOTICE
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.

(1) Selection of lubricating oil

Adopt lubricating oil according to DIN51
825. Use lubricating oil according to
DIN51 502. For the trailer-mounted
concrete pump, the SANY special lithium-
based lubricating grease is adopted.

The NLGI grade requirement should

comply with DIN51 818. Customers can
select lubricating oil from the following
varieties recommended for this trailer-
mounted concrete pump according to
specific season.

● The “00” lithium-based lubricating grease

is used when the temperature of the
surroundings above 10°C;
● The “000” lithium-based lubricating
grease is used when the temperature of
the surroundings below 10°C.

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(2) Precautions
Do not set the lubricating oil in air to
avoid deterioration resulting from
moisture absorption.
Do not mix the lubricating oil with other
oil for application.
SANY SPECIAL
Prevent the foreign substances and dust GREASE NO.00
getting into lubricating grease, and GENUINE PARTS

prevent the lubricating grease contacting

with alkali or acid substances.
The special lithium-based grease for SANY is
preferred, as shown in Fig. 5-1.
Fig.5-1
5.4.2 Hydraulic oil
(1) Selection of hydraulic oil
Adopt hydraulic oil according to Part 2 of
DIN51 524. Use the hydraulic oil
according to DIN51 502. For the trailer-
mounted concrete pump, the SANY
special hydraulic oil is adopted.
Standard for viscosity grade is DIN51
519. Customers can select hydraulic oil
complying with the requirements by this
trailer-mounted concrete pump according
to local conditions. Refer to the following
for the viscosity of hydraulic oil required
by this trailer-mounted concrete pump:
● ISO VG32 (W) applicable in central
Europe in winter
● ISO VG46 (S) applicable in central Europe
and surrounding districts in summer
● ISO VG68 (S) applicable in tropic or high-
temperature districts
For the recommended hydraulic oil models
under different ambient temperatures, see
Table. 5-17.

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Table 5-17 Recommended Hydraulic Oil

Applicable
temperature °C
-40 -30 -20 -10 0 10 20 30 40 50
Grade

32# SANY special high-grade

anti-wear hydraulic oil

Equivis ZS 46S

68# SANY special high-grade

anti-wear hydraulic oil

● The hydraulic oil adopted for the hydraulic

system is mineral hydraulic oil (HLP46),
biodegradable hydraulic oil (HLP-E46)
based on synthetic ester or apyrous
h y d ra ul i c o i l ( H F C 4 6 ) . T h e o r i g i n a l
hydraulic oil in the machine is Equivis ZS
46S.
● In hot regions (air temperature exceeds
35°C), it is recommended to use Equivis
ZS 46S.
● In cold regions (air temperature is lower
than 10°C), please preheat the hydraulic
oil before starting the machine for
concrete pumping. It is recommended to
use 32# SANY special high-grade anti-
wear hydraulic oil.

(2) Precautions
The hydraulic oil can not be mixed for
application.
It is forbidden to use the hydraulic oil with
additives such as molybdenum to prevent
damage of bearing.
Thoroughly replace the hydraulic oil with
the residual hydraulic oil in hydraulic
system less than 2%.
Preheat the hydraulic oil when the
temperature is lower than 20°C.

(3) Preheating of hydraulic oil

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NOTE:When the hydraulic oil temperature is

lower than 20°C, it is required to
preheat the hydraulic oil to ensure the
safety of hydraulic system. Only after
the hydraulic oil is preheated, can the
pumping be carried out.

Start the engine and run it at idle speed

f o r 5 - 1 0 m i n w i t h o u t l o ad , a n d t h e n
increase the engine speed to 1200-1400r/
min and have it run at this speed for
10min or more, so as to make the
hydraulic oil temperature exceed 20°C.
The preheating time can be adjusted
properly according to local environment.
(4) Control for hydraulic oil pollution
During maintenance, wash the system or
elements with large flow or high temperature
(80°C) hydraulic oil. Keep the elements
moving and knock the welded seams and
connecting parts with a copper hammer.
Prevent the pollutant from getting into the
oil. Fill the new hydraulic oil into the
system through oil filter after staying still
for several days; check the dust-proof
seal at the piston rod end frequently and
replace it periodically.
Control the temperature of hydraulic oil
lower than 65°C.
● Replace hydraulic oil periodically.
● Replace hydraulic oil for the first time
after 1000 h of operation;
● Replace it for the second time after 2000
h of operation, and then replace it once
per 2000 h;
● Later, replace the hydraulic oil at least once
per 2000 h, or even if the operation period is
less than 2000 h, replace it every two years.

After discharge the waste oil through the

drainage valve at the bottom of hydraulic

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After discharge the waste oil through the

drainage valve at the bottom of hydraulic
oil tank. Drain the waste oil from the
hydraulic oil tank with a pumping unit (so
that the cleanliness can be maintained).
Add new hydraulic oil through the quick
connector in hydraulic oil tank.

5.5 Visual Check

Before you commence any maintenance work,
you must carry out visual checks that this
maintenance card describes. The service intervals
can be find in the maintenance summary. The
check should be carried out by qualified personnel
and the results should be carefully recorded and
kept. The potential risk of equipment found in
checking process should be handled.

DANGER
You should particularly closely and
carefully check the electrical cables. There
is a danger of overvoltage 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.

5.5.1 General check

The followings items must always be checked
before operation of this machine.
(1) Check the level of working liquid.
● Hydraulic oil level in the hydraulic oil
tank;
● The volume of lubricating grease in the
lubrication device.
● Cooling water level in the washing room.
(2) Check whether all safety equipment are
in position and functioning well.
● Check whether each kind of warning
board is in good condition;

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● Check whether each safety auxiliary device

is in good condition (e.g. whether the hopper
screen can be used still, whether the cover
plate of the washing room is undamaged,
whether the outriggers are unfolded fully and
padded as required, etc.).

5.5.2 Check the hydraulic system

(1) Check all the hydraulic rubber hoses for
leakage;
(2) Check all the hydraulic connectors fixed
with screws for looseness and leakage;
(3) Check the oil filter for blockage. Start the
machine and idle the hydraulic system;
and then observe the indicator of the oil
filter. If the indicator points to the red
area, it indicates that the oil filter is
blocked and should be replaced at once.

5.5.3 Check the electrical system

(1) Check whether all the electrical connectors
are firm and rustless;
(2) Check the electrical circuit for open circuit;
(3) Check the insulators on the wires for 1
aging and peeling.

5.6 Pumping System

Before pumping, check if there is foreign
substances in the hopper, fit the screen and
fill the washing room with clean water. When
the ambient temperature is lower than 10°C,
add 1/3 clean hydraulic oil to improve the
lubrication effect.

During pumping, grille limiting clamp plate

(see Fig. 5-2) on the hopper near the front
Fig.5-2
plate must be in limiting state to make the
grille not to move freely.
1. Grille Limiting Clamp Plate

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After pumping, screw off the water-drain ball

valve to drain the water in the washing room
and retract the piston head for cleaning and
checking.

Keep the washing room clean. Any accumulated

dirt on the oil cylinder piston rod is forbidden.

During forward or reverse pumping, if the

water in the washing room gets turbid, shut
down the machine and check the concrete
seal body immediately.

If the water temperature is over high during

pumping, please replace the water with fresh
one in time.
NOTE:In winter, drain the water in the
washing room after working to avoid
freezing. It is forbidden to add
lubricating grease such as lithium-
based grease into the washing room;
otherwise, the hydraulic system may
easily be polluted, leading to frequent
damage.

5.6.1 Concrete piston

Check the lubrication of the concrete piston
once every week. Disconnect the two
lubricating oil pipes on the delivery cylinder to
check whether there is new oil dropping.
The broken concrete seal body must be
replaced immediately. If continue running, it
may lead to scratch of the delivery cylinder
and increase of maintenance cost and time.
After checking the concrete piston, coating
the concrete seal body and guide ring on the
concrete piston with lithium-based grease for
lubrication can extend the service life of the
concrete piston effectively.
Do not use any hard object or poisonous
detergent to wash the delivery cylinder, as it
may damage the chromium coating.

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Over view
The concrete piston mainly consists of
concrete seal body, piston body, pressure
plate, connecting rod, connecting disc and
several sealing elements. Fig. 3-3 gives the
specific structure.

3
7
3
12

11

2
3
1

7
5 3

8
9
10

Fig.5-3 Structure of Piston Head

1. Connecting rod 5. Piston body 9. O-ring 92.5×3.55

2. Screw M16×50 6. Concrete seal body 10.Pressure plate
3. Washer 7. Screw M16×35 11.Connecting disc
4. Guide ring 8. O-ring 125×3.55 12.Screw M16×45

Pre-inspection procedures
(1) Unscrew the water-drain ball valve to
drain the water in the washing room.

(2) Remove the washing room cover and

unscrew the screws on the connecting
disc.

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(3) Pull the concrete piston into the wash

room.
Hold the switch which is shown in Fig. 5-
4 in the EXIT position until the concrete
piston is completely in the wash room.
Keep

Exit Reset
NOTE:This function will position the concrete
piston in the wash box for inspection 

or removal.

(4) Once the concrete piston is in the wash

I O
+ -

box, release switch and allow it to return RPM+ RPM-

I O I O

to the KEEP position.

Fig.5-4

(5) Inspect the condition of the piston seals

b
(b) for extensive wear or damage. If
extensive wear or damage to the piston
seals (b) are found, the piston assembly
needs to be replaced. Follow the
replacement procedures listed below.
(See Fig. 5-5 for the location of (b).)

NOTE:When inspecting piston seals, always

keep in mind both concrete pistons
must be inspected. Follow the
Fig.5-5
procedures outlined underlying for
each concrete piston.

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Disassembly of the concrete piston

(1) During replacement, the pressure oil of
the accumulator should be unloaded
(see Fig. 5-6).

2 4

1 3

Fig.5-6
1. Main valve block
2. Unloading ball valve of accumulator
3. Accumulator
4. Oil tank

(2) The unloading ball valve of accumulator

is installed under the accumulator. Locate
the valve as shown in Fig. 5-7, to open
CLOSED
the unloading ball valve in order to
release the pressure oil in the
accumulator. Maintenance will be more
convenient. OPEN

WARNING
Failure to set the unloading ball valve in Fig.5-7
the OPEN position could result in
unexpected movement of the concrete
piston during service procedures.
Unexpected movement of a component
could result in serious injury.

(3) Shut down the engine and cut off the

power to avoid unauthorized starting.

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(4) Remove the fastening screw of pressure

plate. Take out the piston body, concrete
seal body (see Fig. 5-8), guide ring, O-
ring etc. Replace the worn or damaged
piston assembly.
(5) Clean and maintain other spare parts.
Assembly of the concrete piston
(1) Coat the O-ring and concrete seal body
with grease, and then fit the O-ring in the
pressure plate groove and the concrete
seal body in the pressure plate.
Fig.5-8
(2) Mount the dust-proof ring into the
connecting rod.
(3) Coat the guide ring with grease, and then
mount it on the piston body; later, fit the
piston body on the pressure plate.

(4) Fix the connecting rod, piston body and

pressure plate firmly with M16 x 50
screws and washers. The tightening
torques of the screws are 200±10 N·m.
NOTE:Before placing the concrete piston in the
washing room, you can put the concrete
piston on a wood block with moderate
thickness and size and then connect it
with the main oil cylinder piston rod.
After the concrete piston is mounted in
position, take out the wood block.

(5) Mount the connecting disc onto the piston

rod of oil cylinder.
(6) Place the concrete piston in the washing
room, and then fit the connecting disc
with the piston rod tightly after alignment.
Mount the concrete piston onto the piston
rod of main oil cylinder.
(7) Mount the connecting disc outer ring
screws, and then tighten the screws.

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(8) Coat the concrete seal body, guide ring

and seal ring on the concrete piston with
lubricating grease fully.
(9) Rotate the unloading ball valve to the
CLOSED position as shown in Fig. 5-7.
(10)Start engine and holding the “Piston
adjust switch” in the RESET position to
insert concrete piston back into the
delivery cylinder (see Fig. 5-4).
(11)Once the piston is in the delivery
cylinder, release “Piston adjust switch”
and allow it return to the KEEP position
(see Fig. 5-4).
(12)After replacing one concrete piston, start
the trailer-mounted concrete pump to
pump air once or twice. Next, replace the
other concrete piston.
(13)Screw down the water-drain ball valve
and fill the washing room with water, and
then fit the washing room cover plate on
the washing room.
If necessary, contact your SANY distributor
for repair procedures.

5.6.2 Glasses plate and cutting ring

maintenance
Check the clearance between the cutting ring
and glasses plate every day. Check the
wearing degree of the cutting ring. As the
cutting ring cuts concrete at the both sides
along its motion direction with the S-valve
reciprocating, it is easily subject to wear.
However, the wear only occurs at the wearing
surfacing welding electrode that is used for
protecting the hard alloy. If finding the cutting
ring is worn to a certain degree, please rotate
the cutting ring for 90 degrees in time, by
which the service life of the cutting ring can
be prolonged.

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In case of the following conditions, the

glasses plate and cutting ring are required to
be replaced.

(1) The clearance between the glasses plate

and cutting ring can be adjusted by screwing
in/out the abnormity nut on the rocker arm.
(2) After several times of clearance adjustment,
the abnormity nut has been reached to its
limit and can't be adjusted any more, but if
the clearance is still big and affects normal
pumping (or there is water jetting out during
cleaning), it is considered to replace the
cutting ring if the glasses plate is subject to
little wear, or the glasses plate if the cutting
ring is subject to little wear, or both of them
if they are subject to wear.
NOTE:Generally, the service life of cutting
ring is half of that of glasses plate.

(3) In case of overhaul, both the glasses

plate and cutting ring should be replaced.

Over view
Fig. 5-9 and Fig. 5-10 show the outline of the
cutting ring and the glasses plate. Fig.5-9 Outline of Cutting Ring

Disassembly of Glasses Plate and Cutting Ring

(1) Release the pressure, shut down the
engine and cut off the power.
Open the unloading ball valve of
accumulator to release the pressure of
pressure oil in accumulator.

Shut down the engine and cut off the

power to avoid unauthorized starting.

Fig.5-10 Outline of Glasses Plate

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(2) Dismount the limiting screws (see Fig. 5-

11) for tightening the rocker arm and 1 2
abnormity nuts, loosen the abnormity
nuts and hold them for 2~3 threads
instead of retracting them completely.

NOTE: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 Fig.5-11
installation position of S-tube can be
recovered after disassembling the front 1. Abnormity nut
and rear bearing seats and swing 2. Limiting screw
cylinder system.

(3) Loosen the connecting screws between

the discharge outlet and bearing seat,
and then dismount the discharge outlet
(see Fig. 5-12).
(4) Use a lever to pry the S-valve in the
hopper to make the S-valve move
towards the discharge outlet for about
30mm. At this time, a clearance of 30mm
exists between the glasses plate and
cutting ring.
2
(5) Knock the flange edge of the cutting ring 1
with a copper bar, take out the cutting
ring from the clearance and then the 4 3
rubber spring.
To take out the glasses plate, just Fig.5-12
dismount the fixing screws for the 1. Bolt 3. Hopper
glasses plate and hopper. 2. Washer 4. -Discharge outlet
(6) Clean and maintain the assembly positions
of the glasses plate and cutting ring.

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Assembly of glasses plate and cutting ring

(1) Coat the new rubber spring with
lubricating grease, and then fit it into the
S-tube (see Fig. 5-13).
1
(2) Coat the cutting ring with lubricating 2
3
grease, and then fit it into the S-tube. 4
5
6
(3) Coat the glasses plate with lubricating
grease, and then fit it to the
Fig.5-13
corresponding position in hopper. The
mounted glasses plate must be even, 1. Bolt 4. Cutting ring
and the clearance between the glasses 2. Washer 5. Rubber spring
plate and the junction surface of hopper 3. Glasses plate 6. S-tube assembly
should not be more than 0.1mm.
NOTE:Check whether the transitional bushing
goes beyond the mounting surface of
glasses plate on hopper. If yes, it will
easily lead to deformation of the
glasses plate.

(4) Tighten the abnormity nuts and make the

S-tube move toward the swing
mechanism until the cutting ring clings to
the glasses plate. Measure the clearance
between the cutting ring and the end face 1 2 3
of S-tube, which should be more than
4mm at this time. Continue tightening the
abnormity nuts slowly until the clearance 4
becomes 4mm (see Fig. 5-14).
(5) Connect the abnormity nuts and the
rocker arm with limiting screws to avoid
rotation of the abnormity nuts. 5
4mm
(6) Mount the discharge outlet properly and 6
tighten the screws.
Fig.5-14
5.6.3 Mixing shaft and mixing blade
1. S-tube assembly 4. Glasses plate
maintenance
2. Rubber spring 5. Screw
Check the mixing shaft for tightness from the
3. Cutting ring 6. Hopper
observation hole at the mixing motor seat
every day.

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Check the mixing blade for wear, as the wear


of mixing blade will lower the material suction 
capacity and increase the accumulated 

material at the bottom of the hopper. In this

case, please replace the mixing blade in time
(see Fig. 5-15) or reinforce it.
NOTE:To apply surfacing welding to the mixing 

blade, keep the distance between the
blade and any position of the hopper 

wall not less than 5cm. Otherwise, it will
cause the hopper to be worn out. 

When mounting the left and right mixing Fig.5-15

blades, pay attention to their installation 1. Mixing shaft 4. Bolt
directions and don't install them reversely. 2. Left mixing blade 5. Gasket
5.6.4 S-tube 3. Right mixing blade 6. Gasket
7. Nut
Replace the S-tube in the following cases:
(1) The S-tube is about to wear out or is
already damaged;
(2) The thickness of S-tube measured by a
thickness indicator in the course of
overhaul is less than 10mm.
While replacing the S-tube, check the
wear condition of such wearing parts as
glasses plate, cutting ring, wearing sleeve
and transitional bushing. If necessary,
replace them as well.
The special tools for mounting and
dismounting the S-tube: bearing assembling
tool and runout measuring apparatus.
NOTE:When a system is disassembled, all
rubber sealing elements should be
replaced and other spare parts in the
system should be subject to cleaning
and maintenance.
Neither small nor large clearance
between the glasses plate and cutting
ring is acceptable. The clearance
between the cutting ring and the end
face of S-tube should be 4mm when
the pumping pressure is properly built
up and there is no pressure difference.

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Over view

1
2
3
4
5
8
6

Fig.5-16
1. Transitional bushing 5. Glasses plate
2. O-ring 6. Cutting ring
3. Bolt 7. Rubber spring
4. Washer 8. S-tube assembly

Disassembly of S-tube
(1) Disassemble the mixing system:
a) Shut down the engine, cut off the power
and release the pressure.
Open the unloading ball valve of
accumulator to release the pressure of
the accumulator pressure oil.
Shut down the engine and cut off the
power to avoid unauthorized startup.
b) Take off the screen, loosen the mounting
screw of mixing blade and dismount the
mixing blade.
c) Dismount the lubricating tube as well as
the three oil tube connectors connecting
to the mixing motor (see Fig. 5-17).

Fig.5-17

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d) Loosen the fastening screws between the

mixing motor seat and hopper. Dismount
the motor seat, motor and water catcher
(seeFig. 5-18 and Fig. 5-19).

e) Loosen the fixing screws on the end

covers at both outer ends of the hopper
to dismount the end covers.

f) Loosen the fixing screws of bearing seat

and dismount the bearing seat.

g) Loosen the M5 screws at both inner ends

of the hopper to dismount the pressure
rings and set the seal retainer ring
clinging to the shaft shoulder.

h) Loosen the fastening screws on the seal cover

and hopper at both outer ends of the hopper.

i) Use a copper bar to knock the mixing shaft

at the side with motor to let the mixing shaft
move to the other side. Thus, the seal
cover at the other side will be pushed out
from the hopper hole by the shaft shoulder.
Take off the seal cover.

j) Push out the seal cover at the other side

by the same method.

k) Push the mixing shaft to one side and

take it out form the hopper.

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18
14
13 11
15
17
16
29

23
30
20
21

19
7
28 24
3
8
26
27
5 6
25
22
9

10 1 2
3
4
12

Fig.5-18

1. Bearing seat 11.Bolt M8×16 21.Pressure ring

2. Bolt M12×35 12.Seal ring 22.Roller bearing
3. Washer 12 13.Seal cover 23.Motor seat
4. O-ring 14.Packing plate 24.Bolt M12×40
5. Packing plate 15.J-type dust-proof ring 25.Retainer ring
6. Screw M8×20 16.O-ring 26.Felt ring
7. Rubber plug 17.Shaft sleeve 27.End sealing cover
8. Water catcher 18.Scew M5×8 28.Spline housing
9. Base ring 19.Screw M5×12 29.Motor
10.Imitated seal ring 20.Seal retainer ring 30.Screw M10×90

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18
17
16
14
15
4 28
13
1
3 22
2
12
11 21
8
10
9
5
7
6
27
24
26
25

23

19
20

Fig.5-19

1. Bearing seat 11.Roller bearing 21.Left mixing blade

2. Bolt M12×35 12.Base ring 22.Mixing shaft
3. Washer 12 13.Imitated seal ring 23.Screw M5×8
4. O-ring 150×3.55 14.Bolt M8×16 24.Screw M5×12
5. Packing plate 15.Seal ring 25.Seal retainer ring
6. Screw M8×20 16.Seal cover 26.Pressure ring
7. End cover 17.Packing plate 27.Rubber plug
8. Shaft end pressure plate 18.J-type dust-proof ring 28.Right mixing blade
9. Bolt M8×25 19.O-ring 46.2×2.65
10.Washer 8 20.Shaft sleeve

(2) Dismount the discharge outlet and

bearing seat (see Fig. 5-20).
a) Dismount the two lubricating grease
tubes on the bearing seat;

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b) Loosen the screw connecting the

discharge outlet and bearing seat, and
dismount the discharge outlet;
c) Loosen the pressure ring screws in the
hopper and dismount the pressure ring;
d) Use a crane and flexible cable to lift the
S-tube;
e) Use two long bolts to push out the
bearing seat and dismount it.

16

15
18
17
14 23
10
24
13
7 9
12
6
8 22
21
6
6
5

11
4
3

2
1
19

20

Fig.5-20

1. Screw M24 9. J-type dust-proof ring 17.Washer

2. Washer 10.S-tube AS 18.Screw M16
3. Material outlet 11.screw plug 19.M24 Protective rubber sleeve
4. O-ring 12.Rubber spring 20. screw plug
5. Bearing seat 13.Cutting ring 21.Screw M8
6. Yx-type seal ring 14.glasses plate 22.Screw plug
7. wearing sleeve 15.O-ring 23.Pressure plat
8. Bearing 16.Transition sleeve 24. Rubber pad

(3) Dismount the rocker arm and small

bearing seat (see Fig. 5-21 and Fig. 5-
22):

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a) Dismount the ball head baffle and limit

baffle. Take the piston rod of swing valve
cylinder out from the upper ball bearing;
b) Loosen the limit screws fastening the
rocker arm and abnormity nut, and take
off the abnormity nut;
c) Dismount the ball head baffle connecting
the rocker arm and swing valve cylinder;
d) Dismount the two lubricating grease
tubes on the bearing seat;
e) Loosen the screws connecting the
bearing seat and hopper at the end of
rocker arm. Use two bolts to push out the
bearing seat and take it off.

4 1
1
9 11
5
12
7 9
5
3 4
15
13
2 8
6

10 3 4

5 1
14
7

6
2
15

Fig.5-21

1. Oil cup M8x1 6. Lower ball bearing 11. Conversion joint

2. Bearing plat 7. Limit baffle 12. Washer 16
3. Screw M8x16 8. Left swing valve cylinder 13. Upper ball bearing
4. Screw M8x16 9. Ball head baffle 14. Right swing valve cylinder
5. Washer 8 10. Rocker arm 15. Bolt M16x20

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8 9 10
7
6
3
11
12
2
1 13
14
5
4

16 15
17

Fig.5-22

1. O-ring (I) 8.Abnormity nut 15. Pressure ring

2. Bearing 9.Washer (II) 16. Screw M5
3. Bearing Seat 10.Screw M8 17.Rubber plug
4. Washer (I) 11. Seal ring
5. Screw M12 12. Dust-proof ring
6. End bearing sleeve 13.O-ring (III)
7. O-ring (II) 14. Rubber pad

(4) Lift out the S-tube and maintain other

wearing parts (see Fig. 5-23):
a) Use a lever to pry the S-tube towards the
discharge outlet, move it to the small
shaft and separate it from the hopper;
b) If necessary, dismount the scraper bolts
at the bottom of the S-tube and take off
the scraper;
c) Adjust the small shaft end of S-tube and
lift the S-tube out from the hopper;

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d) Use a copper bar to knock the flange of

cutting ring and take out the cutting ring
from the clearance, and then take out
and replace the rubber spring;
e) Dismount the fastening bolts of glasses
plate and take out the glasses plate;
f) Check the transitional bushing connecting
with the delivery cylinder and replace it if
necessary;
g) Check the wearing sleeve at the
discharge outlet of S-tube and replace it
if necessary.

1
2
3
4
5
8
6

Fig.5-23
1. Transitional bushing 5. Glasses plate
2. O-ring 6. Cutting ring
3. Bolt 7. Rubber spring
4. Washer 8. S-tube assembly

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(5) Replace the wearing sleeve (see Fig. 5-

24):
If only the wearing sleeve is seriously
1
abraded, replace it separately.
2
Dismount the S-tube before replacing the
wearing sleeve.

a) Dismount the wearing sleeve:

Cut the wearing sleeve on the S-tube into
half with an angle grinder and take them off. Fig.5-24

1. S-tube 2. Wearing sleeve

NOTE:Do not damage the S-tube when
cutting the wearing sleeve or you need
to change a new one.

b) Mount the wearing sleeve:

Heat the wearing sleeve with a heater at
200~210°C for about 10min.

Properly mount the heated wearing

sleeve onto the straight tube of S-tube.

NOTE:Don't heat the wearing sleeve at too

high temperature.
If the heater is not available, put the
wearing sleeve into an appropriate
container, fill diesel oil to a level higher
than the wearing sleeve, and heat it at
200~210°C for about 10min.
The heating temperature should not be
too high. Pay attention to avoid fire.
Don't heat the wearing sleeve directly
with flame.
NOTE:When mounting the wearing sleeve, its
inner groove should face the big end
of S-tube while the o uter g roove
should face the small end or the
pumping operation will be affected.

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Assembly of S-tube
(1) Assembly of S-tube and Swing Mechanism
a) Mount the wearing sleeve onto the
straight tube of S-tube.
b) Lift the S-tube with a crane and flexible
cable. Fit the rubber pads onto both
ends. Adjust the S-tube to the slanting
side and lower it into the hopper. First,
set the outlet hole of S-tube into the
mounting hole on the discharge outlet of
hopper; push it to the end, and then set
the small shaft of S-tube into the
mounting hole of hopper. Mount the
rubber spring and cutting ring applied
with some lubricating grease onto the S-
tube.
c) Replace the YX-type seal ring, J-type
dust-proof ring, dust-proof ring and seal
ring; apply lubricating grease on the
sealing elements, bearing as well as the
inside and outside of the bearing seat;
mount the nylon bearing, YX-type seal
ring and J-type dust-proof ring on the big
bearing seat at the outlet (see Fig. 5-20).
Mount the bearing, dust-proof ring and
seal ring onto the small bearing seat (see
see Fig. 5-22).

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.

d) Mount the small bearing seat into the

hopper hole, set the two lubricating
grease filling holes at 15° above the
horizontal, and then mount the lubricating
oil tube and connector.

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e) Apply lubricating grease on the O-ring

and set it into the end bearing sleeve;
mount spline teeth and use a copper bar
to fit the end bearing sleeve at one end
of the small shaft into the bearing seat
hole from the outside of the hopper.
f) Mount the rocker arm onto the bearing
end of S-tube.

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. 5-25).
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.

2 1

$

Fig.5-25

1. S-tube 2. Rocker arm

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g) After mounting the swing valve cylinder,

mount the ball head baffle and limit baffle.
h) Mount O-ring on the end groove of
abnormity nut, and screw the abnormity nut
on the spline shaft of S-tube till the
clearance between the S-tube end face and
cutting ring is about 4mm. Align the notch
on the abnormity nut with the screw hole
on the rocker arm. Mount the limit screw.
i) Coat the straight part of S-tube with
sealant, and then fit the wearing sleeve
into the straight part of S-tube at the
outlet end from the outside of hopper.
j) Apply lubricating grease on the inside
and outside of the big bearing seat.
Mount the big bearing seat between the
hopper hole and S-tube, set the two
lubricating grease filling holes at 15°
above the horizontal, and then mount the
lubricating oil tube and tube connector.
k) Mount the pressure ring at the inside of
hopper and screw down its screws to
fasten the rubber pad.
l) Finally, fasten the discharge outlet at the
outside of hopper with M24×160 screws
with a tightening torque of 650±18N.m.
(2) Assembly of Mixing System
a) Apply lubricating grease on the O-rings,
and mount the O-ring into the seal ring
groove at each end of the mixing shaft.
Set the seal retainer rings onto the shaft
shoulders at both ends, and then mount
the mixing shaft into the hopper shaft hole.
b) Mount the lip-like seal ring with inner
frame and the dust-proof ring (applied
with lubricating grease) into the seal
cover. Mount the assembled seal cover
into the hopper hole, and fix it with
M8×16 bolts.

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c) Mount two shaft sleeves from the shaft

end and align the notches with the M5
screw holes on the shaft. Fasten them
with M5×8 screws (applied with sealant).
d) Mount O-rings, imitated seal rings and
base rings (applied with lubricating grease)
onto the two bearing seats, and fix the
bearing seats onto the end faces with
M12×35 bolts (applied with sealant on the
surfaces) and washers. The lubricating
holes on the bearing seats should face the
lower rear side.
e) Use bearing assembling tools to mount
the roller bearings into the bearing seats
at both sides.
f) At the side without motor, fix the shaft end
pressure plate with screws and then mount
the end cover; while at the side with motor,
mount the seal ring applied with grease into
end cover and then mount the end sealing
cover and water catcher onto the mixing
shaft.Mount the motor seat: mount the motor
seat on the right plate flange of the hopper
with the mounting groove of lubrication
grease filling tube facing right lower side; fix
it with M12×40 bolts and spring washers
strictly as per the tightening sequence.
g) Measure the runout: measure the runout error
of the mounting hole and end face of motor
seat to the center line of mixing shaft. The
max. allowable radial runout is 0.32mm and
the max. allowable end-face runout is 0.16mm.
This may be achieved by adjustment.
h) Mount the spline housing: coat the inner and
outer spline teeth with lubricating grease and
set the spline housing onto the spline shaft.
Make sure the axial clearance between the
spline shaft, spline housing and the inner
end face of hydraulic motor spline hole is
2~3mm. Pretightening is not allowed.

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i) Mount hydraulic motor: align the hydraulic

motor with the spline and mount it on the
motor seat; fix the motor with M10×90
screws strictly as per the tightening
sequence.
j) Finally, mount the mixing blade. Fix the
auger blade on the mixing shaft with
M16×65 bolts (thread cleaned, dried and
applied with sealant), spring washers and
nuts.

5.6.5 Hopper
The regular check and maintenance of
hopper and its relative spare parts may
effectively prevent abnormal wear of hopper.

(1) After pumping, clean the hopper

completely. Any accumulated material in
the hopper may cause the lower part of
the S-tube to be worn or even worn out
and scrapped.
(2) After pumping each time, clean the
concave in the S-tube to prevent pipe
blockage during next pumping.
(3) The transitional part between the glasses
plate and delivery cylinder is provided
with transitional bushing which should be
checked frequently. In case of severe Fig.5-26
wear, it will be lower than the delivery
cylinder. At this time, please replace the
transitional bushing in time. Otherwise, it
may affect the service life of the delivery
cylinder.
(4) It is forbidden to wrap the mixing motor.
Check the mixing motor seat for mortar
leakage from the observation hole every
day.

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5.6.6 Delivery cylinder

If the mortar leakage occurs but the concrete
piston is fine, check the delivery cylinder
(see Fig. 5-27) for wear and scratch, because
the delivery cylinder works in severe
conditions and rubs against the concrete for a
long time.

Check the scratched parts and damage

degree with lighting when the engine has
been shut down and the mixing cut-off valve
has been closed. Fig.5-27

5.6.7 Delivery pipe

Before pumping each day or each time,
visually check the delivery pipe and clamp. In
1 2 3
case of any mortar leakage at the clamp,
check the wear condition of the rubber seal
ring inside the connector. Replace it in time
as needed to avoid pipe blockage as a result
of mortar leakage.

The delivery pipe can be divided into straight

tube, elbow, tapered tube, clamp, spigot and 3mm
other spare parts (see Fig. 5-28). The straight
tube mainly includes 3m, 2m and 1m
standard straight tubes.

Clearance: The clearance between delivery Fig.5-28

pipes in the delivery pipeline should be 3mm
1. Pipe clamp
(see Fig. 5-29), which may be achieved 2. Seal ring
automatically after a seal ring is mounted.
3. Delivery pipe

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2
9

10

11
1
7
2 4
6

3
5

Fig.5-29

1. Seal ring (150A) 5. Tapered tube 150A-125A 9. Seal ring (125A)

2. Tube clamp bolt 6. Connector 125A 10.-Hose
3. Connector (150A) 7. Elbow Φ125 11.Spigot
4. Elbow Φ150 8. Straight tube Φ125A

Utilization of delivery pipe

The appropriate utilization of delivery pipe
may effectively extend the service life of
delivery pipe, esp. those fixed delivery pipes
at construction site.

(1) Straight Tube

After pumping every 5000m3 of concrete,
rotate the straight tube for 120° or 180° to
make the wear evenly distributed, by which
the service life of straight tube may be
prolonged. Especially for the delivery pipe
with longer service life (generally, such
delivery pipe can be used for pumping at
least 20,000m 3 of concrete during its
service life), the effect is more obvious.

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(2) Elbow
After pumping every 5000m3 of concrete,
turn over the elbow for 180° to make the
wear evenly distributed. The exterior wear
of an elbow is severer than the internal
wear or the wear of a straight tube. Thus,
when measuring the wall thickness of an
elbow, special attention should be paid to
the wall thickness at the positive camber.

Measurement of delivery pipe wall

thickness
Delivery line may burst under the normal
pumping pressure when the wall thickness of
the pipe less than the required value,
especially when blockage occurs.

Measure the wall thickness of the pipe using

wall thickness indicator or other wall
thickness measuring instruments.
Y
CAUTION
200
190
0
Before pumping, measure the wall
80

10

180
14 125
65
DN

DN

thickness of the pipe to prevent damage 170

0

DN
DN

0
DN5

160
or injury of life caused by pipe burst. 0
N

150
15
D

140 N
Concrete Pressure (bar)

130 D 0
120 18
Fig. 5-30 shows the minimum wall thickness 110 DN 0
20
DN
of delivery pipe. 100
90
80
(1) Carry out measurement according to the 70
60
measuring regulation of the equipment. 50
40
Don't measure the wall thickness at one 30
20
point only. Instead, measure at several 10
points around the outer diameter of 0 1 2 3 4 5 6 7 8
X
delivery pipe, in particular at the lateral Min.wall thickness (mm)

surface of the straight tube connected

Fig.5-30
with the elbow where the wear is severer
than that at other points because the flow
rate of concrete here is higher than that
on the medial surface.

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(2) Change the one whose wall thickness

reaches the minimum value. Especially
before large pumping, the pipe wall
thickness closes to the minimum value
must be changed. Otherwise, it would
cause burst or lead to personal injury.

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.

NOTICE
The shock influence to the delivery pipe
during working is depended on many
affects and hard to measure. Therefore,
even the working pressure is under the
normal range, the delivery pipe may burst
also.
When blockage happen, the working
pressure fluctuate. If the wall thickness is
not under the required level, the pipe may
burst.

Replacement of delivery pipe

Replacement Procedure:

(1) Dismount the delivery pipe to be replaced;

(2) Before assembling, lubricate the clamp
and the inside of seal ring with lithium-
based grease.
(3) Mount the straight tube of specified
length.

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5.6.8 Main oil cylinder maintenance

Check the seal of the main oil cylinder for
leakage every day. Repair the main oil cylinder
in the following cases: During pumping
process, the concrete piston reverses more
and more frequently before it reaches the set
stroke closed to the hopper of delivery
cylinder. It is because the hydraulic oil in the
piston connecting side decreases as a result
of the damaged piston seal of the main oil
cylinder making more hydraulic oil leak into the
oil tank. In this case, replace the main oil
cylinder piston seal.

Disassembly of main oil cylinder

(1) Retract the delivery cylinder piston into
the water tank. Shut down the machine,
release the pressure and cut off the
power.

(2) Dismount all hydraulic pipelines and

elements connecting to the main oil
cylinder, including the oil-in flanges in
rod-side and piston-side. Seal the oil
pipes and connectors with plugs to
prevent the hydraulic system from dirt
and foreign substances.

(3) Drain off the water tank, loosen the

fastening screw of bite type fittings and
take off the bite type fittings and concrete
piston.

(4) Dismount the fastening bolt connecting

the water tank and main oil cylinder Fig.5-32
(see Fig. 5-32).
1. Fastening screw 3. Delivery cylinder
2. Water tank 4. Main oil cylinder
(5) Lift the main oil cylinder with the crane
and flexible cable.

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(6) Dismount the bent plate subassembly

and auxiliary support for mounting the
main oil cylinder (see Fig. 5-33).
(7) Shake the main oil cylinder forcibly and
separate the main oil cylinder with the
water tank.
(8) Lift the main oil cylinder out from the
fixed revolving tower.
(9) Dismount the screw connecting the limit
cylinder body and main oil cylinder body,
and take off the limit cylinder.
(10)Dismount the retainer ring, clipping key Fig.5-33
cap and clipping key for shaft which fix
the piston.
(11)Screw 2 M16 bolts into the main oil
cylinder piston and pull the piston out.
(12)Dismount the seals on the piston rod and
piston.
Assembly of main oil cylinder
(1) Assembly of piston and piston rod
(see Fig. 5-34)
a) Coat the O-ring with grease and fit it into
the corresponding groove on the piston
rod.
b) Coat the seal ring and guide ring with
grease, and fit them into the
corresponding grooves on the piston.
c) Coat the assembled piston with grease
and fit it into the piston rod.
d) Fit the clipping key for shaft into the
corresponding groove on the piston rod
and fit the clipping key cap.
e) Fit the retainer ring into the
corresponding groove on the piston rod.

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NOTE:When replacing the main oil cylinder

and sealing parts, you must operate
according to the complicated situation.
For example, if there is an obstructive
pipe when lifting out the main oil
cylinder, you must take measures to
avoid it to prevent main oil cylinder
from collision.

8
7
6

5 2
5

3
2

Fig.5-34 Assembly of Piston and Piston Rod

1. Piston Rod 5. O-ring
2. FR guide ring 6. Shaft clipping key
3. CUT seal ring 7. Clipping key cap
4. Piston 8. Retainer ring

(2) Assembly of pressure cover (see Fig. 5-35)

a) Coat the guide ring with grease and fit it
into the groove on the pressure cover.
b) Coat the seal ring with grease and fit it
into the groove on the pressure cover.
c) Fit the dust-proof ring and the retainer
ring into the pressure cover.
d) Fit the O-ring and retainer ring with grease
coated into the groove on the column.

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Fig.5-35 Assembly of Pressure Cover

1. Piston rod 5. Dust-proof ring 9. Pressure cover
2. O-ring 6. ZBR seal ring 10.O-ring(I)
3. Piston 7. GS seal ring 11.Working cylinder body
4. Retainer ring 8. FR guide ring

(3) Assembly of main oil cylinder Assemble

the sub-assembled main oil cylinder
body, pressure cover and piston.
(4) Lifting the main oil cylinder
Use the crane to lift the main oil cylinder
out from the fixed revolving tower. Coat
the mounting hole on the water tank with
plane sealant and use the screw to
connect the main oil cylinder and water
tank.

(5) Fitting the limit cylinder

Fit the limit cylinder on the main oil
cylinder with bolts.

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(6) Fitting the bite type fittings Screw up the

fastening screw to fit the bite type fittings.
(7) Fit the bent plate subassembly and
auxiliary support of the main oil cylinder.
(8) Checking the runout (Fig. 5-20) Check
the runout of main oil cylinder to delivery
cylinder. It should not exceed 0.6mm.
Use 6 pull-rod nuts to adjust the runout
within the allowable tolerance.
(9) Refit all pipelines Refit all hydraulic
pipelines that have been removed before.
(10)Filling water Fill up the water tank, fit the
water tank cover and operate the boom
to set it back to the original position.

NOTICE
Take care when re-assembling the oil
cylinder. Do not damage the seal and
chromium coating. Use the new bolt for
fastening. Slowly extend and retract the
hydraulic cylinder twice at a speed not
more than 0.5m/min to drain the air in the
cylinder. If the air is compressed, the
hydraulic oil may be burnt so that the
sealing parts of the piston and O-ring will
be damaged.

5.7 Hydraulic System

The hydraulic system mainly consists of
hydraulic pump, valve group, accumulator,
hydraulic motor, oil cylinder, pipeline, and
other hydraulic elements.

In the course of pumping, pay attention to the

working conditions of hydraulic system, for
example, if the hydraulic oil temperature is
normal, if the radiator works normally, and if
there is abnormal noise of oil pump and motor.

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5.7.1 Replacement of hydraulic oil

(1) If the hydraulic oil observed at the oil
level gauge is not transparent or its color
is changed, replace the hydraulic oil
(see Fig. 5-36). Generally, the hydraulic
oil should be replaced once every 2000
working hours or every two years. It
depends on the oil analysis.

(2) Check the hydraulic oil level every day. If

it is lower than the standard line, please
fill hydraulic oil to the level above the
standard line.
Fig.5-36 Oil Level Gauge
(3) The cleanliness is the most important
thing in the maintenance of hydraulic
system. Prevent dust or other dirt from
entering the hydraulic system. Even tiny
grains entering the hydraulic system may
scratch the valve, and block the oil pump
and control hole, resulting in damage of
the hydraulic parts and elements.

(4) Use a special filter or oiling machine to

refill hydraulic oil. Do not directly fill new
oil (new oil is not clean) into the hydraulic
system so as to avoid the dust in air and
dirt at the oil filler opening being carried
into the hydraulic oil tank.

(5) Collect and dispose the used hydraulic oil

according to the environmental protection
regulations and other requirements. Like
the disposal of mineral hydraulic oil, the
biodegradable hydraulic oil should be
separated with other waste materials by
type for disposal.

(6) Dispose the used oil filters and filter

cores according to the effective
regulations.

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Replacement of hydraulic oil

The following work should be done before oil 1 4 5
replacement:
(1) Shut down the engine;
(2) Release the pressure of the accumulator
completely;
(3) In order to guarantee safety, it is
necessary to cut off the power supply;
(4) Ensure the safety equipment in the work
area, especially those in the maintenance
control area, are arranged properly.
6
Replacement of oil 2
(1) Open the drainage valve at the bottom of 3

the oil tank to drain the hydraulic oil. The

location of drainage valve is as shown in Fig.5-37
Fig. 5-37. 1. Oil level gauge 4. Quick joint
(2) Clean the inside of hydraulic oil tank. Use 2. Hydraulic oil tank 5. Metal breather
some clean hydraulic oil to flush out the 3. Oil-drain valve 6. Self-seal device
deposits at the bottom of the oil tank.
NOTE:Don't wear gloves when cleaning the
inside of oil tank. After cleaning the oil
tank, check and make sure nothing is
left in the oil tank.

(3) Replace the oil filter core according to the

procedures in "Oil Filter" on page 5-65.
(4) Refill new oil into the oil tank by oiling machine
from the quick joint at the hydraulic oil tank
body. (It is necessary to use the
recommended hydraulic oil of specified grade).
(5) After commissioning, check the oil level.
If the oil is insufficient, fill oil till it reaches
the level above the standard line.
(6) Re-mount all the removed safety
equipment and signs.

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5.7.2 Water drainage of hydraulic oil

tank maintenance
As the influence of environment, there will be
water mixed in the hydraulic oil. Thus, it is
required to drain the water from the hydraulic
oil tank regularly, so as to prevent the
hydraulic oil from early deterioration and
emulsification and ensure the normal
operation of hydraulic system.

The water drainage cycle should be once

every 50 working hours or a week.

(1) Before drainage, park the equipment

flatly for more than 8h.
(2) Prepare a proper container at the bottom of the
oil tank to collect the drained oil water mixture.
(3) Open the drainage valve at the bottom of
the hydraulic oil tank to drain the oil
water mixture accumulated at the bottom.
Observe the fluid drained from the oil
tank. When the fluid changes from water
to hydraulic oil, close the drainage valve.

(4) Check the hydraulic oil level. If the oil is

insufficient, fill it to an appropriate level.

5.7.3 Rubber hose

WARNING
Check all hoses (including hose fittings) with
the machine running. The hoses at the
slightest sign of damage or even mere
indications of threatened damage must be
replaced. Know the maximum pressure that
your machine can exert on the concrete, and
be sure that the hoses, pipes and clamps are
capable of handling the pressure. Failure to
do so may result in a sudden rupture in the
hose or piping system or hose end-swing
and personal injury.

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Check of rubber hose

(1) Hydraulic Hose (see Fig. 5-38)
Pay attention to the black wet spot on the
connector is the external evidence of
early damage.

a) The rubber hose for defect, crack and

porosity on its surface;
b) The clamp for fixing the rubber hose for
looseness;
c) The middle part of the rubber hose is
made of nonmetal, which should be kept
away from strong sunshine, heat and
chemicals to avoid aging. Fig.5-38 Rubber Hose
NOTE:The service life of all rubber hoses is 6
years, including the storage period of
rubber hoses. (The storage period for
the raw material before being made
into rubber hose is also included.)

(2) Hose Connector

a) Check the tightness of the hose connector;
b) Only the allowed tightening torque can be
used to screw down the connectors. Screw
down the connectors until the force is
obviously increased if no torque spanner is
available. If the leakage continues, replace
these hose connectors.

Replacement of rubber hose

(1) Shut down the engine.
(2) Release the remaining pressure in the
hydraulic system completely.
(3) When dismounting the hose connector,
unscrew it slightly to drain a little hydraulic
oil. When the remaining pressure of
hydraulic oil in the rubber hose is released,
keep on dismounting the rubber hose.
(4) Collect the drained oil and liquid with a
container and dispose them according to
the environmental protection requirements.

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(5) After disassembling the old rubber hose,

block the connector opening immediately
with a clean plug. Keep dust out of the
hydraulic circuit.
(6) Do not over-bend the rubber hose or
form friction points with other objects
during installation.
(7) Discharge the air in the hydraulic system.
(8) After installing a new rubber hose,
conduct commissioning and check all
rubber hoses and connectors for leakage.
NOTE:The hydraulic line can not work
without oil. The inner of new house
should be clean and free of dust. The
crooked hydraulic hose is subjected to
mechanical pre-stressing force;
therefore, the hose will rebound when
disassembling.

Identification of rubber hose

The rubber hose is composed of the
hydraulic hose and the connectors at both
ends.

(1) Rubber Hose Type

1SN:Single-wire braided hydraulic hose;
2SN:Two-wire braided hydraulic hose;
4SP:Four-wire spiral hydraulic hose
(middle pressure);
4SH:Four-wire spiral hydraulic hose (high
pressure).

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(2) Identification of Rubber Hose

As for the rubber hoses manufactured by
SANY Heavy Industry Co., Ltd., the
relevant specifications can be found
directly from the product name. Here, we
take rubber hose 4SP20-DKOS-DKOS90-
1000-V90-XXX for example:

Rubber hose 4SP20-DKOS-DKOS90-1000-V90-XXX

Rubber hose type Type of accessory

Type of connector at one side Mounting angle

Type of connector at the other side Assembly length

5.8 Accumulator
1
NOTICE
T h e ch e c k i n g a n d oi l f i l l i n g w or k o f 2

accumulator must be performed by

3
professional person to avoid nonstandard
operation.

4
DANGER
The accumulator should be filled with
nitrogen. Never use other gases. If it is
filled with air, nitrogen, etc., explosion
may occur. Fig.5-39

1. Gas valve 3. Accumulator housing

The accumulator is composed of housing, 2. Capsule 4. Oil valve
capsule, oil valve, gas valve, etc. (see Fig. 5-
39). The general knowledge about
accumulator is as follows.

5-62
 MAINTENANCE
HBT6013C-5S

(1) The rubber bag for storing nitrogen in the

accumulator has certain air permeability. Air pressure
bar (Mpa)
After a certain time, its air pressure will
78.4 (8)
lower down. Thus, it is required to check
the working pressure of accumulator at Upper limit
68.6 (7)
least once every half a year. When the oil
63.7 (6.5) Allowable
temperature is 50°C, the pressure should pressure
58.8 (6) range
be 7MPa (68.6bar). The allowable
53.9 (5.5)
working pressure of accumulator is as
49 (5) Lower limit
shown in Fig. 5-40.
44.1 (4.5)
(2) If the actual value is 75% of the specified
value or even lower, charge the 0 10 30 50 70oil
temperature
Û&
accumulator with gas.
(3) Only nitrogen instead of other gases can
Fig.5-40 Allowable Pressure of Accumulator
be charged into the accumulator.
(4) The working pressure, charging pressure
and capacity of accumulator are as
shown in Table. 5-18.

Table 5-18 Charging Pressure and Capacity

Working Charging
Capacity
Pressure Pressure

16MPa 7~8MPa 10L

Check of nitrogen pressure in accumulator

The way to measure the nitrogen pressure in
accumulator without gas-filling tools:

(1) Start the engine and conduct pressure

suppression till the pressure of
accumulator reaches 16MPa.
(2) Press down the emergency stopping button.
(3) Slightly open the overflow ball valve of
the accumulator to release the pressure
in the accumulator slowly. Once reaching
the pre-charge pressure of the
accumulator, the reading of the pressure
gauge will abruptly drop. The value
pointed abruptly is the nitrogen pressure
of accumulator.

5-63
MAINTENANCE
HBT6013C-5S

(4) If the nitrogen pressure of accumulator is

not within 7~8MPa, adjust it to this range.
Nitrogen charging and pressure
adjustment of accumulator
(1) Preparation before nitrogen charging: dismount
the charging cap and protective cover from the
accumulator; turn the handle of the gas-filling
tool to the end anticlockwise, and connect it
with the charge valve on the accumulator;
connect the joint at the other end of rubber
hose with the nitrogen gas cylinder.
(2) Charging or recharging: turn the handle
of the gas-filling tool clockwise till the
reading on the pressure gauge on the
gas-filling tool becomes positive; slowly
open the cut-off valve on the nitrogen gas
cylinder to charge the nitrogen into the
rubber bag slowly, and then close the
cut-off valve; observe the readings on the
pressure gauge and repeat the above
procedure for several times till the
reading reaches the upper limit; unscrew
the air release valve to discharge the
redundant nitrogen; dismount the gas-
filling tool; check and confirm the charge
valve is free of leakage and then mount
the charging cap and protective cover.
(3) Discharging or adjusting: open the air-bleed
valve; turn the handle clockwise to push out
the charge valve core with the crown bar and
start discharging; after discharging the gas,
turn the handle back to the original position;
dismount the gas-filling tool; check and
confirm the charge valve is free of leakage
and then mount the charging cap and
protective cover. The method for adjustment
is the same as charging method. In case of
high pressure, conduct adjustment with
discharging method; in case of low pressure,
conduct adjustment with recharging method.

5-64
 MAINTENANCE
HBT6013C-5S

(4) Nitrogen temperature compensation: the

gas pressure varies as the temperature
and the gas pressure in the accumulator is
set as 7MPa (68.6bar) at 50°C. Please
conduct adjustment as per the figure when
charging under room temperature. As for
daily check, do check the hydraulic oil
temperature. If the pressure is lower than
the lower limit, recharge nitrogen gas.

5.9 Oil Filter

(1) Frequently check the hydraulic oil filters
(see Fig. 5-41) for blockage. If the indicator
at the top of oil filter (as indicated by the
arrow in the right figure) turns green, it
indicates that the oil filter is in good
condition, without any blockage; if it turns
red, it indicates that the filter core is seriously
blocked and the operation is stopped, and
the filter core must be replaced.
(2) Keep in mind that the cleanliness is the
most important thing in the maintenance
of hydraulic system.
(3) The filter core can only be replaced
instead of being washed. Before replacing Fig.5-41 High-pressure Oil Filter
the filter core, check all former O-rings and
other sealing elements of the oil filter for
damage. If any, replace them as well.
(4) Replace the oil filter core if the hydraulic
oil is replaced.
(5) Dispose the used oil filter core according
to the effective local regulations.
Replacement of oil filter core
(1) Release the pressure, shut down the
engine and cut off the power.
(2) Remove the oil filter housing.
(3) Take out the filter core from the housing.
(4) Clean the inside of housing.

5-65
MAINTENANCE
HBT6013C-5S

(5) Install a new filter core. (Do use the

original filter core supplied by the
manufacturer.)
(6) Mount the housing.
NOTE:When installing the filter cartridge, if
the threads are not aligned, the
screwing of filter cartridge will
immediately be subjected to large
resistance. Do not apply excessive
force. Draw back the filter cartridge,
realign the tread and screw it to install.
When the filter cartridge is tightened to
the end position, it should be
unscrewed by 1/4-1/2 turn.

5.10 Air Filter

The air filter is located at the hydraulic oil
tank (see Fig. 5-42).

Since there is much dust at the construction site,

the air filter should be replaced once a year.

The air filter and its filter core are integral. Thus,
please replace the air filter with a new one.

NOTE:Dispose the used air filters according

to the local regulations.

5.11 Electrical System

Fig.5-42 Air Filter
The electrical system mainly consists of
electrical control cabinet, remote control box
and harness.

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.

5-66
 MAINTENANCE
HBT6013C-5S

5.11.1 Electrical control cabinet

As the key component of the control system 1
for trailer-mounted concrete pump, the
electrical control cabinet mainly consists of
electrical control cabinet body, SANY motion
controller SYMC, SYCD display, circuit breaker
and so on (see Fig. 5-43 and Fig. 5-44).

For the check and maintenance cycle, see

Table. 5-2.

NOTE:Do not put other items in the electrical

control cabinet, e.g. tool, gloves. The
5 4 3 2
door of electrical control cabinet is
generally closed. Do not open it
Fig.5-43Diagram of Components in the
casually. In addition, the inner of
Electrical Control Cabinet
cabinet should also be dry and
1. SYMC controller
protected from rain water and washing.
2. Intermediate Relay
3. Monopole breaker
CAUTION
4. Truck pump electric plate Assembly SYMCEB
When repairing other components, if 5. Electrical board assembly SYEB
welding work is required, the general
switch of power supply should be closed,
and the ground wire of welder should be
d i r e c t l y c o n ne c t e d t o t h e p a r t t o b e
welded so as to avoid damage to the 1 3
electrical elements in the electric control
cabinet.
2
Electrical Control

(1) Regularly check if the connection

Box

between the relay and box is loose, and

replace the damaged relay with the one
I O
-

of same specification.
+

RPM+ RPM-
I O I O

(2) In case of breaker tripping, check the circuit 4

at once, find out the cause, eliminate the
short circuit or other circuit troubles, and Fig.5-44 Electrical Control Cabinet Panel
then replace the breaker with the one of
same specification. If you are not sure about 1. SYCD display
the breaker specification and circuit trouble, 2. Indicator lights
please contact the after-sales service 3. E-STOP (emergency stop) button
engineer in time. 4. Functional switch

5-67
MAINTENANCE
HBT6013C-5S

(3) Regularly check each solenoid valve

plug, sensor connector, terminal block,
toggle switch and instrument for wiring
looseness. If any, tighten it in time.

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.

Fig.5-45 Remote control box body

5.11.2 Remote control box
The trailer-mounted concrete pump is 1. Cable fastener
provided with a cable remote control box 2. Remote control box
which is mainly used for remote operation of 3. E-STOP button
4. Toggle switch
the trailer-mounted concrete pump (see Fig.
5. Indicator light
5-45). For the check and maintenance cycle,
see Table. 5-2.

(1) Regularly check the connections of

emergency stopping switch, toggle switch
and aviation plug of the control box for
looseness, and tighten them if any
looseness is detected.
(2) Regularly check the waterproof seal
between the panel and box, and replace
the seal if any damage is detected.
NOTE:Please keep the control box for
maintenance closed and don't open it
without permission. Keep the box dry
and protect it from rainwater and
flushing.

5.12 Diesel Engine

The diesel engine of SANY was adopted,
please read the documentation of the
original manufacturer carefully for details.

5-68
 HBT6013C-5S

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HBT6013C-5S

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5-70
 TROUBLESHOOTING
HBT6013C-5S

6 TROUBLESHOOTING
The SANY trailer-mounted concrete pump is
designed for pumping concrete and
implementing a continuous pour during
operation. If the trailer-mounted concrete
pump malfunctions, it will delay the
construction schedule and bring negative
influence on the economic and social benefits
of both sides. Timely diagnosis and
troubleshooting are needed in order to reduce
economic losses and maintain a good
corporate image.
This section will elaborate on common
malfunctions and troubleshooting the
machinery, hydraulic system, electrical
systems and diesel engine.

6-1
TROUBLESHOOTING
HBT6013C-5S

6.1 Troubleshooting Mechanical System

Table 6-1
No. Malfunction Cause
Serious abrasion of concrete seal
Mortar leakage in
1 body or over-abrasion of delivery
washing room
cylinder.
Change failure of oil controlled valve
controlling the swing of S-valve.
S-valve jammed by foreign substances
in the hoper.
One side of S-valve
2 Over-abrasion of swing valve cylinder
swing improperly
piston seal.
The concrete fed into the hopper
mainly gathers at one side.
One side of S-valve swing improperly
Abnormal abrasion Deviation between the bearing end of
3 of glasses plate and S-valve and rocker arm during
cutting ring manufacturing leads to synchronous
displacement of the cutting ring and
glasses plate.
Troubleshooting
In case of mortar leakage in
washing room during pumping,
stop the pumping operation and
check the delivery cylinder for
wear. If the delivery cylinder is not
abraded, immediately replace the
concrete seal body.
Check if the oil controlled valve is
jammed and clean or replace it.
Stop the machine and clear the
foreign substances in the hopper.
Stop the machine and disassemble
the swing valve cylinder to replace
the piston seal.
Adjust the concrete feeding
position and try to feed material at
the middle as possible.
Eliminate the trouble according to
procedures above.
Check the rocker arm for wear and
replace the S-valve assembly or
rocker arm.

6.2 Troubleshooting of Hydraulic System

Table 6-2

No. Malfunction Cause Troubleshooting

Valve core of cartridge valve of main

Replace the cartridge valve of
overflow valve jammed at upper
main overflow valve.
location.
The main system
without pressure or Abrasion of valve core of main overflow Replace the cartridge valve of
1 with the pressure not valve. main overflow valve.
up to the setting Abrasion of valve core of Dt1 solenoid Replace Dt1 solenoid change
32MPa change valve. valve.
Loose plug or valve core abrasion of the Screw down the plug or replace
constant pressure valve of main oil pump. the constant pressure valve.

6-2
 TROUBLESHOOTING
HBT6013C-5S

Table 6-2

No. Malfunction Cause Troubleshooting

The control electromagnets DT2~DT5 Check circuit or replace DT2 ~

No reversing of the not electrified or get blocked. DT5 control electromagnets.
pumping system (with
2 The main four-way valve or swing Replace the main four-way
normal pressure of
main system) cylinder four-way valve blocked or valve or swing cylinder four-
damaged. way valve.
Abrasion between the cones of valve
cores of cartridge valves 28.1 and 28.4
leads to hydraulic oil of main system
Replace cartridge valves 28.1
leaking into connecting chamber
and 28.4.
without rod from cone of valve core,
When pumping at low which results in increase of hydraulic
pressure, the main oil oil of connecting chamber without rod.
cylinder piston rod
3 Abrasion between valve core and valve
stroke shortened and
sleeve for cartridge valves 28.1 and
reversing times Replace cartridge valves28.1
28.4 leads to pressure oil of
increased and 28.4.
accumulator leaking into connecting
chamber without rod at idle speed.
Damage of limit cylinder piston seal leads to
Replace the limit cylinder
pressure oil of accumulator leaking into
piston seal.
connecting chamber without rod.
Abrasion between valve core and valve
sleeve of cartridge valve of rod-side
connecting chamber of main oil
cylinder (cartridge valve 29) leads to
Replace cartridge valve 29.
When pumping at high hydraulic oil of rod-side connecting
pressure, the main oil chamber leaking into oil tank, which
cylinder piston rod results in diminishment of hydraulic oil
4 of rod-side connecting chamber.
stroke shortened and
reversing times Blockage of damping holes of cover plates
increased of high pressure change cartridge valves Check or replace the
28.1~28.4 leads to abnormal oil-adding damping holes of cover
during reversing of main oil cylinder, which plates of cartridge valves
results in diminishment of hydraulic oil of 28.1~28.4.
rod-side connecting chamber.
Insufficient nitrogen pressure of accumulator. Check it and fill nitrogen.
The plug of the main four -way valve or
Check it.
swing cylinder four-way valve broken off.
The shuttle valve in the main oil pump
Check or replace the shuttle
Weak reversing of the blocked, resulting in the pressure in the
5 valve in the main oil pump.
swing cylinder accumulator fled to the main system.
The one-way valve at the oil inlet of the Check or replace the one-
accumulator blocked, resulting in no way valve at the oil inlet of the
pressure preservation. accumulator.
Damaged dual-gear pump. Replace the dual-gear pump.

6-3
TROUBLESHOOTING
HBT6013C-5S

Table 6-2

No. Malfunction Cause Troubleshooting

Blockage of the damping hole in the oil-
drain valve
Random reversing of
6 Check or replace the small oil
the pumping system The valve core of small oil controlled
valve of the swing cylinder blocked
The main overflow valve with overflow
during pumping.
The hydraulic oil No rotation of the air-cooled motor or
7 temperature rising with low rotation speed due to decline
abnormally of volume efficiency.
The air cooler radiator grill blocked by
dust, making the cooling not smooth.
Check the damping hole in
the oil-drain valve.
controlled valve of the swing
cylinder.
Replace the main overflow
valve.
Replace the air-cooled motor.
Clear the dust on the radiator
grill.

6.3 Troubleshooting of Lubrication System

Table 6-3

No. Malfunction Cause Troubleshooting

Insufficient oil supply of

1 Blockage of hydraulic oil circuit. Unblock the oil circuit.
lubrication center
Blockage of lubricating points. Unblock the oil circuit.
Blockage of sheet oil
2 Clean or replace the sheet oil
separator Foreign substances in the oil circuit.
separator.
In case of seizure, clean and
Blockage of lubricating Blockage of lubricating points; the
3 unblock the lubricating grease
grease distribution valve lubricating grease not clean
distribution valve.

6.4 Troubleshooting of Electrical System

Refer to the corresponding electrical basic diagram for the common malfunction diagnosis and
troubleshooting of electrical control system. Carry out analysis, diagnosis and troubleshooting
according to the following methods:

6-4
 TROUBLESHOOTING
HBT6013C-5S

Table 6-4

No. Malfunction Cause Troubleshooting

SYMC output points B101, B201 or

Replace the SYMC main module.
B206 (B103, B201 or B206) damaged.
Step motor driver damaged (normal
Replace the step motor driver.
The engine cannot input signal, abnormal output signal).
accelerate during
1 Step motor damaged. Replace the step motor.
forward/reverse
pumping. Mechanical seizure of step motor. Check and repair its mechanical part.
No speed sensor input into the
Check the wiring or repair the
SYMC terminal B124 (or B109) from
silicon rectification generator.
the silicon rectification generator.
Starter relay JN damaged. Replace or repair the relay JN.
The SYMC output point A126 (or
A127) controlling the starter relay Replace the SYMC module.
damaged.
Failure in starting
2 Starter electromagnet Dt16 (or Dt18) Replace or repair the starter
diesel engine
damaged. electromagnet DT16 (or Dt18).
Starter motor damaged. Replace or repair the starter motor.
Stopping electromagnet Dt15 (or Replace or repair the stopping
Dt17) damaged. electromagnet DT15 (or Dt17).
Single-pole circuit breaker Q4 Check the circuit and reset the
tripped. single-pole circuit breaker Q4.
No power supply for
3 The corresponding control relay Check, repair or replace the
control circuit
KA1 damaged; poor contact of control replay KA1; check and
circuit. repair the circuit.

6-5
TROUBLESHOOTING
HBT6013C-5S

6.5 Troubleshooting of Diesel Engine

Table 6-5

No. Malfunction Cause Troubleshooting

No oil in the fuel tank
Fuel filter screen blocked by foreign
substances
Fuel filter screen or pipeline blocked
Failure in engine by wax deposits in winter
1
startup
Poor seal of fuel pipe
Indicator lamp off (but bulb in good
condition)
Solenoid overflow valve in the
hydraulic system not returned.
Main pump damaged or jammed.
Insufficient voltage of battery, loose or
oxidized terminal.
Application of engine oil with great
viscosity in winter.
Difficult engine
2
startup
Small fuel flow (fuel system blocked
by wax deposits in winter).
Blockage of diesel oil filter.
Diesel oil of poor quality (for example,
containing water)
Air in the oil-in circuit.
Loose diesel oil filter.
Small fuel flow.
Engine power
decreases or Valve clearance not in accordance
3 Adjust the valve clearance and
engine works with the requirements; breakage of
abnormally valve spring.
Fuel injector damaged.
Dirty air filter.
Fill oil and carry out bleeding.
Clean the primary filter screen or
replace the filter
Replace it with winter-grade fuel; use
pump oil or hot water to submerge the
lower part of the filter to melt the wax,
discharge the air and clean the pipeline.
Check all fuel pipe connectors for
tightness; if necessary, tighten the
connectors.
Check and fasten all connections of
terminals and conductors.
Check if the solenoid valve is
electrified and if the overflow valve
works normally.
Repair or replace the main pump.
Check the battery voltage; clean
and fasten the terminal; coat the
terminal with carbon-free grease.
Use engine oil suitable for the
specific environment.
Replace it with winter-grade fuel;
use pump oil or hot water to
submerge the lower part of the filter
to melt the wax, discharge the air
and clean the prefiltration screen
and oil circuit.
Clean or replace the diesel prefiltration.
Drain the diesel oil of poor quality
and use qualified diesel oil.
Bleed the diesel oil circuit.
Fasten it.
Replace the filter, discharge the air,
clean the primary filter screen and
tighten the tube connector.
replace the spring.
Replace the fuel injector.
Clean or replace the filter core.

6-6

Table 6-5
No. Malfunction Cause
Blue smoke: high engine oil level.
Blue or black Black smoke: coking at valve or poor
4 smokes from the seal due to improper valve clearance.
exhaust pipe Black smoke: oil injector damaged.
Black smoke: blockage of air intake
system or poor seal.
Coolant pump damaged.
Incorrect adjustment of injection
Engine quantity for oil injection pump.
overheated and
Insufficient cooling air from the cooling fan.
the indicator of the
thermometer
5 Slow blowing speed of cooling fan.
pointing to the red
area; engine
stopped Too less or too much engine oil.
immediately
Too less coolant.
Poor seal of air intake tube.
Incorrect engine oil level or engine oil
diluted by diesel oil (with the diesel
engine working normally).
Engine oil diluted by diesel oil with the
diesel engine working unstably or with
insufficient power.
Engine oil diluted by water.
Engine oil diluted by coolant
Low engine oil (antifreeze coolant).
6
pressure
Engine oil with incorrect grade.
Failure of engine oil pressure gauge.
Seizure of pressure regulating valve or
breakage of pressure regulating spring.
Blockage of engine oil filter.
Loose oil-suction tube or failed seals.
TROUBLESHOOTING
HBT6013C-5S
Troubleshooting
Lower the engine oil level to the
“MAX” mark on the oil level gauge.
Check and adjust the valve clearance
by professional personnel.
Replace the oil injector.
Clean the intake system and
fasten the clamp.
Replace the coolant pump.
Adjust it by professional
personnel.
Unblock the air duct.
Check and adjust the exhaust regulator;
check the belt for looseness and crack.
Adjust the oil level to the “MAX”
mark on the oil level gauge.
Fill coolant to the specified level.
Check the air intake tube.
Fill or drain the engine oil; dismount the
oil delivery pump and check the
sealing condition of its plunger; replace
the oil delivery pump with leakage and
replace the engine oil.
Check the coupling parts of nozzle for
seizure; if not, exchange the fuel
injector and replace the engine oil.
Check if the filler cover or oil level gauge
falls off; replace the engine oil.
Check the engine oil cooler, water
jacket and water seals for leakage;
replace the spare parts with leakage;
replace the engine oil.
Check the specifications of engine oil.
Check the engine oil pressure gauge
and engine oil pressure sensor;
replace the damaged parts.
Check and clean the pressure
regulating valve and replace the
damaged spring.
Replace the engine oil and engine
oil filter.
Replace the sealing elements and
fasten the oil-suction tube.
6-7
TROUBLESHOOTING
HBT6013C-5S

Table 6-5

No. Malfunction Cause Troubleshooting

Blockage of air filter.
Incorrect timing of oil injection pump.
Air leakage of connecting tube
between the turbocharger and air
Heavy smoke intake tube.
7 when the diesel
engine is loaded More than 1 packing washers under
the oil injector.
Oil injector works abnormally.
Turbocharger works abnormally.
Low water temperature when the
diesel engine is under operation.
Large diesel oil supply quantity.
Failure to reach
the rated rotation Improper adjustment of throttle control
8 speed when the lever.
diesel engine is
loaded Failure of tachometer.
Blockage of fuel supply.
Check, clean and replace the air filter.
Check or adjust the oil injection
timing.
Get rid of the air leakage trouble.
Remove the redundant washers.
Dismount the oil injector for
calibration or replace it if
necessary.
Replace the turbocharger.
Check the thermostat and cooling
system.
Dismount and check the oil
injection pump.
Check the position of throttle
control lever.
Conduct calibration with manual or
digital tachometer.
Replace the fuel filter, check the
fuel pipeline, primary filter and
filter screen for blockage.

6-8
 HBT6013C-5S

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6-9
HBT6013C-5S

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6-10
 SPECIFICATIONS
HBT6013C-5S

7 SPECIFICATIONS

7.1 Overall Technical Data

Dimensions
Lengt h 6785 mm
Width 2100 mm
Height 2630 mm
Feeding height 1320 mm
Gross weight 6300 kg

1320 mm

6785 mm

2100 mm

2630 mm

Fig.7-1

7-1
SPECIFICATIONS
HBT6013C-5S

7.2 Pumping System Technical Data

Pump Specifications

Max. concrete output Low pressure 65 m3/h

(theoretical) High pressure 40 m3/h

Max. delivery pressure Low pressure 8 MPa

(theoretical) High pressure 13 MPa
Φ150 mm delivery
50 mm
pipe
Max. aggregate size
Φ125 mm delivery
40 mm
pipe
Delivery cylinder diameter 200 mm
Max. stroke 1400 mm

Hopper capacity 0.7 m3

Rated power of diesel engine 114 kW

7-2
 SPECIFICATIONS
HBT6013C-5S

7.3 Pumping Curve

Concrete pressure (MPa)

Concrete output (m3/h)

High-pressure Low-pressure
pumping pumping

Fig.7-2

7-3
HBT6013C-5S

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7-4
 APPENDIX
HBT6013C-5S

8 APPENDIX
8.1 Hydraulic Basic Diagram

Fig.8-1 TPHDCA_EN_01

8-1
APPENDIX
HBT6013C-5S

8.2 Electrical Basic Diagram

General electrical schematic diagram，which are subject to actual configuration。

Battery Control power Power indicator

Fig.8-2 Power supply circuit TPEDCA_EN_01

8-2
 APPENDIX
HBT6013C-5S

Remote Control circuit

Grille switch E-stop Remote Forward Reverse Outpur Output Reverse Swing
control pumping pumping increase decrease mixing cylinder
indicator inching

Fig.8-3 Remote control circuit TPEDCA_EN_01

8-3
APPENDIX
HBT6013C-5S

Controller power supply and communication circuit

Special for programme

download and test

SYMC-01 controller power supply and communication part

Display GPS
Power
confirm

Fig.8-4 Controller power supply and communication circuit TPEDCA_EN_01

8-4
 APPENDIX
HBT6013C-5S

Diesel engine start/stop control circuit

Motor start Engine Electromagnet 1 Electromagnet 2

Fig.8-5 Diesel engine start/stop control circuit TPEDCA_EN_01

8-5
APPENDIX
HBT6013C-5S

Diesel engine speed adjustment control circuit

Diesel engine
speed
Pulse counter adjusting
Direction Enable

Step motor driver

Yellow

Green
Blue

Red

Step motor

Note: The initialization current of the step motor driver is 2.1A,

which means that the switch 2 and switch 3(SW2,SW3)
at the position of “U+201CON/U+201D”.

Fig.8-6 Diesel engine speed adjustment control circuit TPEDCA_EN_01

8-6
 APPENDIX
HBT6013C-5S

Solenoid output loop

piston-return
double
Pump solenoid valve
Proportional valve
control

Fig.8-7 Solenoid output loop TPEDCA_EN_01

8-7
APPENDIX
HBT6013C-5S

I/O control of diesel engine

push rod motor

Position Feedback
+5V output
Speed decrease
place
Speed decrease
PWM

Speed increase
place

Speed increase
PWM

Water temperature
A signal

Oil pressure A
signal
Diesel engine
start
Speed
decrease

Speed
increase
Fault
indicator
Operation
indicator
Diesel engine A
thickened
Diesel engine A
start
E-stop
output
Electrical
change

Fig.8-8I/O control of diesel engine TPEDCA_EN_01

8-8
 APPENDIX
HBT6013C-5S

Function control 1

Reverse mixing

Swing cylinder
backward

Forward mixing

Reset
Piston
Keep
adjusting
Exit

Water pump
control

Diesel engine
stop

Reverse
pumping

Forward
pumping

Local control

Remote control

Main cylinder
backward
Main cylinder
forward

Pressure detect
of oil pump

Output decrease

Output increase

Fig.8-9 Function control 1 TPEDCA_EN_01

8-9
APPENDIX
HBT6013C-5S

Function control 2

Oil level

Agitating pressure

Hydraulic oil
temperature 1

Hydraulic oil
temperature 2

Hydraulic oil level

change-over
switch 2

change-over
switch 1

Change-over pressure
detect 2

Change-over pressure
detect 1

S-valve
high/low pressure
Slide valve
flush control
Speed adjusting
select

Pre-heat

Outrigger adjusting

Hopper switch

E-stop

Fig.8-10 Function control 2 TPEDCA_EN_01

8-10
 APPENDIX
HBT6013C-5S

Diesel engine Bstart/stop control circuit

Motor start Engine

Note: Apply to diesel engine B of trailer-mounted concrete pump

with dual diese engine

Fig.8-11 Diesel engine Bstart/stop control circui TPEDCA_EN_01

8-11
APPENDIX
HBT6013C-5S

Diesel engine B speed adjustment control

Diesel engine
Pulse counter speed
B adjusting B Direction Enable

Step motor driver

Yellow

Green
Blue

Red

Step motor

Note: 1. The initialization current of the step motor driver is 2.1A,

which means that the switch 2 and switch 3(SW2,SW3)
at the position of “U+201CON/U+201D”.
2. Apply to diesel engine B of trailer-mounted concrete
pump with dual diesel engine

Fig.8-12 Diesel engine B speed adjustment control circuit TPEDCA_EN_01

8-12
 APPENDIX
HBT6013C-5S

I/O control of diesel engine

Diesel engine
startl

Diesel engine
B start

Diesel engine B
thickened

Oil pressure B
signal

Water temp B
signal

Note:Added I/O for trailer-mounted concrete pump with dual diesel engine

Fig.8-13 I/O control of diesel engine TPEDCA_EN_01

8-13
APPENDIX
HBT6013C-5S

CAN bus trailer-mounted concrete pump diesel engine A control

To preheat
system
Oil-water
seperate swith

A control unit EMR1

Detect plug

Note: Apply to trailer-mounted concrete pump with CAN bus diesel engine

Fig.8-14 CAN bus trailer-mounted concrete pump TPEDCA_EN_01

diesel engine A control

8-14
 APPENDIX
HBT6013C-5S

CAN bus trailer-mounted concrete pump diesel engine B control

Local control

Remote control

To preheat
system Oil-water
seperate swith

B control unit EMR2

Detect plug

Note: Apply to diesel engine B of trailer-mounted concrete pump with CAN bus diesel engine

Fig.8-15 CAN bus trailer-mounted concrete pump TPEDCA_EN_01

diesel engine B control

8-15
APPENDIX
HBT6013C-5S

Solenoid valve action list for S-tube pump with large output I

Working state

Fo rwar d
pu m pin g Ele ct ric
High r ev er si n g

pressure
Rev ers e
pu mp in g No e lec t ri c Elec tric
r eve r si ng r eve r si ng

Forwar d
Elec tric
Low pu mp in g
r eve r si ng
pressure
Re ve rs e
p um p ing No e lect ri c Elec tric
r ev er si ng r eve r si ng

Forward inching No e lect ri c Ele ct ric

r ev er si ng r ev er si n g

Backward inching Ele ctric

r ev er si n g

Swing cylinder
Elec tric
forward r eve r si ng

Swing cylinder No e lect ri c

backward r eve r si ng

Forward mixing

Reverse mixing

Air cooling

Water pump

Outrigger

Exit Elec tric

r eve r si ng

Piston
Keep

Reset

Mode

Fig.8-16 Solenoid valve action list for S-tube pump with large output I TPEDCA_EN_01

8-16
 APPENDIX
HBT6013C-5S

Solenoid valve action list for S-tube pump with large output II

Working state

F orwa r d
pumpin g
High
pressure Re verse
pu mp in g

Fo rwa rd
pu mp in g
Low
pressure Re ve rse
pumping

Forward inching

Backward inching

Swing cylinder
forward

Swing cylinder
backward

Forward mixing

Reverse mixing

Air cooling

Water pump

Outrigger

Exit

Piston
Keep

Reset

Mode

Fig.8-17 Solenoid valve action list for S-tube pump with largel output II TPEDCA_EN_01

8-17
APPENDIX
HBT6013C-5S

Solenoid valve action list for S-tube pump with small output I

Working state

F o rwa r d
p u m p in g
High
pressure Re ve rse
p u m p in g

F o rw a r d
p u m p in g
Low
pressure Re ve rse
p u m p in g

Forward inching

Backward inching

Swing cylinder
forward

Swing cylinder
backward

Forward mixing

Reverse mixing

Air cooling Dual-diesel

pump

Water pump

Outrigger

Exit

Piston
Keep No dual
power

Reset

Mode

Fig.8-18 Solenoid valve action list for S-tube pump with small output I TPEDCA_EN_01

8-18
 APPENDIX
HBT6013C-5S

Solenoid valve action list for S-tube pump with small output II

Working state

Forward pumping

Reverse pumping

Forward inching

Backward inching

Reverse mixing

Air cooling

Mode

Fig.8-19 Solenoid valve action list for S-tube pump with small output II TPEDCA_EN_01

8-19
APPENDIX
HBT6013C-5S

Solenoid valve action list for slide valve pump with small output I

Forward pumping

Reverse pumping

Forward inching

Backward inching

Swing cylinder
forward

Swing cylinder
backward

Reverse mixing

Air cooling

Water pump

Outrigger

Exit

Keep

Reset

Mode

Fig.8-20 Solenoid valve action list for slide valve pump with small output I TPEDCA_EN_01

8-20
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SANY AUTOMOBILE MANUFACTURING CO., LTD.

SANY Industry Town, Economic and Technological Development Zone, Changsha,

Hunan China 410100
Tel: 0731-84031888 Fax: 0731-84031999
Email: Sanyservice@sany.com.cn
Service Hotline: 4008 87 8318 Complaint Hotline: 4008 87 9318

Materials and specifications are subject to change without notice in accordance with our continuous technical innovations.
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