HBT80C-1818DIII Trailer-Mounted Concrete Pump Operation Manual

HBT80C-1818DIII

HBT80C-1818DIII
TRAILER-MOUNTED CONCRETE PUMP
OPERATION MANUAL
PREFACE
HBT80C-1818DIII TRAILER-MOUNTED CONCRETE PUMP OPERATION MANUAL
Preface
This Operation Manual, attached with hydraulic and electrical basic diagrams, introduces
in detail the technical features of HBT80C-1818DIII trailer-mounted concrete pump,
operation illustration of the complete machine and major parts, and safety precautions
during operation.
Before operation of equipment, please read this Operation Manual carefully and familiarize
yourself with all the content. Only after completely understanding the Operation Manual,
can you operate the machine skillfully and safely. This will help you:
- To get a better understanding of the structure and performance of the trailer-mounted
concrete pump;
- To avoid the danger and machine malfunction due to improper operation;
- To increase the reliability in operation of the trailer-mounted concrete pump;
- To prolong the service life of the trailer-mounted concrete pump;
- To reduce the maintenance cost and stoppage time.
The operation and safety are inseparable, and the safety precautions in this Operation
Manual are only a part of safe operation. For more details about safety precautions, please
carefully read the Safety Manual matching with this Operation Manual.
Failure to follow the Operation Manual and Safety Manual for operation or carelessness of
operators and on-site operating personnel will cause casualties and serious damage of
trailer-mounted concrete pump and property. Therefore, the operators and owners should
attach great importance to the safety issue.
For the modification due to the improvement and updating of products, some details or
instructions shown in the Operation Manual may differ from your machine. For any
question on the machine or the Operation Manual, contact SANY Heavy Industry Co., Ltd.
through 24-hour service hotline (0086-21-58590631) for service support.
Please attach it with the machine for reference at any time.
SANY Heavy Industry Co., Ltd.
Please carefully read this Operation Manual,

and operate the trailer-mounted concrete pump based
on full understanding of all the content.
I
READING GUIDANCE
Reading Guidance
The Operation Manual is provided as a guide to operate the machine properly, covering the technical
instructions of complete machine, starting of equipment, parts operation and safety precautions, as well as
equipment cleaning and moving, etc.
1.Technical Instructions
This part introduces the composition of complete machine, technical features and technical parameters,
etc., and then introduces the structures and working principles in terms of the mechanical, hydraulic and
electrical systems.
2. Basic Knowledge and Construction Technology of Concrete Pumping
This part introduces the basic knowledge of concrete delivery construction.
3. Starting of Equipment
This part introduces the operation method, precautions and check points for start of trailer-mounted
concrete pump.
4. Operation of Equipment
This part introduces the operation and knowledge related to trailer-mounted concrete pump.
5. Cleaning of Equipment
This part introduces the cleaning of trailer-mounted concrete pump.
6. Moving and Lifting of Equipment
This part introduces the moving and lifting of trailer-mounted concrete pump.
7. Annex
The annex includes the hydraulic and electrical basic diagrams.
Explanation of Signs:
This is a sign of “Caution”.

When you see this sign on the machine or in this Operation Manual, it indicates the possible injury of
personnel or property damage. It is a prohibition.
Please obey the precautions and methods suggested for the safe operation.
On the sign boards, the is used together with such words that mean hazard as “Danger”,
“Warning” and “Caution”.
II
READING GUIDANCE
Danger
Be vigilant on serious danger! It means an immediate danger, which may cause death or serious injury if
no preventive measure is taken.
Warning
Be vigilant on medium danger! It means a potential danger, which may cause serious injury if no preventive
measure is taken.
Caution
Pay close attention to slight danger! It means a potential danger, which may cause slight or moderate
injury if no preventive measure is taken.
The sign of “Danger” or “Warning” should be established nearby the place where the special hazard is
easy to occur, while the general precautions should be listed on the sign of “Caution” for calling attention to
the safety indication.
PROMPT
It is used to give additional instructions to some specific information.
It indicates the current operation fails to comply with the safety regulations and it is easy to cause casualty
accident, so it should be forbidden.
It indicates the current operation complies with the safety regulations.
III
CONTENTS
Contents
1 Technical Instructions………………………………………………………………………………………1
1.1 Basic Structure……………………………………………………………………………………………………1
1.2 Main Features……………………………………………………………………………………………………2
1.3 Technical Parameters……………………………………………………………………………………………4
1.4 Mechanical Parts…………………………………………………………………………………………………6
1.5 Hydraulic System………………………………………………………………………………………………16
1.6 Electrical System………………………………………………………………………………………………31
2 Basic Information and Construction Technology of Pumped Concrete……………35

2.1 Basic Information of Pumped Concrete………………………………………………………………………36
2.2 Construction Technology of Pumped Concrete………………………………………………………………42
3 Starting of Equipment……………………………………………………………………………………53
3.1 Check and Preparation Before Starting………………………………………………………………………53
3.2 Starting and Running of Trailer-mounted Concrete Pump…………………………………………………55
4 Operation of Equipment……………………………………………………………………………… 57
4.1 Precautions During Operation…………………………………………………………………………………57
4.2 Equipment Adjustment………………………………………………………………………………………61
4.3 Local Control Operation………………………………………………………………………………………63
4.4 Remote Control Operation……………………………………………………………………………………63
4.5 Precautions after Stoppage……………………………………………………………………………………64
4.6 Working Media…………………………………………………………………………………………………64
5 Cleaning……………………………………………………………………………………………………………71
6 Transportation and Lifting of Equipment…………………………………………………………73

6.1 Package…………………………………………………………………………………………………………73
6.2 Transportation and Storage……………………………………………………………………………………73
7 Annex……………………………………………………………………………………………………………77
7.1 Hydraulic Basic Diagram………………………………………………………………………………………77
7.2 Electrical Basic Diagram………………………………………………………………………………………78
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TECHNICAL INSTRUCTIONS
1 Technical Instructions
The trailer-mounted concrete pump is an

equipment installed on a trailer body
understructure and used for concrete pumping by
means of pipeline, which features safe operation,
high efficiency, high quality, low cost and eco-
friendly. It is widely used for such concrete
construction projects as city, airport, road, bridge,
water conservancy, electricity and energy
construction works.
1.1 Basic Structure

The trailer-mounted concrete pump consists of five
main parts, namely, mechanical system, cooling
system, lubrication system, hydraulic system, and
electrical system (see Fig. 1-1).
1 2
3 4 5
1-Mechanical system 2-Cooling system 3-Lubrication system

4-Hydraulic system 5-Electrical system
Fig.1-1 General Drawing of trailer-mounted concrete pump
(1) Mechanical system

The mechanical system is made up of pumping
system, main power system, hydraulic oil tank,
body understructure, machine body, axle, guide
wheel, etc.
1
(2) Cooling system

Three cooling methods are available for the
cooling of hydraulic oil, namely, water cooling, air
cooling and the combination of air cooling and
water cooling. Select the proper one according to
the local climate and construction conditions. The
cooling system is made up of water cooler/air
cooler radiator, hydraulic motor, rubber hose,
connector, etc.
(3) Lubrication system
As an essential part of mechanical equipment, the
lubrication system mainly functions for the
lubrication of mechanical moving parts.
(4) Hydraulic system
The hydraulic system is made up of hydraulic
pump, valve group, accumulator and other
hydraulic elements.
(5) Electrical system
The electrical system is made up of control cabinet,
remote controller and other electrical elements.
1.2 Main Features

HBT80C-1818DIII trailer-mounted concrete pump
has the following main technical features. You will
get better understanding in these features in the
following sections:
(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
3
can be used for pumping 20000 m 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.
2
(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℃ ~ +70℃, strong waterproof &
dustproof ability, IP67 protection level and a
malfunction rate reduced by 80%.
(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 15 min, 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 leakage and
pollution to eliminate the blockage of pipe.
3
1.3 Technical Parameters

1.3.1 Technical Parameters Table of trailer-
mounted concrete pump (see Table 1-1)
Table 1-1 Technical Parameters of trailer-mounted concrete pump
Model
HBT80C-1818DIII
Technical Parameters
Max. theoretical concrete pressure (low/high pressure): MPa 10/18
3
Max. theoretical concrete output (Low/high pressure) : m /h 85/50
Rated power of diesel engine: kW 181/186
Max. aggregate size: Φ150 mm 50
Pipeline size
mm Φ125 mm 40
Concrete slump: mm 100~230
Delivery c ylinder bore × max. stroke: mm Φ200X1800
3
Hopper capacity × feeding height: m /mm 0.7X1420
Overall dimension (length × width × height ): mm 7431 X2075 X 2628
Gross mass: kg 7300
4
1.3.2 Pumping Curve of trailer-mounted concrete

pump (see Fig. 1-2).
Concrete pressure (bar)
3
Concrete output (m /h) Low-pressure
High-pressure pumping
pumping
Fig. 1-2 Pumping Curve
5
1.4 Mechanical Parts

The mechanical system is made up of pumping
system, main power system, hydraulic oil tank,
body understructure, machine body, axle, guide
wheel, etc.
1.4.1 S-valve Pumping Mechanism

The pumping mechanism is made up of main oil
cylinder, water tank, delivery cylinder, concrete
piston, swing mechanism, mixing mechanism,
hopper, S-valve, etc. (See Fig. 1-3).
1a 3a 4a 5a 6 7
1b 2 3b 4b 5b 8
1a-Main oil cylinder 1b-Main oil cylinder 2-Water tank 3a-Delivery cylinder
3b-Delivery cylinder 4a-Concrete piston 4b-Concrete piston 5a-Swing valve cylinder
5b-Swing valve cylinder 6-Mixing system 7-Hopper 8-S-valve
Fig. 1-3 Basic Diagram of S-valve Pumping Mechanism
6
When pumping concrete, under the action of main

oil cylinders 1a and 1b, concrete piston 4b moves
forwards, and concrete piston 4a moves
backwards. At this time, swing valve cylinder 5b
extends and swing valve cylinder 5a draws back.
Through the swing arm, S-valve 8 is connected
with concrete delivery cylinder 3b, thus the
concrete in 3b can be driven from S-valve into the
delivery pipe by 4b. While the concrete in hopper 7
is sucked into concrete delivery cylinder 3a by
continuously retracting piston 4a. After 4b moves
forwards and 4a draws back to the designated
positions, the control system sends a signal to
make swing valve cylinder 5a extend out and 5b
draw back. After swing valve cylinders 5a and 5b
reverse to designated positions, a signal is sent to
make main oil cylinders 1a and 1b reverse and
push piston 4a to move forward and 4b draw back.
The concrete sucked into delivery cylinder 3a in
last cycle is pushed into S-valve 8 and then into
delivery pipe. At the same time, delivery cylinder
3b sucks material. By repeating the above actions,
the pumping of concrete is completed.
In case of reverse pumping, the concrete cylinder
in suction stroke is connected with the S-valve
through the reverse pumping to make the concrete
cylinder in pushing stroke be connected with the
hopper, so as to pump the concrete in pipeline
back into the hopper (see Fig. 1-4).
A) B)
1-Forward pumping state 2-Reverse pumping state

Fig. 1-4 Schematic Diagram for Working State of Pumping System
7
1.4.2 Main Power System

The power source of the trailer-mounted concrete
pump is diesel engine.
The diesel engine, by means of the coupling,
drives the oil pump to run at a high speed and
provide the pressure oil to the hydraulic system.
The diesel engine adopted in SANY trailer-
mounted concrete pump is DEUTZ diesel engine,
with strong power, low oil consumption, little noise
and low emission (see Fig. 1-5).
The axial plunger variable pump is adopted in the 1 2 3 4 5
trailer-mounted concrete pump, whose output flow
is in direct proportion with the driving rotation 1. Gear pump 2. Main oil pump 3. Pump seat
speed and pump capacity, and can be adjusted 4. Coupling 5. Diesel engine
steplessly between zero and maximum, with Fig.1-5 Schematic Diagram of Main Power System
functions of constant-power control, pressure cut-
off and electro proportional flow adjustment. 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 maching.
PROMPT
The diesel-powered trailer-mounted concrete

pump also contains an automatic throttle
adjusting device, a diesel tank and attached
accessories of diesel engine.
The automatic throttle adjusting device is used to

1 2 3 4
control the diesel engine speed (see Fig. 1-6).
The attached accessories of diesel engine include

diesel filter, exhaust pipe, silencer, manual pump,
etc.
1-DC motor 2-Controller 3-Cable 4-Strain plate

Fig. 1-6 Schematic Diagram for
Automatic Throttle Adjusting Device
8
1.4.3 Hydraulic Oil Tank

The hydraulic oil tank, a specially made container, 6 7
has functions of eliminating heat and depositing oil
5
dirt (see Fig. 1-7) besides storing hydraulic oil. To
keep the hydraulic oil free of foreign substances, it
is forbidden to uncover the hydraulic oil tank at
random.
The functions of each component are as follows: 4
Drainage valve: It is used for draining dirty oil in
3
case of cleaning the oil tank. Mostly, it is closed.
Tank body: It is used to store hydraulic oil. 2
Self-sealing device of oil suction: It is used to
prevent the hydraulic oil from leaking from oil tank
when the main oil-suction pipe is removed.
Temperature sensor: It is used to measure the
hydraulic oil temperature.
1
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 1- Drainage valve 2- Tank body
level. 3- Self-sealing device of oil suction
Air cleaner: It is used to block foreign substances 4- Temperature sensor
and filter air. 5- Oil level meter 6- Air cleaner
7- Quick oiling connector
Fig. 1-7 Schematic Diagram for Hydraulic Oil Tank
1.4.4 Body Understructure 8 9

The body understructure, the basic part for the 1 2 3 4 5 6 7
connection of each part of the trailer-mounted

concrete pump, is used to support each part. As its
front is connected with the hopper and its rear is
with towing ring, so the trailer-mounted concrete
pump can be transferred from one worksite to
another through it (see Fig. 1-8).
11 10
14 13 12
1-Hopper fixed seat 2-Diesel tank support

3-Main valve group support 4-Water tank bearer
5-Diesel engine bearer 6-Battery box seat
7-Toolbox 8- Guide wheel support
9-Towing ring 10- Free outrigger
11-Outrigger cylinder 12-Electric control cabinet bearer
13-Pedal 14-Mounting seat of axle
Fig. 1-8 Schematic Diagram for
Structure of Body Understructure
9
1.4.5 Machine Body

1 2 3
The machine body (covering parts) is installed on
the body understructure and mainly used to protect
the internal parts (see Fig. 1-9).
6 5 4
1.Side door power support 2.Top cover

3. Framework 4.Tail cover
5. Door lock 6.Side door
Fig.1-9 Schematic Diagram for
Structure of Machine Body
1.4.6 Axle of trailer-mounted concrete pump
The axle of trailer-mounted concrete pump mainly

1 2
works as the traveling mechanism when the trailer-
mounted concrete pump is being towed with guide
wheel and outrigger retracted and the speed not
more than 15 km/h on Class 2 road and not more
than 8 km/h on Class 3 road.
3 4 5
1.Tyre cover 2.Tyre rim 3.Axle

4. Mounting seat 5.Wheel hub
Structure of Axle
10
1.4.7 Guide Wheel
The guide wheel is the auxiliary device for the

short-distance traveling and supporting of trailer-
1
mounted concrete pump (see Fig. 1-11).
1. Mounting seat 2.Support

3.Wheel
Structure of Guide Wheel
Caution
When the trailer-mounted concrete pump is

towed, its guide wheel should be completely
retracted and should not contact the ground.
11
1.4.8 Cooling System
Three cooling methods are available for the

cooling of hydraulic oil, namely, water cooling, air
cooling and the combination of air cooling and
water cooling. Select the proper one according to
the local climate and construction conditions. 1 2 3 4 5
(1) Water Cooling System
The water cooling system is composed of water-
in/out connecting tube, valve, oil-return tube,
cooler, oil-in tube, etc. (see Fig. 1-12). It is installed
under the body understructure generally, featuring
convenient use, simple structure, fast cooling and
low cost. It is applicable when the cooling water is
available easily.
When the oil temperature ≥ 50℃, open the water
cooler valve, and the water will flow in at the water
inlet and flow out at the water outlet after passing 1-Water inlet/outlet 2-Valve
through the cooler. At this time, heat exchange is 3-Oil-return tube 4-Cooler 5-Oil-in tube
conducted between the hydraulic oil and the water Fig. 1-12 Schematic Diagram for
in the cooler, so that the hydraulic oil is cooled. Water Cooling System
(2) Air Cooling System

3 2 1
The air cooling system is composed of radiator,
hydraulic motor, fan, rubber hose, etc. (see Fig. 1-
13). It can adjust the hydraulic oil temperature.
When the oil temperature is higher than 55℃, the
contact of temperature switch will close
automatically and give out command to make the
electromagnet of hydraulic motor move. Then, the
hydraulic motor starts to work and cool the
hydraulic oil under the effect of radiator; When the
oil temperature is lower than 38℃, the contact of
temperature switch will open automatically, so the 1-Radiator 2-Hydraulic motor 3-Fan
hydraulic motor stops working and the cooling is Fig. 1-13 Air Cooling System
stopped. The adoption of high-performance
radiator and hydraulic motor in this cooler makes it
be able to work in adverse condition for a long
time.
12
1.4.9 Lubrication System
As an essential part of mechanical equipment, the

lubrication system mainly functions for the
lubrication of 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.
(1) Manual Lubrication System
A lubricating oil cup of screw cover is equipped on
each of the two swing valve cylinder seats. 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 4
status.
(2) Automatic Lubrication System 5
1 2 3
The automatic lubrication system, integrating the
advantages of double-line lubrication system and 6
the stepping lubrication system, can perform

lubrication with lubricating grease and hydraulic oil. 7
The automatic lubrication system is composed of
manual lubrication pump, filter, single four-way 8 9 10 11 12 13 14
valve, stepping distribution valve, double-line
lubrication center and pipeline (see Fig. 1-14).
Lubricating points: mixing bearing, big and small 1- Lubrication pump 2- Filter 3- One-way valve
bearings of S-valve, and concrete piston in delivery 4- Alternate pressure oil 5- Lubrication center
cylinder. 6- Four-way valve 7- Stepping distribution valve
The manual lubrication pump is an auxiliary grease 8- Big bearing seat of S-valve
supply device for lubrication. Every time before 9- Mixing bearing seat
pumping, it is required to pull the handle of manual 10- Small bearing seat of S-valve
lubrication pump. The manual oil pumping can be 11- Small bearing seat of S-valve
stopped immediately after there is lubricating 12- Mixing bearing seat
grease overflowing from the mixing bearing and 13- Big bearing seat of S-valve
the big and small bearings of S-valve. 14- Concrete piston in delivery cylinder
During concrete pumping, this system Fig. 1-14 Automatic Lubrication System
automatically lubricates the mechanical system
with the lubricant, namely the hydraulic oil supplied
from the double-line lubrication center.
13
The working principle of double-line lubrication

center is based on the alternate pressure effect on
the two pipelines. The alternate pressure oil of this
system comes from the signal pressure oil for
reversing of the main oil cylinder in the pumping
system. This not only meets the use requirements
but also lubricates the concrete piston in delivery
cylinder; in addition, the plunger offset in
distribution valve is adjusted so as to precisely
control the volume of lubricating oil.
PROMPT
In summer, use #00 semifluid non-extreme-

pressure lithium-based lubricating grease; in
winter, use #000 semifluid non-extreme-
pressure lithium-based lubricating grease.
Manual Lubrication Pump (see Fig. 1-15)

The structure of adopted SB-M manual lubricating
grease pump is unique. The oil scraper and mixer
are set up in the oil barrel. When the handle is
moved to and fro, the oil scraper will scrape off the
oil from the barrel arm, the mixer presses the
lubricating grease to the oil suction after mixing it,
so that the air suction due to poor flowability of
lubricating grease is solved. The trailer-mounted
concrete pump is equipped with exhaust valve. If
there is air in the pump, loosen the connector of
exhaust valve and move the handle continuously
till the lubricating grease mixed with air is drained.
a) Operation Method:
Turn the handle to the horizontal position, and then
move the handle to and fro to make the oil reach Fig. 1-15 Manual Lubrication Pump
each lubricating point for lubrication after passing
through the grease filter, single four-way valve and
sheet oil separator.
14
b) Operation Regulations:
This lubrication system is an auxiliary oil supply
device for lubrication. Therefore, every time before
starting the trailer-mounted concrete pump (after
cleaning the complete machine), perform check
and keep the oil tank of manual lubricating grease
pump full with lubricating grease. Later, pull the
handle of lubricating grease pump. After there is
grease overflowing at the mixing bearing and big
and small bearing ends of S-valve, immediately
stop the manual oil pumping and start the pumping
system. During operation of the trailer-mounted
concrete pump, the system automatically lubricates
the machine by taking the hydraulic oil as
lubricating medium, and the manual lubricating
grease pump is no longer required.
c) Main Parameters
Maximum working pressure: 30 MPa
Maximum oil supply: 2 ml/cycle
Oil container capacity: 1.5 L
Applicable lubricating oil: in summer, #00 lithium-
based lubricating grease; in winter, #000 semifluid
lubricating grease
(Needle penetration should be above 250.)
Stepping distribution valve: an integral precision
element, functioning to distribute the pressure oil to
each lubricatiing point with quota.
Single four-way valve: acting to prevent the
lubricating grease from entering the hydraulic
system via the lubrication center.
Filter: filtering lubricating grease and preventing
foreign substances from entering the stepping
distributor and each lubricating point.
PROMPT
- The manual lubrication pump should be kept

clean constantly. Strictly prevent dust and
other foreign substances from entering it, and
keep it away from acid or alkali substances.
- The applied lubricating grease should comply
with the type requirements and must be clean.
- After the lubrication cycle ends, turn the
handle back to vertical position.
15
1.5 Hydraulic System

1.5.1 Hydraulic Circuit
The hydraulic system of trailer-mounted concrete
pump is composed of hydraulic circuit of pumping
system and auxiliary hydraulic circuit, of which the
hydraulic circuit of pumping system has two
operating functions of “forward pumping” and
“reverse pumping”, and two working modes of
“high pressure” and “low pressure”. All of these are
completed through the controls of hydraulic and
electrical systems.
The forward pumping is to continuously deliver the
concrete in hopper to the working side through
pumping system and pipeline, while the reverse
pumping is to suck the concrete in pipeline back to
hopper for the sake of blockage cleanup, and it
can also be used for cleaning pipeline.
The switching of modes of pumping with high/low
pressure is one of the most important operating
modes of the trailer-mounted concrete pump. From
is the diagram for hydraulic circuit of both modes of
pumping with “high pressure” and “low pressure”
(see Fig. 1-16), it is easy to find that the basic
difference is whether the piston chamber or the
piston rod chamber is used to drive pumping. If
using piston chamber to drive, the pressure of
trailer-mounted concrete pump outlet is high under
the same system pressure P, namely, it is named
as “high pressure”. Contrarily, if using piston rod
chamber to drive, it is named as “low pressure”. As
the active area of piston chamber is larger than
that of piston rod chamber, in case of constant
output flow of main oil pump, the reversing times of
main oil cylinder in unit time under “high pressure”
work condition is less than those under “low
pressure” work condition, namely, the concrete
output of the trailer-mounted concrete pump is
relatively low.
16
a. High pressure b. Low pressure
Fig. 1-16 Hydraulic Circuit
(1) Hydraulic Circuit of Pumping System

The hydraulic circuit of pumping system is
composed of main circuit, distribution valve circuit,
automatic high-low pressure switch circuit, full
hydraulic reversing circuit, and mixing circuit (see
Fig. 1-17).
17
1-Oil tank 2-Liquid level meter 3-Air filter 4-Oil thermometer 5-Main oil pump 6-Gear pump
7-Gear pump 8-Water cooler 9-High-pressure filter 10-Electromagnetic overflow valve
11-Electromagnetic change valve 12-Overflow valve 13-One-way valve 14-Ball valve
15-Pressure gauge 16-Main four-way valve 17-Four-way valve of swing cylinder 18-Accumulator
19-Small oil controlled valve 20-Electromagnetic change valve 21-Electromagnetic change valve
22-Overflow valve 23-Electromagnetic change valve 24-Pressure relay 25-Mixing motor
26-Oi-drain valve 27-Shuttle valve 28-Cartridge valve 29-Cartridge valve
30-One-way valve 31-Threaded cartridge valve 32-Main oil cylinder 33-Swing valve cylinder
Fig. 1-17 Basic Diagram for Hydraulic System
18
a) Main Circuit
This circuit is composed of main oil pump 5,
electromagnetic overflow valve 10, main four-way
valve 16, and main oil cylinder 32. The main oil
pump is an electro proportional pump with constant
power and pressure cut-off functions; the
electromagnetic overflow valve 10 serves as a
safety valve and controls the loading and
unloading of the system.
The main oil cylinder 32 is an actuating
mechanism, which could drive the concrete pistons
in the left and right delivery cylinders to
reciprocate; the oil outlets A1 and B1 of the main
four-way valve 16 are connected with the oil ports
A1L and B1L of the piston rod chamber through the
high-low pressure switch circuit and the oil ports
A1H and B1H of the piston chamber, accordingly,
its reversing can change the movement directions
of the concrete pistons in the left and right delivery
cylinders.
b) Distribution Valve Circuit
This circuit includes gear pump 6, high-pressure
filter 9, electromagnetic change valve 11, overflow
valve 12, one-way valve 13, four-way valve of
swing cylinder 17, accumulator 18, and swing
valve cylinder 33, of which, the gear pump 6,
electromagnetic change valve 11, and overflow
valve 12 form the oil source with constant
pressure, the electromagnetic change valve 11 is
always energized during pumping; while it is
energized and deenergized alternatively under
standby mode, so as to ensure the pressure of the
accumulator 18 will not fall to zero and the
pressure oil of the gear pump will not be in
overflow state, consuming power to produce heat.
The swing valve cylinder 33 is an actuating
mechanism, which could drive the S-valve
distribution valve to swing leftwards and
rightwards; as the oil outlets A and B of the four-
way valve of swing cylinder 17 are connected with
the piston chambers of the left and right swing
valve cylinders. Its reversing can change the
direction of the S-valve distribution valve ultimately.
19
c) Automatic High-low Pressure Switch Circuit

This circuit includes cartridge valve 28, cartridge
valve 29, electromagnetic change valve 21.2, and
shuttle valve 27. It can form two working circuits of
“high pressure” and “low pressure” by means of
connection and disconnection of the cartridge
valves, and switch these two working circuits by
switching the control pressure oil through the
electromagnetic change valve. Its process is as
follows:
Pressure oil of DT5 is deenergized; electromagnetic

main oil pump 5 change valve 21.2 is at right position
Shuttle valve 27,

obtaining
higher pressure oil
Pressure oil of DT5 is energized; electromagnetic

accumulator 18 change valve 21.2 is at left position
The control chambers of cartridge inserted valves 28.1, 28.4, and 28.5 obtain pressure oil,
closed; the pressure oil in the control chambers of cartridge inserted valves 28.2, 28.3,
and 29 is drained back to oil tank, open. The system is under
pumping with low pressure.
The control chambers of cartridge inserted valves 28.2, 28.3, and 29 obtain pressure oil,
closed; the pressure oil in the control chambers of cartridge inserted valves 28.1, 28.4,
and 28.5 is drained back to oil tank, open. The system is under pumping with high pressure.
d) Full Hydraulic Reversing Circuit

The full hydraulic reversing circuit can form two
working modes of “forward pumping” and “reverse
pumping”; the alternative reversing of the main oil
cylinder and swing valve cylinder can be
completed by the hydraulic system itself. The
circuit includes small oil controlled valve 19,
electromagnetic change valve 20, electromagnetic
change valve 21.1, oil-drain valve 26, one-way
valve 30, and threaded cartridge valve 31. The
difference between the forward pumping and
reverse pumping in interms of control is that the
electrified electromagnet is different, accordingly,
the relevant controlling oil circuits will be changed.
For forward pumping, the electromagnets DT1 and
20
DT2 are energized; while for reverse pumping, the

electromagnets DT1, DT3 and DT4 are energized.
We take the forward pumping as the example to
introduce the work cycle of the full hydraulic
reversing.
When “forwarding pumping” is started, the
electromagnets DT1 and DT2 will be energized.
The former half work cycle is as follows:
- The former half cycle of forward pumping:
Electromagnetic Make the four-way

change valve Small oil controlle valve 17 of swing
21.1 is at d valve 19.2 cylinder at
right position. is at right position. right position.
Four-way valve The movement of swing

17 of swing Piston-side
valve cylinder makes
cylinder is at of swing valve
right position the S-valve be connected
cylinder 33.1 with the delivery cylinder
connected with main oil
cylinder 32.1.
Pressure oil
of accumulator
18
Control oil circuit C3
makes the small oil
controlled valve 19.1
at right position.
Electromagnetic Small oil controlled Make the main

change valve 20 valve 19.1 is four-way valve
is at left position. at right position. 16 at right position.
Pressure oil of Main four-way Piston of main The delivery cylinder

main oil valve 16 is at oil cylinder connected with 32.2 sucks
pump 5 right position. 32.2 retracts. material from hopper.
The delivery cylinder

Piston of main oil connected with 32.1
cylinder 32.1 discharges material
The piston of main oil cylinder 32.1 moves forwards. into S-valve.
moves forwards. When it approaches the
end, C1 moves to make the small oil
controlled valve 19.2 at left position.
21
Subsequently, the pumping enters the latter half

cycle automatically.
- The latter half cycle of forward pumping:
Electromagnetic Small oil controlled Make the four-way
change valve 21.1 valve 19.2 is valve 17 of swing
is at right position. at left position. cylinder at left position.
Four-way valve The movement of swing

Piston-side
17 of swing valve cylinder makes
of swing valve
cylinder is the S-valve be connected
cylinder 33.2
at left position with the delivery cylinder
connected with main
oil cylinder 32.2.
Pressure oil of
accumulator 18
Control oil circuit C4 makes
the small oil controlled
valve 19.1 at left position.
Electromagnetic
change valve Small oil Make the main
20 is at controlled valve four-way valve
left position. 19.1 is at 16 at left position.
left position.
Pressure oil Main four-way Piston of main The delivery cylinder

of main oil valve 16 is oil cylinder connected with
pump 5 at left position. 32.1 retracts. 32.1 sucks
material from hopper.
Piston of main oil The delivery cylinder

cylinder 32.2 connected with 32.2
The piston of main oil cylinder 32.2 moves forwards. discharges material
moves forwards. When it approaches into S-valve.
the end, C2 moves to make the small
oil controlled valve 19.2 at right position.
22
e) Mixing Circuit Pressure oil of accumulator

This circuit is composed of overflow valve 22, 1
electromagnetic change valve 23, pressure relay 24,
ball valve 14.2, and mixing motor 25. The function of 25MPa
pressure relay 24 is to inform the controller to 2
energize the electromagnet DT7 when detecting that
the mixing pressure is up to the set value of 11 MPa 3
to make the electromagnetic change valve 23 at left
position and the mixing motor reverse. After lasting a
certain time, it deenergizes the electromagnet DT7 to 4.1 4.2
make the electromagnetic change valve 23 at right 5
position and the mixing motor resume forward
rotation. The overlying type overflow valve 20 is used
to set the maximum pressure of mixing system as 12 1-One-way valve 2-Overflow valve
MPa. The mixing motor 25, an actuating mechanism, 3-Washing chamber 4-Y-ring
drives the mixing device to conduct forward or 5-Piston rod of main oil cylinder
reverse rotation. Fig. 1-18 Waterproof Hydraulic Circuit of
(2) Auxiliary Hydraulic Circuit Piston Rod of Main Oil Cylinder
The auxiliary hydraulic circuit of trailer-mounted
concrete pump consists of waterproof sealing
hydraulic circuit of piston rod of main oil cylinder, air-
cooling circuit, hydraulic circuit of automatic concrete
piston retraction and hydraulic outrigger circuit.
a) Waterproof Sealing Hydraulic Circuit of Piston
Rod of Main Oil Cylinder
This circuit is composed of one-way valve 1,
overflow valve 2 and Y-ring 4 (see Fig. 1-18).
The piston rod of main oil cylinder of trailer-mounted
concrete pump is always completely immersed in the
water. In this case, the dust-proof ring of main oil
cylinder can not completely scrape off the water
layer attached on the piston rod when the piston rod
of main oil cylinder is retracting quickly. The residual
water is always taken into the hydraulic system,
which leads to emulsification of hydraulic oil.
One high-pressure buffer area is formed by Y-rings
4.1 and 4.2, into which the pressure oil of
accumulator is inducted through the one-way valve
1. In this case, the high-pressure oil in the buffer
area will make the lip of Y-ring 4 enclasp the piston
rod and the water attached on piston rod would not
intrude into the hydraulic system any more because
the enclasping force originating from high-pressure
oil is much greater than the pretightening force of Y-
ring 4 itself. As it is not avoidable that some water
would enter the high-pressure buffer area during
pumping, the pressure in buffer area will be
increased. The function of overflow valve 2 is to
discharge the oil water mixture in buffer area into the
washing chamber when the pressure in buffer area
rises to the set pressure.
23
b) Air-cooling Circuit
This circuit is composed of electromagnetic valve
1, overflow valve 2, air-cooled motor 3 and air
DT12
cooler 4 (see Fig. 1-19). 2 3 4
There are two cooling methods for hydraulic oil of
trailer-mounted concrete pump: water-cooling and 1
air-cooling. According to the requirements of
customer and the specific construction conditions,
it is possible to assemble one of them or both of
them simultaneously. As for the trailer-mounted 1-Electromagnetic valve 2-Overflow valve
concrete pump, normally the air-cooling circuit 3-Air-cooled motor 4-Air cooler
commonly uses the same oil source with the Fig. 1-19 Air-cooling Circuit
mixing circuit and is equipped between the gear
pump and mixing part; while the air cooler only
cools the returned oil of mixing circuit and the
drained oil of main oil pump.
The specific operating principle is that when the
temperature sensor equipped on the air cooler 4
detects that the temperature of hydraulic oil
reaches the set value of 55℃ , the electromagnet
DT12 is energized and the electromagnetic valve 1
is at left position, and then the air-cooled motor will
be driven to run by the pressure oil to cool the
hydraulic oil; when the temperature sensor detects
that the temperature of hydraulic oil is lower than
the set temperature of 38℃ , the electromagnet
DT12 is deenergized, the electromagnetic valve 1
is at right position and the air-cooled motor stops
running. The function of overflow valve 2 is to
ensure the pressure difference between the oil
outlet and oil inlet of air-cooled motor is not more
than the set value.
24
c) Hydraulic Circuit of Automatic Concrete Piston

Retraction
The hydraulic principle of this circuit is as shown in
Fig. 1-20. It is composed of one-way valve 1,
electromagnetic change valve 2 and limit cylinder
3. The structural sketch for main oil cylinder and
limit cylinder is as shown in Fig. 1-21. When the
electromagnet DT11 is deenergized, the
electromagnetic change valve 2 is at right position,
and then the pressure oil of the accumulator will
enter into limit cylinder 3 through the
electromagnetic change valve 2 and fix the two
pistons of limit cylinder 3 at upper position through 3 3
one-way valve 1, so that the piston of main oil
DT11
cylinder can only move to the normal stroke
position. To replace or check the concrete piston, 2
start the “Concrete piston retraction” on the electric
control cabinet, and then the system will be under Pressure oil
the state of pressure suppression, making the of accumulator 1
electromagnet DT11 be energized and the
electromagnetic change valve 2 at left position.
When the piston of main oil cylinder moves to the 1-One-way valve
normal stroke position, through pressurizing the 2-Electromagnetic change valve
piston of limit cylinder, drive the hydraulic oil in the 3-Limit cylinder
corresponding limit cylinder to return to oil tank Fig. 1-20 Hydraulic Circuit of Automatic
after passing through electromagnetic change Concrete Piston Retraction
valve 2, so that the piston of main oil cylinder can
move backwards continuously to retract the
concrete piston into the washing chamber.
High-pressure oil
Fig. 1-21 Structural Sketch for Main

Oil Cylinder and Limit Cylinder
25
d) Hydraulic Outrigger Circuit 3 3

The trailer-mounted concrete pump employs two
rear hydraulic outriggers and the hydraulic
principle of this circuit is as shown in Fig. 1-22. It is
composed of manual change valve 1, hydraulic
control one-way valve 2 and outrigger cylinder 3.
The manual change valve is to switch the
movements of downward support and retraction of
outrigger cylinder 3; the hydraulic control one-way
valve 2 acts as a hydraulic lock to ensure that the
outrigger cylinder is kept at the specified position.
2
1
Pressure oil of
accumulator
1-Manual change valve

2-Hydraulic control one-way valve
3-Outrigger cylinder
Fig. 1-22 Circuit of Two Rear Hydraulic Outriggers
26
1.5.2 Operating Device of Outriggers
The trailer-mounted concrete pump is controlled by

mechanical limit and manual change valve.
The control of manual change valve is realized by
manual control valve group, which mainly includes
overlying type one-way valve and manual change
valve, as shown in Fig. 1-23:
1 2 3
1. Manual control valve block

2. Overlying type one-way valve
3. Manual change valve
Fig. 1-23 Diagram for Control of
Manual Change Valve
Caution
To operate the outriggers, pull the handle

leftwards or rightwards. The manual change
valve can reset by way of spring. It
automatically returns to zero position after the
handle is released, at this moment the
outriggers stop action.
The mechanical limit is mainly achieved by

outrigger cross pin as shown in Fig. 1-24.
Cross pin
of outrigger
Fig.1-24 Outrigger Limit
27
1.5.3 Mixing and Mixing Cut-off Valve

The auxiliary valve block equipped with mixing
control valve is installed on the left side of oil tank
(taking the hopper as front). Make the mixer switch
between the two rotation directions by controlling
the reverse mixing electromagnetic valve. During 1
forward mixing (when the electromagnet is
deenergized), the mixer “feeds” the delivery
cylinder with concrete; during reverse mixing (the 2 3
electromagnet is energized), the mixer pushes the
concrete out from the delivery cylinder (see Fig. 1-
25 and Fig. 1-26).
1. Hopper 2. Mixing motor 3. Mixing ball valve

Fig. 1-25 Mixing Control
Caution
1
The mixing magnetic valve installed on the 2

auxiliary valve block (No. 1 in the Fig. 1-26) is
3
used to adjust the operating pressure of mixing
motor; while the pressure relay is used to 4
ensure that when the mixing pressure is
excessive, let the mixing electromagnetic valve 5
reverse to make the mixing motor reverse.
1. Mixing electromagnetic valve

2. Mixing overflow valve 3. Pressure relay
Fig.1-26 Auxiliary Valve Block
28
1.5.4 Accumulator and Unloading Ball Valve of

Accumulator
The 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. The trailer-mounted concrete pump is
2 4
equipped with an unloading cut-off valve of
accumulator. When this cut-off valve is opened, the
pressure oil of accumulator is unloaded for the
convenience of inspection and repair. The 1 3
unloading ball valve of accumulator is installed
beside the main valve block (see Fig. 1-27).
1. Main valve block

2. Unloading ball valve of accumulator
3. Accumulator 4. Oil tank
Fig. 1-27 Accumulator
Danger
When the accumulator is unloaded but the

basic machine still operates, the S-valve may
still move. At this time, if you go to check the
hopper and S-valve, there may be danger of
crushing or cutting of your fingers. Therefore, it
is necessary to stop the machine before
inspection.
When the machine still operates, do remember
that don't enter the hopper from the flushing
port at the lower part of hopper or the grid at the
upper part of hopper. Don't throw foreign
substances into the hopper.
29
1.5.5 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 hydraulic system to
prevent the hydraulic oil in the oil tank from leaking 1
outwards. What adopted for the oil suction sealing
device of main oil pump is “self-sealing device of
oil suction”, see Fig. 1-28; while the gear pump
directly takes oil from the oil-suction tube of main
oil pump. 2
1. Oil tank
Caution 2. Self-sealing device of oil suction
3. Oil-suction tube of main oil pump
Fig.1-28 Self-sealing Device of
The self-sealing device of oil suction must be Main Oil Pump Oil Suction
opened usually to keep smooth oil suction of
pump. Otherwise, the pump will suck air
resulting in damage.
The self-sealing device of oil suction is
adjusted by the adjusting threaded rod. Screw
it down to open the oil circuit, screw off the
threaded rod 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 of self-sealing device of
oil suction after system inspection and repair.
30
1.6 Electrical System

1.6.1 Introduction
(1) This electrical control system employs 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 control system is provided with “speed
adjustment by way of diesel engine and automatic
control of computer” which has obtained the
domestic sole patent. The display is the SANY-
made SYLD with pages for original parameters
setup and parameter modification. There are two
main page available according to whether the
trailer-mounted concrete pump is powered by
motor and or diesel engine. The basic information
covered by the page for motor includes clock,
output meter, total pumping time, total running
time, current states (local/remote control, high/low
pressure), motor start information ( start
information about two motors in case of double
power units and start information about a motor in
case of single power unit), current operation
information, various function information (fan,
water pump, etc.), warning messages; and the
basic information covered by the page for diesel
engine includes clock, speed meters (two speed
meters with output shown below in case of double
power units; and a speed meter and an output
meter in case of single power unit), total pumping
time, total running time, current states
(local/remote control, high/low pressure), current
operation information, various function information
(fan, water pump, etc.), And warning messages.
There is energy-saving button in the main page for
diesel engine.
(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 SYLD communication circuit, CAN bus
diesel engine control circuit and remote control box
control circuit.
31
1.6.2 Electrical Control Device

The electrical control cabinet panel is as shown in
Fig. 1-29.
1 4
No. Identification 2 Local control

Electric control system of
trailer-mounted concrete pump
Low
pressure
F1
5
F2
1 Engine oil pressure gauge showing the

F3
Start
Metering F4
Reversing Times
Pumping Timing
Pumping Times
Forced
Control
F5
Rotation Angle
F6
oil pressure of diesel engine

Function
Menu
3
2 Voltmeter of power supply showing the
6
working voltage of equipment
3 SYLD display showing the operation
7 9
information and parameters
4 Fuel gauge showing the diesel level 8
5 Water thermometer showing the diesel
engine coolant temperature
Fig. 1-29 Schematic Diagram for Operation
6 Emergency stopping button Panel of Electric Control Cabinet
7 Starting button of control power supply
8 Starting toggle switch of diesel engine
9 Control toggle switch of swing cylinder
The switches on the operation panel are mainly for

the operation of start and stop of diesel engine and
all relevant functions. In addition, there are
voltmeter of power supply indicating the operating
voltage of equipment, water thermometer
indicating the diesel engine coolant temperature,
fuel gauge showing the diesel level, SYLD display
showing the operating conditions and data as well
as providing parameter selection and modification.
32
(2) Elements of Electrical Control Cabinet

7 6
The elements of electrical control cabinet are in the
electrical control cabinet (see Fig. 1-30).
-XD5 -XD8
GPS
SYMC
No. Identification
-XD10
-XD7
-XD6
1 Step motor driver JN Q1 Q2 Q3
-X D 3
SYEB
MD
-XD9
KA1 KA2
-X D 4
-XD13
2 High-current relay
3 Monopole breaker
4 Intermediate relay
5 Electrical board assembly
1 2 3 4 5
6 SYMT terminal assembly
7 SYMC controller
Fig. 1-30 Schematic Diagram for Elements
in Electrical Control Cabinet
The cabinet is mainly used for installing the electric

appliance elements required by the trailer-mounted
concrete pump in order to facilitate the centralized
wiring and maintenance and provide high
protection level. When checking and replacing the
elements, it is necessary to cut off the main power
supply and reset various functional switches.
Caution
It is prohibited to flush the electrical control

cabinet and electric appliance elements with
water or expose them to water.
33
K
AN
BL
FT
LE
LY
AL
N
O
TI
N
TE
IN
E
G
PA
IS
TH
34
BASIC INFORMATION AND CONSTRUCTION TECHNOLOGY OF PUMPED CONCRETE
2 Basic Information and Construction Technology of Pumped Concrete
Concrete pumping can help improving the quality

of concrete construction, saving raw material,
shortening construction period, developing working
productivity, reducing working strength, preventing
environment pollution and bringing good economic
and social benefits.
Because it differs from traditional concrete
construction method, the requirements for concrete
are not the same: not only the strength and
durability stipulated in the design but the
requirements of concrete mixture by pipeline
should be met, that is to say, the concrete mixture
should have good pumpability. The requirements
on material and mix proportion are different
between pumped concrete and ordinary concrete,
so not all kinds of concrete mixture is pumpable.
The so-called pumpability refers to that the
concrete mixture should have the capability of
passing through pipelines smoothly, with little
friction resistance and good cohesiveness, without
segregation or blockage.
When concrete pumping is applied for
construction, the trailer-mounted concrete pump
must be used properly. The key parameter of the
trailer-mounted concrete pump is its pumping
capacity. The pumping capacity is represented by
the maximum deliverd concrete quantity (output)
through concrete pumping and the maximum
delivery pressure. The pumping capacity indicated
in the nameplate of trailer-mounted concrete pump
is calculated under certain conditions. For
example, in case of poor concrete quality, mix
proportion, aggregate gradation, sand ratio, water
cement ratio, slump or layout of concrete piping,
the pumping capacity of the trailer-mounted
concrete pump will be influenced. Proper
measures, if taken, can improve the pumping
capacity. In this section, the information related to
pumping capacity, like selection and arrangement
of pumping concrete and delivery pipes, will be
introduced.
35
2.1 Basic Information of Pumped Concrete

2.1.1 Requirements for Raw Materials
(1) Cement
Cement is a kind of hydraulic gel material,
generally including Portland cement, ordinary
Portland cement and slag Portland cement, all of
which should comply with GB175-99 and GB1344-
99.
(2) Admixture
Fly ash is the admixture usually used in pumped
concrete.
The fly ash admixed into the pumped concrete can
greatly improve the liquidity of the concrete
mixture, prevent bleeding and dry shrinkage, and
obviously develop concrete pumpablity. As to
large-sized concrete structure, certain amount of
fly ash being admixed can reduce concrete
hydration heat and help preventing temperature
flaws.
(3) Sand
River sand is more common in regular
construction. The sand should comply with JGJ52-
92, Technical Requirements and Test Methods of
Sand for Ordinary Concrete. As the sand is
categorized by fineness modulus, the sand for
pumped concrete is usually medium sand of
modulus (3.0-2.3).
(4) Stone
The stone is categorized into igneous rock,
sedimentary rock and metamorphic rock. Most
igneous rocks are good stone raw material. The
stone used in pumped concrete should comply
with JGJ53-92, Technical Requirements and Test
Methods of Sand for Ordinary Concrete.
(5) Additive
The so-called concrete additive is added during or
before the mixing process of concrete, with the
added amount being no more than 5% of the
cement weight, and it can change the concrete
performance as required. The additive commonly
used includes water reducing agent, air admission
agent, thickening time control agent and anti-
freezing agent, with water reducing agent being
the most popular. The additive should comply with
JGJ56-84, Quality Standards of Concrete Additive.
36
2.1.2 Material and Mix Proportion of Pumped

Concrete
The pumped concrete is one of the important
measures for guaranteeing good construction
quality. Properly choosing the material and mix
proportion of pumped concrete is an important
method to guarantee good quality.
(1) Coarse Aggregate
a) Variety and quality of coarse aggregate
Gravel, macadam and combined aggregate of
gravel and macadam can be adopted for pumped
concrete. The pumpability 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
pumpability.
b) 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 2-1.
Table 2-1 Comparison of Sizes of

Aggregates in Delivery Pipe
Maximal Size of
Minimal Diameter of Coarse Aggregate
Delivery Pipe (mm) (mm)
Gravel Macadam
100 30 25
125 40 30
150 50 40
37
B) Gradation of coarse aggregate

The pumpability of concrete is extremely sensitive
to discontinuity or unevenness of gradation of
coarse aggregate. It is not that the smaller, the
better for coarse aggregate, or the more, the better
for small aggregate; while reasonable gradation is
truly important. Refer to Table 2-2 for details of
gradation of coarse aggregate.
Table 2-2 Gradation of Coarse Aggregate
Nominal Size of Sieve Pore (mm)

Aggregate
50 40 30 25 20 15 10 5 2.5
Size (mm)
Weight percentage of aggretates 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
Note
Sizes in parentheses are

only for reference.
38
(2) Fine Aggregate

Because mortar lubricates the pipe wall while
aggregate suspends in grout, concrete mixture can
flow smoothly in delivery pipe. So fine aggregate
influences concrete pumpability more than coarse
aggregate. It is required to get a good gradation of
fine aggregate. Refer to Table 2-3 for the weight
percentage of fine aggregate passing through the
sieve:
Table 2-3 Gradation of Fine Aggregate
Nominal Size of Sieve Pore(mm)

Fine 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
Caution
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%.
(3) Cement Proportion

Different from the ordinary concrete, the lubrication
of pumped concrete uses cement or mortar, and is
applied to the pipe wall. The cement proportion
bears upon the friction inside the pipeline and the
concrete level in the concrete cylinder during
pumping, so 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 proportion 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 2-4).
Table 2-4 Proportion of Fly Ash in Case of Different Cement Grades
Cement Type and Grade

5~25 Portland 5~25 ordinary Portland 425 slag Portland
Class of Concrete
cement cement cement
Strength
≤C25 30% 20% 15%
39
(4) Determination of Sand Ratio

The optimum sand ratio is the one with minimum
cement proportion on the premise of ensureing
good concrete strength and pumpability. The sand
ratio of pumped concrete is greater than that of
non-pumped concrete by 2~5%. The
recommended sand ratio is shown in the table
below:
Table 2-5 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
(5) 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.
(6) Additive for Concrete

For the pumped concrete, besides the strength,
durability, etc., its pumpability (workability) should
be ensured. To ensure its pumpability, some quality
indexes have to be put aside, and the cost of pump
concrete will be increased. The adoption of
additive is a relatively economical method for partly
solving these problems. These additives include
air-entraining agent, water reducing agent,
superplasticizer, retarder, pumping aid, etc. To
improve the pumpability of concrete as well as
improve its quality and save cement, it is
suggested to adopt one or more than one kind of
additive for use. As for the use effect, quantity and
adding method, please follow the stipulations for
pumped concrete and consult with the
constructors, and according to the experiment
results, make timely adjustment to ensure smooth
pumping.
40
(7) Mix Proportion of Pumped Concrete

The purpose of mix proportion design for pumped
concrete is to choose raw materials and produce
concrete with good economic indexes, superior
quality, and good pumpability according to project
requirements on concrete characteristics and
pumping.
In determining the mix proportion of pumped
concrete, the method for the concrete whose
construction is conducted by ordinary methods can
still be adopted. But special treatment should be
conducted in respect of cement proportion, slump,
sand ratio, etc., with the feature of pipe delivery
taken into consideration.
a) Selection of slump
The slump of the concrete whose construction is
conducted by ordinary methods is determined
according to the tamping method, while for
pumped concrete, not only tamping construction
but also its pumpability should be taken into
account, that is: high pumping efficiency and no
blockage.
If the slump is excessively great, the concrete
mixture is easy to segregate, causing blockage.
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.
b) Strict control of the mixt proportion of concrete
- Shorten the transportation time of concrete
before pumping as much as possible. Long-time
transportation will affect the slump of concrete
greatly, and it is generally required to finish
pumping within 90 min after mixing.
- Ensure homogeneity of concrete. To ensure
smooth concrete pumping, machines and
methods for the transportation of mixed concrete
from the mixing spot to the pumping spot should
ensure no segregation in concrete during
transportation. If machines without mixing
devices are used in transportation, the concrete
can be put into the hopper of the trailer-mounted
concrete pump only after the mixing of concrete
following its arrival at the pumping spot. If a
mixer truck is used, it should be ensured that the
transportation capacity is greater than the
pumping capacity to ensure continuous pumping.
Besides, for the concrete discharged from the
41
mixer truck, the gradation always changes, and

the concrete discharged later may have a
relatively large amount of big aggregates.
Therefore, to avoid the blockage due to
gradation variation, it is suggested that a period
of collocation should be arranged in discharging,
that is: as soon as one truck mixer is unloaded,
another begins its discharging, to ensure
basically unchanged gradation.
- Adopt the cement in conformity with national
standards. The rapid setting concrete is
forbidden for pumping.
- The concrete with too much deviation of slump or
obvious quality problems is not allowed to be put
into the hopper.
- It is forbidden to add water into the hopper.
2.2 Construction Technology of

Pumped Concrete
2.2.1 Proper Selection of Concrete Pipe
Concrete delivery pipe is commonly called
concrete pipe, including tapered tube, elbow,
spigot, straight tube, hose and tube connector.
Generally, there is a set of standard piping for the
equipment, but reconfiguration can be carried out
as required by the construction site. The commonly
used secondary piping are pipes of diameters of
125 mm and 150 mm respectively. The basic
requirements for selection are as follows:
125 mm delivery 150 mm delivery 205 mm tertiary

Concrete pipe
pipe pipe delivery pipe
Aggregate size
40 mm /30 mm 50 mm/40 mm 80 mm/ 70 mm
gravel/ macadam
42
(1) Preparation of Piping

Prepare piping and tube connectors according to
the secondary piping breakdown (as shown in Fig.
2-1)
(2) Operation Requirements of Concrete Delivery
Pipe
a) Pay attention to the piping parts easy to wear
out. For the 125A high-pressure pipe, the wall
thickness limit for delivery pipe near the pump
outlet is 4 mm for high-pressure construction, and
the wall thickness for the part to the pouring site
and connected with the placing pipe, can't be less
than 3.5 mm.
b) The damaged, cracked or thin-wall piping is
forbidden for use.
c) On the premise of ensuring smooth pumping
and normal delivery, shorten the distance as much 1-Discharge outlet 2-Tapered tube
as possible and reduce the elbows in the piping 3-45° elbow 4-Spigot
layout to reduce delivery resistance. 5-125A straight tube
d) It is suggested that the hose in the front pouring Fig. 2-1 Secondary Piping
place should be placed vertically. If horizontal
placement is demanded indeed, too much bending
is forbidden.
e) For all the pipelines, it should be ensured that
the connections are firm, the firm fixed devices are
set at the elbows, and the horizontal pipeline is
fixed with firm supports instead of being
suspended.
f) All the tube clamps should be tight enough,
ensuring tube connectors are sealed properly
without slurry leakage, especially ensuring there is
no water seepage at any tube clamp during water
pumping.
g) A certain gap should be spared between each
tube clamp and the ground or support for the
convenience of disassembly and assembly. The
contact of the tube clamps with the ground or
supports is forbidden.
h)It is suggested to wrap the delivery pipes with
heat preservation materials in cold winter to keep
the concrete from cold exposure.
I) It is suggested to cover the delivery pipes with
wet grass sacks, etc. in summer to avoid slump
loss to cause pipe blockage.
43
2.2.2. Pipe Laying

(1) Upward vertical pipe laying
In upward vertical pipe laying, when the distribution
valve of the concrete pump sucks concrete (or stop
pumping) reversely, the gravity of the concrete in
the vertical pipe will produce refluent pressure
(abbreviated as “counter pressure”) on the
concrete pump, and the higher the vertical pipe is,
the greater the refluent pressure is. This refluent
pressure will decrease the volumetric efficiency of
the trailer-mounted concrete pump, affect the
discharge capacity of the trailer-mounted concrete
pump, and cause concrete segregation to block
the pipe. Thus, try to overcome this refluent
pressure in upward vertical pipe laying. And the
methods are:
a) 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, which balances the refluent
pressure by the friction resistance between the
concrete mixture and the delivery pipe wall in the
horizontal pipe.
b) When the vertical height is relatively large or
confined by the site, it is hard to balance the
refluent pressure only by setting horizontal pipes.
So it is suggested to set a spigot between the
tapered tube and the straight tube in the delivery
pipeline, and to seal the spigot to prevent the
concrete from backflow at the time of stopping
pumping.
44
The fixing of elbows and the fixing of vertical pipe

on wall or wall body are as shown in Fig. 2-2.
1-trailer-mounted concrete pump 2-Hopper 3-Discharge outlet 4-Tapered tube 5-45˚ elbow
6. Spigot 7-Straight tube 8-Base 9-90˚ elbow with R=1000 10- Vertical pipe support
11-90˚ elbow with R=1000 12-Horizontal support
Fig. 2-2 Diagram for Pipe Laying
The elbow should have a firm base to minimize the

vibration transferred from the trailer-mounted
concrete pump to the vertical pipe. The vertical
pipe should also be fixed firmly to avoid producing
vibration.
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 substituted for all the places under high
pressure.
45
(2) For the downward piping and concrete

pumping, when the inclination of the piping is over
4 ~ 7º, the concrete with a large fluidity in the
inclined pipe may flow downwards for its dead
weight, causing a hollow space in the delivery pipe
or pipe blockage due to concrete segregation for
its gravity flow. Thus, a horizontal pipe should be
set at the front end of the downward inclined pipe,
with a length more than 5 times of the fall height
“H” (or 3H plus a hose), preventing the concrete
from gravity flow by using its friction resistance.
When the inclination of the piping is over 7 – 12º,
besides the horizontal tube of 5H set at the front
end of the downward inclined pipe (or 3H plus a
hose), an air release valve should also be set at
the upper end of the downward inclined pipe.
During pumping, if a hollow space exists in the
inclined pipe, open the air release valve to
discharge air by pumping at first. When the
inclined pipe is filled with concrete and mortar
starts to overflow from the air release valve, close
the air release valve to conduct normal pumping.
If there is no enough space for laying a horizontal
pipe at the front end of the downward inclined pipe
due to site condition, it is allowed to use hoses,
elbows or ring pipes to increase the friction
resistance to prevent the concrete in the downward
inclined pipe from gravity flow.
For the close relation between the gravity flow of
the concrete and its slump during downward
pumping, in order to avoid downward gravity flow
causing segregation of concrete, set sponge
rubber balls in the pipeline at the beginning of
pumping for the downward concrete delivery at a
large angle.
46
(3) Horizontal conversion length for different pipe

laying
In actual pipe laying, for different pipeline forms,
quantities, and landforms, as well as different
actual delivery distances and heights, convert the
lengths of tapered tube, elbow, hose, upward
vertical pipe, downward vertical pipe, etc. Into
horizontal lengths. The horizontal conversion value
is related to the concrete characteristics and pipe
diameter. Reference can be made to Table 2-6.
Table 2-6 Horizontal Conversion Length for Different Pipe Laying
Horizontal Conversion Length

Delivery Pipe Slump Slump Slump
Type Unit
Specification (mm) (mm) (mm)
50-120 130-170 190-230
Upward vertical
meter 125A 3.5 4 4.5
Pipe
Tapered tube piece 150A-125A 6 6 6
Elbow piece 90° 6 6 6
Hose piece 2 2 2
For downward pipeline, calulation is carried out according to the actual length.
47
2.2.3 Pipe Blockage and Troubleshooting

Under normal situations, if the pressure peak value
of each pumping stroke rises rapidly with the
alternation of strokes, and reaches the set
pressure (32 MPa) soon, the normal pumping
circulation may stop automatically, which indicates
the occurrence of blockage. In that case, the
blockage can generally be remedied by running 1
~ 2 reverse pumping cycles. If there is no effect
after several cycles, it indicates that the blockage
is serious and needs rapid treatment. Caution: the
reverse pumping – forward pumping operation
can't be conducted repeatedly for too many times,
otherwise the blockage will become more serious.
(1) Possible Causes and Prevention of Blockage.
The remedy of blockage is troublesome. So,
prevention is the main countermeasure for
blockage. The prevention work should be done
mainly in the following aspects to reduce the
occurrence possibility of blockage.
a) Concrete quality: poor workability of concrete,
appearing as too large coarse aggregate or
unqualified gradation; too low sand ratio or
unqualified gradation; improper cement proportion
or poor quality; uneven mixing or segregation due
to long stay after mixing; excessively large
hydroscopicity of artificial light-type aggregate,
unsuitable additives, unstable slump, poor
cohesiveness, and poor water retention. Control
should be conducted over concrete quality to
prevent blockage, as the problem of concrete
quality is the main cause for blockage.
b) Pipeline: water leakage of pipe or connector
leading to slump decrease or pressure relief during
delivery; small bending radius of elbow; difference
of pipelines causing recess; misalignment.
c) Equipment: improper adjustment of hydraulic
system parameters.
d) Operation: Long standby or stoppage.
48
(2) Treatment Measures in the Event of Blockage

In the event of blockage, firstly, conduct reverse
pumping. If it doesn't work, immediately identify the
blocked part, stop the machine and clean the
pipeline.
a) The method for identifying blocked part is that
while the operator is conducting the forward
pumping -- reverse pumping operation, other
people look for the blocked part along the delivery
pipeline. Generally speaking, the pipeline from the
pump outlet to the blocked part will vibrate strongly,
while the pipeline after the blocked point is still;
there is noise when the concrete in the blocked
pipe is sucked, while there is no noise after the
blocked point; if the pipeline is knocked, the
blocked part sounds stifling and feels compacted.
b) Once the blocked part is found, while performing
the forward pumping ---- reverse pumping
operation, knock this part with a wooden hammer,
by which the blockage can be eliminated
sometimes. If it doesn't work, immediately
dismount this section of pipeline and clean it.
c) In case of wrong judgement, the cleaning by
section can also be conducted. If the concrete in
the pipe is found to begin coagulate during pipe
dismounting, open all the pipe connectors without
any hesitation, clear them up rapidly, and clean the
trailer-mounted concrete pump, lest the concrete
coagulates and can’t be cleared, making the
concrete pipe be scrapped .
(3) General Rules of Blockage
a) During upward pumping, reverse pumping is
easy to occur, with seldom blockage occurrence,
but the blockage of distribution valve, or tapered
tube and elbow in horizontal section, easily occurs.
b) During horizontal long-distance pumping or
downward inclined pumping, reverse pumping is
not easy to occur. Blockage mainly occurs in
elbows and horizontal pipes at the lower end.
When dealing with blockage, notice the followings:
- Before dismounting the pipe connector, reduce
the rest pressure inside the pipe to zero. The
method is: loosen the pipe connector, and
shake it lightly to relieve the pressure in the
pipe.
49
- 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.
(4) Pipeline Cleaning
Set a plug-in board in the spigot, dismount the
hose at the front end, dismount the pipe connector
from the 150A – 125A tapered tube, pour the
concrete in this tapered tube out, and mount
cleaning tools which are different 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
delivery pipe of a length of 100 – 500 m, the
cleaning tools include one 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), Later, reconnect the
tapered tube, fasten tube clamp, fill the hopper
with water and connect it with a water source, pull
out the plug-in board, cover the lid, start the pump,
press “Forward pumping start” to 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, continue pumping water until no concrete
residues flow out. At this time, the cleaning of
delivery pipe is finished (see Fig. 2-3).
Above 500 m
Below 100m
3
1 1
2 2
1
2 3 3
Pu
Pu
m
Pu
mp
pin
mp
in
gD
gD
ing
ire
ire
D
ctio
cti
irec
on
n
tion
1-Sponge plug 2-Cleaning piston 3-Cement sack

Fig. 2-3 Diagram for Pipeline Cleaning
50
(5) Cleaning of trailer-mounted concrete pump

The trailer-mounted concrete pump should be
cleaned after use, which is divided into daily
cleaning and warehouse-in cleaning.
a) Daily cleaning
First, regulate the output of the main oil pump to
the minimum, perform no-load running for 3 – 4
strokes to discharge the residual concrete, and
stop the no-load running.
Dismount the tapered tube, 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, perform running for 3 - 4
strokes to make the residual concrete be
discharged with the water, perform no-load running
for 20 min when the water is drained, supply
lubricating grease, and shut down the machine
and cut off the power after cleaning.
b) Warehouse-in cleaning
If the trailer-mounted concrete pump will not be
used for a period, it should be put into the
warehouse, with maintenance cleaning conducted
in advance.
Clean it with the method of daily cleaning.
Pull back the concrete piston to drain the water
tank.
Dismount the piston and 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.
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STARTING OF EQUIPMENT
3 Starting of Equipment
3.1 Check and Preparation Before
Starting
(1) The trailer-mounted concrete pump is supported
by the outriggers when operating and the outriggers
should be lowered as follows:
a) Operate the cross pin of guide wheel to retract
the guide wheel and then insert the cross pin.
b) Operate the handle of manual pump and turn the
handle of manual change valve to a proper position
to retract the outrigger cylinder and lower the front
end of body understructure as well as make the
complete machine lean forwards.
c) Pull out the rear free outriggers, insert the lock
pins of outriggers and lock the anti-looseness
mechanism.
d) Operate the handle of manual pump and turn the
handle of manual change valve to the opposite
position to extend the outrigger cylinder and jack up
the front end of body understructure to a proper
position, and then insert and lock the lock pin.
e) After the above operations, ensure that the
complete machine is level and each outrigger is on
the ground with wheels bearing no load, and finally
retract the guide wheel and insert the cross pin.
Retract the outriggers in the reverse order.
(2) Inspection of Electrical Elements
a) Set all switches on the operation panel and the
remote control box at “OFF” position.
b) Disconnection, wire off, looseness of contact
screws and short circuit of electrical elements are
impermissible.
(3) Inspection and Preparation of Engine
a) Before starting, check if the coolant suitable for
ambient temperature is filled to the specified level in
the water tank.
b) Use fuel and engine oil (above Grade CD)
adaptable to local ambient temperature and check
the level of fuel and diesel.
c) Check the battery and circuit. Make sure the
voltage is 24±2 V, and there is no disconnection,
wire off and looseness in the circuit
d) Check the fuel, engine oil and coolant pipe
connectors and sealing surfaces for leakage.
e) Get rid of the obstacles influencing operation.
(4) Check of trailer-mounted concrete pump
a) Keep sufficient hydraulic oil in the oil tank and
sufficient grease in the grease pump and oil cup.
b) Conduct air release for the main oil pump in case
of restart after maintenance and oil filling.
c) Pull the lever of grease pump and turn the oil cup
cover for well lubrication of each point.
53
Caution
- Check the trailer-mounted concrete pump for

its positioning. The trailer-mounted concrete
pump should be installed on even and solid
ground. To avoid automatic slide, the trailer-
mounted concrete pump cannot be set on a
slope.
- Check whether the delivery pipes are laid
correctly and whether the mode and
capacity for concrete delivery and feeding
are normal.
- Check whether the power and water supply
meet the demand by normal operation, and
make sure the electrical, hydraulic and
mechanical systems are in good condition.
- Check the oil level in the hydraulic oil tank.
Fill it in case of insufficiency. The filled
hydraulic oil should meet the requirements.
- Check whether the lubricating grease in the
lubricating grease pump is sufficient. Fill it in
case of insufficiency. Always firstly carry out
manual lubrication if there is a manual
lubrication pump, and then carry out lubrication
by air pumping to check whether the grease
supply at each lubricating point is normal.
- Before starting the trailer-mounted concrete
pump according to the operation
instructions, check and confirm the hopper
screen is closed and the water tank is filled
with clean water and free of foreign
substances. After starting the diesel engine,
operate it with a rotation speed of 800~1000
r/min for 3~5 min.
- A period of idling is necessary if the
temperature is low. Only after the
temperature of the hydraulic oil rises up to
20℃, can the concrete be fed for pumping.
- Conduct idling for 10 min to check whether
the indication of the pressure gauge is
normal, whether the mixing device can
achieve reverse mixing and whether the
reverse pumping is normal.
- Check whether there is explosive gas and
substance around.
- It is prohibited to put your hand into the
hopper and water tank to avoid injury.
54
3.2 Starting and Operation

The operator can start the trailer-mounted concrete
pump after having conducted all the inspection
work.
(1) Separate the engine and the driven device.
(Stop forward pumping and reverse pumping).
(2) Turn off the power supply and press the “Control
power supply start” button, and the indicator lamp
goes on and the meter displays the current state.
(3) Press the “Diesel engine start” button, After the
diesel engine starts, all the meters 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 measuring
devices (gauges) used to measure engine oil
pressure, voltage, fuel level, water temperature and
rotation speed of diesel engine. Only after
everything goes well, can the engine be allowed to
work with load.
(5) Operation of diesel engine in winter.
a) Winter-grade engine oil
b) Winter-grade diesel
c) Under the temperature of lower than -20℃ ,
remove the startup motor if possible, and often
lubricate the ring gear of flywheel using cold-
resistant grease through the mounting hole of the
motor for proper engagement of the startup gear.
(6) Remove the drain plug of the diesel tank to drain
thick deposits off once a week.
(7) Check the complete machine for abnormal noise
and check the oil filter for blockage.
(8) Press “Forward pump start” button, and the
concrete piston begins to move. Check the main oil
cylinder and swing valve cylinder for normal
reversing, check each pipe clamp for looseness,
and each pipe connector for leakage.
(9) When the reverse pumping is required at the
time of blockage, just press “Reverse pumping start”
button. But do not conduct reverse pumping too
frequently, otherwise more serious blockage could
be caused
Press the emergency stopping button to stop the
machine in case of emergency during operation.
Before restarting, make sure that all the switches on
the operation panel and the remote control box are
set at “OFF” position and the emergency stopping
button is reset.
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OPERATION OF EQUIPMENT
4 Operation of Equipment
4.1 Precautions During Operation

(1) Before pumping concrete, first pump water and
check each clamp to make sure it is sealed well
without leak, and then pump pipeline lubricant
(generally mortar generally or cement grout). In
case of mortar, the used amount should be 0.5
m3/200 m, and the mixing proportion (cement:
sand) should be 1:2 for pipeline with a length less
than 150 m, or 1:1 for pipeline with a length more
than 150 m.
(2) 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.
(3) The slump of pumped concrete should not vary
greatly, and the variation scope should be
controlled within 100~230 mm. Before using a
truck mixer to dump concrete into the hopper,
quickly mix the concrete in the mixing drum for
several minutes at first.
(4) 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.
(5) When the trailer-mounted concrete pump is
running, it is forbidden to put your hands into the
hopper or the water tank (see Fig. 4-1).
Fig. 4-1
57
(6) 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. 4-2).
Fig. 4-2
(7) 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. 4-3).
Fig. 4-3
58
(8) 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 or jetting of concrete (see Fig. 4-4).
Fig. 4-4
(9) The concrete level should be above the mixing

shaft during pumping. Air suction or pumping is not
permitted.
(10) 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 aggregation inside the pipes.
(11) During pumping, if the pumping pressure rises
suddenly or the delivery pipeline is subject to
vibration, start reverse pumping immediately for 2-
3 strokes to decrease the pressure in the pipeline,
and then conduct forward pumping. It may also be
helpful to use a wooden hammer to knock the
parts of the tapered pipes and elbows easy to be
blocked. If the pumping pressure remains too high
after several successive operations, the pipeline
must be blocked. In this case, stop pumping to
eliminate the blockage.
(12) Always observe the hydraulic oil temperature
during pumping. When it rises up to 55℃ , it is
required to start the cooling system; if it continues
rising up and exceeds 80℃ , stop the machine for
check.
(13) 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.
59
(14) 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.
(15) 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.
(16) Stop pumping and do troubleshooting in time
when the mixing shaft is seized.
(17) 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
motar in the hopper, remove some aggregates and
add mortar for remixing.
(18) 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.
(19) In the event of working pause, if there is an
intubation in the pipeline, fit the plug-in board well
to protect the concrete in the vertical or up tilting
pipes against backflow.
60
4.2 Equipment Adjustment

(1) Precautions
The equipment should be adjusted to the best
state according to working conditions. Adjustment
should be executed to the hydraulic system, after
each half year or after the machine has finished
15000m3 of concrete construction, to ensure
perfect work performance of the trailer-mounted
concrete pump.
a) Adjust the pressure of hydraulic system properly
with the proper temperature of 40-45℃.
b) When it is necessary to dismount the hydraulic
fittings or valves, it is required to stop the diesel
engine and set all power switches at “OFF”
position.
(2) Adjustment of the Electromagnetic Overflow
Valve
a) Adjust the system pressure to 34 MPa.
b) Adjust the constant pressure valve on the main
oil pump to 32 MPa.
(3). Adjustment of the Auxilairy Valve Group
Adjust the mixing pressure to 12 MPa.
(4) Charging and Adjustment of Accumulator (refer
to Fig. 4-5)
Air pressure bar(MPa)
78.4(8)
Upper limit
68.6(7)
63.7(6.5) Allowable Pressure

range
58.8(6)
53.9(5.5)
Lower limit
49(5)
44.1(4.5)
0 10 30 50 70 Oil temperature ℃
Fig. 4-5 Allowable Pressure of Accumulator
61
a) The accumulator's rubber container storing

nitrogen has slight air permeability and the air
pressure will decrease after it has been used for a
while, so at least an inspection should be required
every half-year. When the oil temperature is 50℃,
the pressure value will be 7 MPa (68.6 bar).
b) The accumulator can be charged only with
nitrogen rather than other gases, otherwise an
explosion can be generated. The charging way is
as follows:
- Preparation before charging: Remove the
charging cap from the protection cover of
accumulator; rotate the handle of charging tool
to the end anticlockwise, then connect it with the
charging valve of accumulator; link the connector
of rubber hose with the nitrogen bottle.
- Charging or gas replenishing: screw in the
handle of charging tool clockwise until the
pressure gauge on the charging tool displays
pressure; and then slowly open the cut-off valve
on the nitrogen bottle and charge the rubber
container slowly; then close the cut-off valve on
the nitrogen bottle and observe the pressure
gauge on the charging tool. Repeat the above
procedures until the reading reaches the upper
limit in the figure; loosen the bleeding valve on
the charging tool to release the remaining
nitrogen; remove the charging tool; inspect
whether the charging valve leaks, and then
install the charging cap and protection cover.
- Bleeding or adjustment: open the bleeding valve;
rotate the handle clockwise, and make the
mandrill prop move downwards to push open the
charging valve cartridge to bleed; after bleeding,
the handle should be rotated to the original
position; dismount the charging tool; inspect
whether the charging valve leaks, and then
install the charging cap and protection cover.
The pressure adjustment method is similar with
that of charging, when the pressure is high,
bleeding should be conducted, and if the
pressure is low, gas replenishing should be
conducted.
62
- Nitrogen temperature compensation: the gas

pressure varies with the temperature, and the
gas pressure of accumulator is 7 MPa (68.6 bar)
at 50℃ . For charging at normal temperature,
adjustment should be conducted in accordance
with the figure, and for the routine inspection, the
hydraulic oil temperature should be observed. If
the pressure is below the lower limit, gas should
be refilled.
4.3 Local Control Operation

If local control is required by the system, switch on
the control power supply, select “Local control”
mode through the “local control and remote control”
toggle switch on the panel of electric control cabinet.
Then forward and reverse pumping and other
auxiliary functions can be achieved. For each
function, such as adjustment of main oil cylinder,
shift between high and low pressure and automatic
piston retraction, a corresponding switch is provided
on the panel of electric control cabinet. Under local
control mode, the operation switches on the remote
control box are ineffective. To shift control mode,
operate the “local control and remote control” toggle
switch on the panel of electrical control cabinet to
the position for “remtoe control”.
4.4 Remote Control Operation

If remote control is required by the system, connect
the ten-pin plug connected with remote control box
with the ten-pin socket on the side of electric control
cabinet, switch on the power supply, and select
“remote control” mode through the “local control and
remote control” toggle switch on the pannel of
electric control cabinet. At this time, the power
indicator lamp on the remote control box goes on,
which indicates the remote control box is operable.
On the pannel of remote control box, there are four
operation switches for forward pumping, reverse
pumping, reverse mixing and emergency stop, by
which the forward and reverse pumping, manual
reverse mixing and emergency stop can be
achieved. Under remote control mode, the switches
for forward and reverse pumping on the electric
control box panel are ineffective, but the switches for
automatic reverse mixing and emergency stop are
still operable.
63
4.5 Precautions After Stoppage

(1) After pumping, it is required to idle the diesel
engine for 3~5 min before stoppage.
(2) Every time after concrete pumping, clear away
the concrete remaining in the trailer-mounted
concrete pump and the pipeline immediately.
(3) When the temperature is lower than 5℃ , clear
away the water in the trailer-mounted concrete
pump, especially the accumulated water in the
water cooler, to protect the parts against frost
crack.
(4) Carry out the maintenance after shift, including
fastening of loose parts and lubrication of
transmission parts, after ensuring the engine is
stopped and the pressure in the accumulator is
released.
(5) For trailing, such parts as the guide wheel
should be withdrawn completely and cannot touch
the ground.
4.6 Working Media

(1) Engine Oil
a) Quality Grade:
There are different standards for oil quality grade,
and the following standards among them are
applied for trailer-mounted concrete pump:
- API grading standard (American Petroleum
Institute), the oil products in common use are:
CF-4, CG-4 and CH-4;
- ACEA grading standard (European engine oil
sequence), the oil product in common use is: E1-
E3-96 + E4-98.
b) Viscosity
- See the viscosity diagram (Fig. 4-6) for selection
of oil viscosity grade which relies on the ambient
temperature.
- If the ambient temperature is temporarily lower
than the limit of corresponding viscosity, it is the
cold starting ability of engine rather than the
engine itself will be affected.
- To decrease wear, it is inadvisable to use it at the
temperature beyond limit.
- For trailer-mounted concrete pump used
frequently, the oil with complex viscosity is
available.
64
Only for engine

oil preheating
Fig. 4-6 Viscosity Diagram
(2) Diesel (Refer to Operation Manual for Deutz
Diesel Engine)
a) Quality Grade
Please use the diesel with sulfur content less than
0.5%. If the sulfur content is within 0.5%~1% and
the ambient temperature keeps being lower than -
10℃, the oil replacement interval will be reduced by
half. If the sulfur content of the diesel is more than
1%, please contact our After-sales Service
Department for consultant. To meet the emission
requirement, the diesel complying with the following
specifications or standards is recommended to be
used for our trailer-mounted concrete pump:
DIN/EN 590;
BS 2869 (1998): A1 and A2;
ASTM D975-88: 1-D and 2-D;
NATO Code F-54 and F-75.
2. Winter-grade Diesel:
As the wax will be separated out from diesel when
the ambient temperature is low, malfunction will be
caused due to blockage of diesel pipeline. Apply
winter-grade diesel when the temperature is lower
than 0℃ ; add kerosene into diesel when the
temperature is lower than -20℃ in winter, and see
Fig. 2-14 for specific mixing method. If summer-
grade diesel is used when the temperature is lower
than 0℃ in winter, the max. volume of kerosene
mixed with diesel will be 60%.
65
Caution
Do not mix petrol with diesel.

Conduct mixture in diesel tank in the order of
kerosene-diesel (see Fig. 4-7). Illustration of Diagram
I-Summer-grade diesel
II-Winter-grade diesel
A-Ambient temperature
B-Proportion of kerosene
Fig. 4-7
(3) Hydraulic Oil
a) Selection of Hydraulic Oil
- Standard for use of hydraulic oil: DIN51 502. For
the trailer-mounted concrete pump, the SANY
special hydraulic oil is adopted.
- Standard for application of hydraulic oil: Part II in
DIN51 524.
- Standard for viscosity grade: DIN51 519. The
customer 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
b) Precautions:
- The hydraulic oil products with different
characteristics can not be mixed for application.
For example: the synthetic hydraulic oil can not
be mixed with inorganic mineral hydraulic oil.
- It is forbidden to use the hydraulic oil with
additives such as molybdenum; as the bearing
will be damaged by this kind of additive.
- Thoroughly replace the hydraulic oil to make the
residual hydraulic oil in hydraulic system less
than 2%.
66
- Conduct pre-heating when the temperature of

hydraulic oil is lower than 15℃.
c) Control for Hydraulic Oil Pollution
- During maintenance, wash the system or
elements with hydraulic oil with large flow rate or
high temperature (80℃ ), actuate the elements
and knock the welded seams and connecting
parts with a copper hammer.
- Prevent the pollutant from getting into the oil:
place the purchased hydraulic oil still for several
days and then fill them into the system after
filtering by oil filter; check the dustproof seal at
the piston rod end frequently and replace it
periodically.
- Control the temperature of hydraulic oil as too
high working temperature of hydraulic oil will do
harm to hydraulic oil and reduce the service life
of the hydraulic device due to speeded-up
oxygenation of hydraulic oil and resultant
materials. The temperature of hydraulic oil
should be no higher than 65℃.
- Replace hydraulic oil periodically and the specific
requirements are as follows: replace hydraulic oil
for the first time after 500 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 once per year.
- Replacement of Hydraulic Oil
- 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.
(4) Lubricating Oil
a) Selection of Lubricating Oil
- Standard for use of lubricating oil: DIN51 502.
For the trailer-mounted concrete pump, the
SANY special lithium-based lubricating grease is
adopted.
- Standard for application of lubricating oil: DIN51
825.
- The NLGI grade requirement should comply with
DIN51 818. The customer can select lubricating
oil from the following varieties recommended for
67
this trailer-mounted concrete pump according to

specific season:
“00” lithium-based lubricating grease in winter
“000” semi-liquid lubricating grease in summer (the
penetration degree is above 250)
b) Precautions:
- Do not set the lubricating oil in air, so as to avoid
deterioration resulting from moisture absorption.
- Do not mix the lubricating oil with other oil for
application.
- Prevent the foreign substances and dust getting
into lubricating grease, and prevent the
lubricating grease contacting with alkali or acid
substances.
(5) Environmental Protection for Working Media
a) Carefully collect the used liquid and treat it
according to relative requirements for
environmental protection. The used oil (including
oil resulting from biodegradation), oil filter, auxiliary
oil and coolant must be stored separating from
other waste materials. The used oil with different
models must be separated, so as to decrease
treatment cost as much as possible.
b) Send the waste working medium to authorized
waste treatment company in accordance with local
(nation or region) regulations.　
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CLEANING
5 Cleaning
After maintaining the trailer-mounted concrete

pump or adding functional liquid, clear the marks of
hydraulic oil, fuel or other preservatives on the
trailer-mounted concrete pump firstly, and then well
treat the cloth stained with erosive or smeary
liquid.
It's not allowed to use any flammable substance,
seawater, rainwater or other salty fluid as
detergent. After cleaning, check the fuel,
lubricating and hydraulic systems for leakage,
looseness and damage. If any, carry out treatment
at once.
(1) Clearing of Remains

a) After pumping, clear away the concrete in the
pipeline and hopper to prevent blockage due to the
coagulation of remaining concrete. It's forbidden to
clear the remains with compressed air. Otherwise,
our company bears no responsibility for the
consequences arising therefrom.
b) To clean the delivery pipe, wet cleaning can be
applied. Before the sponge ball is sucked into the
pipe, be careful as the remaining concrete and
sponge ball may jet out suddenly to cause physical
injury.
(2) Cleaning of Equipment

After cleaning the delivery pipes, open the
discharge outlet of the hopper to discharge the
remains completely, and then install a water gun to
clean the hopper, S-valve and delivery cylinder.
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TRANSPORTATION AND LIFTING OF EQUIPMENT
6 Transportation and Lifting of Equipment
6.1 Package
(1) The exposed surfaces should be treated
against corrosion and rust at the time of delivery of
trailer-mounted concrete pump.
(2) The concrete delivery pipes and other
accessories should be treated against corrosion
and rust. The delivery pipe connectors should be
protected against collision.
6.2 Transportation and Storage

(1) The trailer-mounted concrete pump should be
transported and stored in accordance with ISO
6749-1984. In addition, the following precautions
should be taken:
a) Release the accumulator oil pressure
completely;
b) Drain the water system (including the oil water
cooler);
c) Set all switches and operating handles at the
OFF position;
d) Close and lock the doors and covers of the
control box and operator's station.
Caution
-The places for product storage or

transportation should be rain-proof, corrosion-
proof, sun-proof and ventilated, with a
temperature of -40℃~40℃
-The relative humidity for product storage or
transportation should be 30%~95%.
(2) In case of site transition, the trailer-mounted

Trailer velocity (v≤8km/h)
concrete pump should be loaded and transported
as follows:
A) 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. 6-1).
Fig. 6-1
b) If the distance between the two worksites is not
less than 1000 m, use a crane to load the trailer-
mounted concrete pump onto a truck.
73
TRANSPORTATION AND LIFTING OF EQUIPMENT
Caution
- Check whether the hook of the trailer-

mounted concrete pump and the sling of the
crane are in good condition (see Fig. 6-2);
- Check whether the lifting method is correct
(see Fig. 6-3). During lifting, no person
should stand under the trailer-mounted
concrete pump in case the sling breaks
abruptly and thereby hurts people.
Fig. 6-2
Fig. 6-3
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.
74
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76
ANNEX
7 Annex
7.1 Hydraulic Basic Diagram
Fig. 7.1 Basic Diagram of Hydraulic System
77
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ANNEX
7.2 Electrical Basic Diagram
Motors A and B start/stop Piston adjustment Oil pressure Water temperature Outrigger Speed Oil level and Oil pressure Water temperature
High pressure/ Temperature Main Forward Water A alarming Reverse Remote Flush Preheating selection B alarming Tunnel
Output Output Main cylinder Local control Forward Reverse Swing cylinder Swing cylinder A alarming Emergency Reversing Reversing Electrical adjustment sampling signal B alarming Temperature Temperature
low pressure control switch cylinder mixing pump mixing control control pump
increase decrease forward pumping pumping forward backward stop switch 1 switch 2 reversing special for sensor 1 sensor 2
Special for motor (input) backward control special for special for signal special for selection
Retract Hold Retract diesel Special for diesel (output)
diesel diesel motor
Liquid level
sensor
To Electromagnet Actions for Large-output trailer-mounted concrete pump
Working Condition DT1 DT2 DT3 DT4 DT5 DT6 DT7 DT8 DT9 DT10 DT11 Electromagnet Actions for Small-output trailer-mounted concrete pump
Forward pumping + + + 1. The action of each electromagnet is shown below:
Under high pressure
Reverse pumping + + + + + Forward pumping: DT1, DT 2 and DT8 energized for action; Connection of Tunnel Pump Electromagnetic Valves
Reverse pumping: DT1, DT3, DT4 and DT8 energized for action; Technical Requirements
Forward pumping + + +
Under low pressure Inching forward: DT1, DT3, DT4 and DT8 energized for action; 1.For forward pumping, DT1, DT 2 and DT8 should be energized;
Reverse pumping + + + + + Inching backward: DT1, DT3 and DT8 energized for action;
2.For reverse pumping, DT1, DT3, DT4 and DT8 should be energized;
3.For inching forward, DT1, DT3, DT4 and DT8 should be energized;
Inching forwarding + + + + + Reverse mixing: DT6 energized for action; 4.For inching backward, DT1, DT2 and DT8 should be energized;
Inching reversing + + + + Pumping with high pressure: DT5 energized for action; 5.For reverse mixing, DT5 should be energized;
Piston retracting: DT1, DT3, DT5, DT7 and DT8 energized for action; 6.For flushing control, DT6 should be energized;
Swing cylinder forwarding + 7.For adjustment of slide valve cylinder, DT1 and DT4 should be energized;
Piston holding: DT3, DT5 and DT7 energized for action;
Swing cylinder reversing + + Piston recovering: DT3, DT5 and DT8 energized for action.
8.For piston retracting, DT1, DT2, DT7 and DT8 should be energized;
Forward rotation for agitation + For piston holding, DT2 and DT7 should be energized;
Reverse rotation for agitation + + For piston recovering, DT2 and DT8 should be energized;
2. The step motor driver current is set at 2.1A, that is, both switches
Air cooler +
SW2 and SW3 are set at position “ON”.
Water pump + S17 and S19 are the stop switches of diesel engine.
Recoil + + + + + S03 and S04 are the stroke switches of hopper screen.
Piston Holding + + + + S18, S20, HL4 and HL5 are malfunction switches and malfunction detection lamps.
Return + + +
Rotation Rotation Soft start Reverse

Pulse Diesel speed Diesel speed Diesel engines A and B Motor A Motor A Motor B Motor B Blower fan Preheating Speed Speed Diesel engines A and B
Forward
Direction B Enable B Pulse count A Direction A Enable A pumping pumping
Proportional valve Hour meter (special for tunnel pump) speed signal A speed signal B count B governing B governing A start and enrichment start running start running running stop up down start indication indication
Pumping electromagnetic valve
control Special for diesel (output) Special for motor (output) Special for motor (input) Special for tunnel pump
Display 8(Confirmation of
power supply)
Switch power supply S-350-24 GPS Controller
SYMC-01 controller power supply and communication part
Heat radiation Preheating
Basic machine
Starting of Stopping of
basic machine basic machine
Switching between local control and remote control

Heat radiation Preheating Forward Reverse Reverse mixing Local control
pumping pumping signal
Working lamp
8(Confirmation of
Display power supply)
GPS Controller
Oil pressure gauge
Oil pressure gauge

Water thermometer
Water thermometer
Oil level meter
SYMC-01 controller power supply and communication part
Alarming signal B Alarming signal B of Storage

Switching between local control and remote control
Parking Oil level meter and sensor Alarming signal A of oil Alarming signal A of water Parking Control power
of oil pressure gauge water thermometer Interlock for local
Voltmeter and sensor and sensor
electromagnet pressure meter and sensor thermometer and sensor electromagnet battery supply control/remote control Forward Reverse Reverse mixing Local control
signal
pumping pumping
Fuel water
To preheating system separator switch
Fuel water
To preheating system separator switch
Terminal resistor
Terminal resistor
Step motor driver Step motor driver
A control unit EMR 1

B control unit EMR 2
Dark red & white
Dark red & white

Orange & white
Orange & white

Black & white
Black & white

Yellow & white
Yellow & white
Orange
Orange
Dark red
Dark red
Yellow
Black
Yellow
Black
Step motor Step motor
Diagnosis connector Diagnosis connector
Fig. 7-2 Basic Diagram of Electrical System

78
Due to continuous improvement on product performance,
the products are subject to change without further notice.
For after-sales service support, please contact us through

service hotline 0086-21-58590631.
Company Address: SANY Industry Town, Changsha National Economic & Technical Development Zone, Hunan, China
Tel.: 0086-731-84031888 After-sales Service Hotline: 0086-21-58590631
Fax: 0086-731-84031999 Postal Code: 410100
Website: http:// www. Sany.com.cn E-mail: sanyservice@sany.com.cn
Copyright SANY HEAVY INDUSTRY CO., LTD.

No copy or reproduction without the written permission from SANY HEAVY INDUSTRY CO., LTD.

HBT80C-1818DIII Trailer-Mounted Concrete Pump Operation Manual

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HBT80C-1818DIII Trailer-Mounted Concrete Pump Operation Manual

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HBT80C-1818DIII

SANY Heavy Industry Co., Ltd.

Please carefully read this Operation Manual,

This is a sign of “Caution”.

It is used to give additional instructions to some specific information.

It indicates the current operation complies with the safety regulations.

2 Basic Information and Construction Technology of Pumped Concrete……………35

6 Transportation and Lifting of Equipment…………………………………………………………73

The trailer-mounted concrete pump is an

1.1 Basic Structure

1-Mechanical system 2-Cooling system 3-Lubrication system

(1) Mechanical system

(2) Cooling system

1.2 Main Features

(3) Domestically pioneered streamlined hopper

1.3 Technical Parameters

Table 1-1 Technical Parameters of trailer-mounted concrete pump

1.3.2 Pumping Curve of trailer-mounted concrete

Fig. 1-2 Pumping Curve

1.4 Mechanical Parts

1.4.1 S-valve Pumping Mechanism

When pumping concrete, under the action of main

1-Forward pumping state 2-Reverse pumping state

1.4.2 Main Power System

The diesel-powered trailer-mounted concrete

The automatic throttle adjusting device is used to

The attached accessories of diesel engine include

1-DC motor 2-Controller 3-Cable 4-Strain plate

1.4.3 Hydraulic Oil Tank

1.4.4 Body Understructure 8 9

connection of each part of the trailer-mounted

1-Hopper fixed seat 2-Diesel tank support

1.4.5 Machine Body

1.Side door power support 2.Top cover

1.4.6 Axle of trailer-mounted concrete pump

The axle of trailer-mounted concrete pump mainly

1.Tyre cover 2.Tyre rim 3.Axle

1.4.7 Guide Wheel

The guide wheel is the auxiliary device for the

1. Mounting seat 2.Support

When the trailer-mounted concrete pump is

1.4.8 Cooling System

Three cooling methods are available for the

(2) Air Cooling System

1.4.9 Lubrication System

As an essential part of mechanical equipment, the

the stepping lubrication system, can perform

The working principle of double-line lubrication

In summer, use #00 semifluid non-extreme-

Manual Lubrication Pump (see Fig. 1-15)

- The manual lubrication pump should be kept

1.5 Hydraulic System

a. High pressure b. Low pressure

Fig. 1-16 Hydraulic Circuit

(1) Hydraulic Circuit of Pumping System

c) Automatic High-low Pressure Switch Circuit

Pressure oil of DT5 is deenergized; electromagnetic

Shuttle valve 27,

Pressure oil of DT5 is energized; electromagnetic

d) Full Hydraulic Reversing Circuit

DT2 are energized; while for reverse pumping, the

Electromagnetic Make the four-way

Four-way valve The movement of swing