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SYG5360THB 47 Truck-mounted Concrete Pump Operation and Maintenance Manual Read and follow the safety precautions and instructions in this manual and on the machine decals. Failure to do can cause serious injury, death or property damage. Keep this manual with the machine for reading and future reference. WARNING SYG5360THB 47 © 2015 by SANY Group. All rights reserved. No part of this publication may be reproduced, used, distributed or disclosed except during normal operation of the machine as described herein. All information included within this publication was accurate at the time of publica- tion. Product improvements, revisions, etc., may result in differences between your machine and what is presented here. SANY Group assumes no liability. For more informa- tion, contact SANY Group. SANY GROUP SANY AUTOMOBILE MANUFACTURING CO., LTD. SANY Industry Town, Economic and Technological Development Zone, Changsha, Hunan China 410100 http://www.sanygroup.com.cn China Email: sanyservice@sany.com.cn Tel: 0731- 84031888 Fax: 0731- 84031999 Service Hotline: 4008 87 8318 Complaint Hotline: 4008 87 9318 Overseas Email: crd@sany.com.cn Service Hotline (Complaint/Enquiry): 0086 4006098318 SPECIFIC DECLARATION The truck-mounted concrete pump is a special vehicle which integrate the pumping system for concrete pumping and the boom system for concrete placing on the vehicle chassis. Any other use or any operation beyond the specified working range is not authorized use. Sany expressly bears no liability for any consequence due to any unauthorized use. Information on this manual is used to guide qualified operators to operate and maintain truck- mounted concrete pump correctly. Sany expressly bears no liability for any consequence due to any use not observing the information on this manual. It is forbidden to convert the truck-mounted concrete pump without authorization. Sany expressly bears no liability for any consequence. When crack or electrical malfunction on the truck-mounted concrete pump occurs, please contact the supplier, and don’t conduct welding or make changes without permission, or else, for any consequence due to such contravention, Sany shall not bear any liability. Use genuine spare parts from Sany. Sany expressly bears no liability for any machine damage or accident due to the use of untested or unauthorized spare parts or tools.Operate and maintain parts (such as engine, a/c) on the truck-mounted concrete pump, and observe related regulations on Users' guide supplied from their manufacturer. Sany expressly bears no liability for any machine failure or damage due to force majeure of natural disasters (earthquake, typhoon) and wars. Sany cannot predict every circumstance that might involve a potential hazard in operation or maintenance. Operators and owners should highly attach importance to safety. Local specific safety rules of the countries may be stricter. If they differ from the regulations on this manual, observe the stricter one. Duty of Sany • Be responsible for providing qualified products. • Fulfill their promises on after-sales service, and document all maintenance and repair working done by after-sales service personnel. • Train the operation and maintenance personnel based on their needs. Duty of Owners or Other Authorized Personnel • Only after each person involved in the product’s operation, maintenance and repair is trained and fully understands the Parts Book and Operation and Maintenance Manual, can they operate and maintain the truck-mounted concrete pump. • Ensure the operation and maintenance personnel are qualified and know their related responsibilities. • Periodically check related personnel's safety consciousness during working. • If any fault which will lead to unsafety occurs, stop the truck-mounted concrete pump immediately. • If necessary Sany service personnel have the right to check the truck-mounted concrete pump for safety. • Besides check items regulated by Sany, observe local laws and regulations to check the truck-mounted concrete pump. • Ensure timely maintenance and repair on the truck-mounted concrete pump. • Carefully plan the use of the truck-mounted concrete pump. Duty of all working personnel • If there is any abnormal symptom which may cause abnormal working of the truck-mounted concrete pump or potential hazard, report to your leader. If possible, correct fault in time. • All personnel working around the truck-mounted concrete pump must observe all warning signals and take care of their own and others' safety. • All personnel should know their working tasks and procedures. • Watch something like high voltage wire, unrelated personnel and poor ground for potential danger, and report to the operators and signalmen. Duty of managers • Ensure the operators are trained and fully understand the Operation and Maintenance Manual supplied by Sany. Ensure they are in physical fitness and have the certification of operation. Otherwise, it is forbidden to operate the truck-mounted concrete pump. • Ensure the operators have good judgment ability, teamwork consciousness and psychological quality. Otherwise, it is forbidden to operate or repair the truck-mounted concrete pump. • Ensure the signalmen have good vision and acoustic judgment, master standard command signals. At the same time, they should have enough experience in recognizing danger factors correctly, and inform the operators of danger factors to avoid them in time. • Ensure assistant workers can identify the model and working condition to choose a proper truck-mounted concrete pump. • Publicize safety consciousness to working personnel, and make them aware of safety precautions and their related responsibilities. • Sany expressly bears no liability for any consequence due to use of informality accessories, not comply with the provision for maintenance, or start the machine without authorization after it is locked. Table of Content 1 Table of Content 1 Introduction 1.1 Manual Section Descriptions ............................................................................. 1-4 1.1.1 Introduction .................................................................................................. 1-4 1.1.2 Safety........................................................................................................... 1-4 1.1.3 System functions.......................................................................................... 1-5 1.1.4 Operation ..................................................................................................... 1-5 1.1.5 Maintenance................................................................................................. 1-5 1.1.6 Troubleshooting............................................................................................ 1-5 1.1.7 Specifications............................................................................................... 1-5 1.1.8 Appendix ...................................................................................................... 1-5 1.2 Machine Serial Number & Information ............................................................... 1-6 1.3 Contact Information ........................................................................................... 1-7 1.4 Icons and Symbols ............................................................................................ 1-7 2 Safety 2.1 Definition of terms .............................................................................................. 2-4 2.1.1 Concrete pump............................................................................................. 2-4 2.1.2 Boom pedestal ............................................................................................. 2-4 2.1.3 Arm assembly............................................................................................... 2-4 2.1.4 Placing boom................................................................................................ 2-4 2.1.5 Base structure.............................................................................................. 2-4 2.1.6 Truck mixer................................................................................................... 2-4 2.1.7 Delivery line systems.................................................................................... 2-5 2.1.8 Machine........................................................................................................ 2-5 2.1.9 Operator....................................................................................................... 2-5 2.1.10 Machine operator ....................................................................................... 2-5 SYG5360THB 47 Table of Content 2 2.1.11 Hoseman.................................................................................................... 2-6 2.1.12 Signaller and other auxiliary personnel...................................................... 2-6 2.1.13 Truck mixer driver ...................................................................................... 2-6 2.1.14 Authorized inspector .................................................................................. 2-6 2.1.15 Subject expert ............................................................................................ 2-7 2.1.16 Qualified personnel .................................................................................... 2-7 2.1.17 After Sales Service personnel.................................................................... 2-7 2.1.18 Maintenance............................................................................................... 2-7 2.1.19 Place of work, working area, danger zone................................................. 2-8 2.2 Designated use .................................................................................................. 2-13 2.2.1 Inspection intervals ...................................................................................... 2-14 2.3 Use contrary to designated use ......................................................................... 2-15 2.3.1 Transporting goods ...................................................................................... 2-15 2.3.2 Lifting loads.................................................................................................. 2-15 2.3.3 Removing obstacles..................................................................................... 2-15 2.3.4 Extending the reach ..................................................................................... 2-16 2.3.5 Extensions.................................................................................................... 2-16 2.3.6 Impermissible end hose ............................................................................... 2-16 2.3.7 Impermissible working area ......................................................................... 2-16 2.3.8 Climbing the placing boom........................................................................... 2-17 2.3.9 High-pressure delivery ................................................................................. 2-17 2.3.10 Accessories and attachments .................................................................... 2-17 2.4 Exclusion of liability ............................................................................................ 2-17 2.5 Personnel ........................................................................................................... 2-18 2.5.1 Requirements............................................................................................... 2-18 2.5.2 Qualifications................................................................................................ 2-19 2.5.3 Responsibility of the machine operator........................................................ 2-19 2.6 Operating Instructions, operating procedures and other regulations ................. 2-19 2.6.1 Operating Instructions.................................................................................. 2-19 SYG5360THB 47 Table of Content 3 2.6.2 Operating procedures................................................................................... 2-20 2.6.3 Other regulations.......................................................................................... 2-21 2.7 Personal protective equipment .......................................................................... 2-21 2.8 Before starting work ........................................................................................... 2-23 2.8.1 Checking that the machine is ready for operation........................................ 2-23 2.8.2 Rendering the machine ready for operation................................................. 2-23 2.9 Danger due to high-voltage ............................................................................... 2-24 2.9.1 High-voltage lines......................................................................................... 2-24 2.9.2 Discharge voltage pattern ............................................................................ 2-24 2.9.3 Clearances................................................................................................... 2-25 2.9.4 High-voltage warning devices ...................................................................... 2-26 2.9.5 Procedure in the event of a flash over.......................................................... 2-26 2.9.6 Earthing in the event of electrostatic charging ............................................. 2-27 2.10 Stationary machines .......................................................................................... 2-27 2.10.1 Set-up site.................................................................................................. 2-27 2.10.2 Stationary booms ....................................................................................... 2-28 2.10.3 Lifting machines and components.............................................................. 2-28 2.10.4 Loading and transporting............................................................................ 2-28 2.11 Mobile machines ................................................................................................ 2-29 2.11.1 Set-up site.................................................................................................. 2-29 2.11.2 Supporting ground...................................................................................... 2-29 2.11.3 Corner bearing loads.................................................................................. 2-30 2.11.4 Supports..................................................................................................... 2-31 2.11.5 Driving........................................................................................................ 2-32 2.11.6 Towing........................................................................................................ 2-33 2.11.7 Loading ...................................................................................................... 2-33 2.12 Placing booms ................................................................................................... 2-34 2.12.1 Unfolding the placing boom........................................................................ 2-34 2.12.2 End hose.................................................................................................... 2-35 SYG5360THB 47 Table of Content 4 2.12.3 Procedure in storms................................................................................... 2-36 2.12.4 Concreting in cold weather......................................................................... 2-37 2.13 Delivery line systems ......................................................................................... 2-37 2.13.1 Suitable delivery lines ................................................................................ 2-37 2.13.2 Securing delivery........................................................................................ 2-37 2.13.3 Tightness and blockages ........................................................................... 2-38 2.13.4 Opening delivery lines................................................................................ 2-38 2.13.5 Clearance to delivery lines......................................................................... 2-38 2.13.6 Fastening delivery lines.............................................................................. 2-39 2.13.7 Continuation delivery lines ......................................................................... 2-39 2.14 Pumping operations ........................................................................................... 2-39 2.14.1 Place of work.............................................................................................. 2-39 2.14.2 Safety......................................................................................................... 2-40 2.14.3 Remote control........................................................................................... 2-40 2.14.4 Moving machine components and hot surfaces......................................... 2-41 2.14.5 Constant observation of the machine......................................................... 2-41 2.14.6 Truck mixer ................................................................................................ 2-42 2.15 Cleaning ............................................................................................................. 2-42 2.15.1 General ...................................................................................................... 2-42 2.15.2 Cleaning agents ......................................................................................... 2-43 2.15.3 Hazards...................................................................................................... 2-43 2.15.4 Cleaning with compressed air.................................................................... 2-43 2.15.5 Protection against water............................................................................. 2-45 2.15.6 Post-cleaning procedure ............................................................................ 2-46 2.16 Maintenance and special work .......................................................................... 2-46 2.16.1 Requirements for special work................................................................... 2-46 2.17 Welding .............................................................................................................. 2-48 2.18 Working on the placing boom ............................................................................ 2-49 2.19 Safety-relevant components .............................................................................. 2-50 SYG5360THB 47 Table of Content 5 2.20 Software ............................................................................................................. 2-50 2.21 Protective and safety ......................................................................................... 2-50 2.22 Electrical power ................................................................................................. 2-51 2.22.1 General ...................................................................................................... 2-51 2.22.2 Electrical components................................................................................ 2-52 2.22.3 Power at the construction site.................................................................... 2-52 2.23 Hydraulic systems .............................................................................................. 2-53 2.23.1 General ...................................................................................................... 2-53 2.23.2 Replacing hydraulic hoses ......................................................................... 2-54 2.23.3 Noise emissions......................................................................................... 2-54 2.24 Exhaust fumes ................................................................................................... 2-55 2.25 Functional fluids ................................................................................................. 2-55 3 System Functions 3.1 General Overview .............................................................................................. 3-3 3.1.1 Main component locations............................................................................ 3-3 3.1.2 Main characteristics...................................................................................... 3-4 3.2 Boom System .................................................................................................... 3-6 3.2.1 Boom overview............................................................................................. 3-6 3.2.2 Boom components ....................................................................................... 3-6 3.2.3 Boom control................................................................................................ 3-7 3.3 Outrigger System ............................................................................................... 3-9 3.3.1 Outrigger overview....................................................................................... 3-9 3.3.2 Outrigger components.................................................................................. 3-9 3.3.3 Outrigger control........................................................................................... 3-10 3.3.4 Outrigger pads.............................................................................................. 3-11 3.4 Truck Chassis .................................................................................................... 3-12 3.4.1 Truck chassis overview................................................................................ 3-12 3.4.2 Truck chassis components........................................................................... 3-13 SYG5360THB 47 Table of Content 6 3.5 Pumping System ................................................................................................ 3-14 3.5.1 Pumping system overview ........................................................................... 3-14 3.5.2 Pumping system & related components....................................................... 3-14 3.5.3 Pumping system operation........................................................................... 3-15 3.5.4 Pumping controls ......................................................................................... 3-16 3.6 Hydraulic System ............................................................................................... 3-17 3.6.1 Outrigger controls......................................................................................... 3-17 3.6.2 Outrigger and boom backup hydraulics ....................................................... 3-19 3.6.3 Pump hydraulics........................................................................................... 3-20 3.6.4 Mixing control valve and mixing cutoff valve................................................ 3-20 3.6.5 Accumulator and Unloading Ball Valve of Accumulator............................... 3-21 3.6.6 Self-sealing Device of Main Oil Pump Oil Inlet and Gear Pump Oil Suction Cut- off Valve ................................................................................................................ 3-22 3.6.7 Water pump.................................................................................................. 3-23 3.6.8 Filter ............................................................................................................. 3-23 3.7 Electric Control System ..................................................................................... 3-24 3.7.1 Electric Control Cabinet ............................................................................... 3-24 3.7.2 Small operation box ..................................................................................... 3-29 3.7.3 Maintenance and operation box................................................................... 3-32 3.7.4 Electromagnetic valves for mixing................................................................ 3-36 3.7.5 Electromagnetic valve of boom.................................................................... 3-37 3.7.6 System gauges & indicators......................................................................... 3-37 3.7.7 Light ............................................................................................................. 3-41 3.7.8 E-STOP buttons........................................................................................... 3-45 3.8 Remote Control System ..................................................................................... 3-47 3.8.1 In-Cab receiver............................................................................................. 3-47 3.8.2 Remote controller......................................................................................... 3-48 4 Operation SYG5360THB 47 Table of Content 7 4.1 Pre-operational Checks ..................................................................................... 4-3 4.2 Set-up Site ......................................................................................................... 4-5 4.3 Starting Up ......................................................................................................... 4-7 4.3.1 Test run........................................................................................................ 4-7 4.3.2 Start the machine and engaging the transfer gearbox power take- off ........ 4-9 4.4 Outrigger Set-Up ................................................................................................ 4-10 4.4.1 Working area................................................................................................ 4-10 4.4.2 Danger zone................................................................................................. 4-11 4.4.3 Operation of outriggers................................................................................. 4-12 4.4.4 OSS.............................................................................................................. 4-15 4.4.5 Levelling the machine................................................................................... 4-16 4.5 Function Checks ................................................................................................ 4-18 4.5.1 Pump functions............................................................................................. 4-18 4.5.2 Filter functions.............................................................................................. 4-19 4.5.3 E-STOP function .......................................................................................... 4-20 4.5.4 Function check on the boom control block................................................... 4-21 4.5.5 Function check on the agitator safety cutout................................................ 4-21 4.6 Boom Movements .............................................................................................. 4-23 4.6.1 Restrictions on use....................................................................................... 4-23 4.6.2 Danger zone................................................................................................. 4-25 4.6.3 Spontaneous retraction of the boom and support cylinders......................... 4-26 4.6.4 Uncontrolled boom movements.................................................................... 4-27 4.7 Hand Signals for Boom and Pump Operations .................................................. 4-28 4.7.1 Standard boom hand signals........................................................................ 4-28 4.7.2 Pump operation hand signals....................................................................... 4-31 4.8 Extending the Boom .......................................................................................... 4-34 4.8.1 Preparing the Remote Controller.................................................................. 4-35 4.8.2 Unfolding the boom...................................................................................... 4-36 4.8.3 Unlocking the end hose................................................................................ 4-38 SYG5360THB 47 Table of Content 8 4.8.4 Checking outrigger stability.......................................................................... 4-38 4.9 Pumping Operations .......................................................................................... 4-39 4.9.1 Safety precautions ....................................................................................... 4-39 4.9.2 Notes on correct pumping............................................................................ 4-44 4.9.3 Pre-operational checks ................................................................................ 4-45 4.9.4 Pumping....................................................................................................... 4-46 4.9.5 Possible faults.............................................................................................. 4-49 4.9.6 Special cases............................................................................................... 4-52 4.10 Equipment Clean-up ......................................................................................... 4-53 4.10.1 Cleaning the Boom Piping.......................................................................... 4-53 4.10.2 Hopper, delivery cylinder and S-tube......................................................... 4-57 4.10.3 Truck superstructure and post-cleaning procedure.................................... 4-59 4.11 Retracting the Boom & Outriggers .................................................................... 4-61 4.12 Driving, Towing and Loading ............................................................................ 4-62 4.12.1 Driving........................................................................................................ 4-62 4.12.2 Towing........................................................................................................ 4-65 4.12.3 Loading ...................................................................................................... 4-66 4.13 Machine Decals ................................................................................................ 4-67 4.13.1 Locations of safety marks on the complete vehicle................................... 4-68 4.13.2 Mark descriptions...................................................................................... 4-70 4.13.3 Detailed explanation to safety marks ........................................................ 4-71 5 Troubleshooting 5.1 General .............................................................................................................. 5-3 5.2 Troubleshooting Mechanical System ................................................................. 5-3 5.3 Troubleshooting Hydraulic System .................................................................... 5-6 5.4 Troubleshooting Lubrication System ................................................................. 5-10 5.5 Troubleshooting Electric System ....................................................................... 5-11 6 Maintenance SYG5360THB 47 Table of Content 9 6.1 Routine Maintenance & Mandatory Overhaul .................................................... 6-3 6.2 General Tightening Torques .............................................................................. 6-8 6.3 Lubrication ......................................................................................................... 6-11 6.3.1 Lubrication Method....................................................................................... 6-11 6.3.2 Lubricant Recommendation ......................................................................... 6-15 6.4 Visual Checks .................................................................................................... 6-20 6.4.1 General check.............................................................................................. 6-20 6.4.2 Check the hydraulic system ......................................................................... 6-24 6.4.3 Check the electrical system.......................................................................... 6-25 6.5 Pumping System ................................................................................................ 6-25 6.5.1 Pumping cylinder piston............................................................................... 6-26 6.5.2 Agitator shaft and leaf .................................................................................. 6-30 6.5.3 S-valve Assembly......................................................................................... 6-31 6.5.4 Hopper ......................................................................................................... 6-50 6.5.5 Delivery cylinder........................................................................................... 6-51 6.5.6 Delivery line.................................................................................................. 6-51 6.6 Slewing Mechanism ........................................................................................... 6-62 6.6.1 Overview ...................................................................................................... 6-62 6.6.2 Slewing gear transmission ........................................................................... 6-64 6.6.3 Ball-Bearing Slewing Ring............................................................................ 6-66 6.7 Transfer Case and Drive Shaft .......................................................................... 6-67 6.7.1 Transfer case ............................................................................................... 6-68 6.7.2 Drive shaft.................................................................................................... 6-70 6.8 Hydraulic System ............................................................................................... 6-71 6.8.1 Overview ...................................................................................................... 6-71 6.8.2 Changing the hydraulic fluid......................................................................... 6-72 6.9 Accumulator ....................................................................................................... 6-75 6.9.1 Overview ...................................................................................................... 6-75 6.9.2 Checking the nitrogen pressure of accumulator........................................... 6-77 SYG5360THB 47 Table of Content 10 6.9.3 Nitrogen filling and pressure adjustment of accumulator ............................. 6-77 6.10 Oil Filter ............................................................................................................ 6-79 6.10.1 Replacing hydraulic oil filters..................................................................... 6-79 6.11 Air Filter ........................................................................................................... 6-81 6.12 Hoses ................................................................................................................ 6-82 6.12.1 Checking the hoses.................................................................................... 6-82 6.12.2 Replacing the hoses................................................................................... 6-83 6.12.3 Identifying the hoses .................................................................................. 6-84 6.13 Electrical System .............................................................................................. 6-84 6.13.1 Electric control cabinet............................................................................... 6-85 6.13.2 Maintenance operation box........................................................................ 6-88 6.13.3 Small operation box ................................................................................... 6-89 6.13.4 Outrigger operation box ............................................................................. 6-89 6.13.5 Mechanical encoder .................................................................................. 6-90 6.13.6 Temperature sensor................................................................................... 6-91 6.13.7 Liquid level sensor ..................................................................................... 6-91 6.13.8 Limit switch of boom................................................................................... 6-92 6.13.9 Limit switch of outrigger ............................................................................. 6-92 6.13.10 Proximity switch of transfer case.............................................................. 6-93 6.13.11 Rocker switch .......................................................................................... 6-93 6.13.12 Electromagnetic valve and its plug........................................................... 6-94 6.13.13 Wire.......................................................................................................... 6-94 6.13.14 Wireless remote control system............................................................... 6-95 7 Specifications 7.1 Technical Data ................................................................................................... 7-3 7.2 Dimension .......................................................................................................... 7-5 7.3 Boom Operating Range ..................................................................................... 7-6 SYG5360THB 47 Table of Content 11 8 Appendix 8.1 Hydraulic Basic Diagram ................................................................................... 8-3 8.2 Electrical Basic Diagram .................................................................................... 8-5 .......... 8-14 8.3 Specifications of twin pipes ........................................... .............. ............. SYG5360THB 47 Table of Content 12 BLANK PAGE SYG5360THB 47 1-1 Introduction 1 Introduction 1.1 Manual Section Descriptions ............................................................................1-4 1.2 Machine Serial Number & Information ..............................................................1-6 1.3 Contact Information ..........................................................................................1-7 1.4 Icons and Symbols ...........................................................................................1-7 Introduction SYG5360THB 47 1-2 Introduction WARNING Always read the Safety section of this manual before attempting to operate this equipment. Failure to do this could result in machine damage, personnel injury or death. SYG5360THB 47 1-3 Introduction 1 INTRODUCTION ● SANY-built equipment offers high-quality performance and excellent after-sales service support. ● SANY-built equipment is widely used throughout the industry for various types of applications. ● SANY is a leading manufacturer of heavy construction equipment worldwide. This manual provides safety, technical descriptions, operation, troubleshooting and maintenance. In order to properly use your equipment, it is important to read this manual carefully before beginning any operations. Items addressed in this manual are designed to help you: ● Understand the structure and performance of your equipment. ● Reduce improper operation and point out possible hazardous situations when using equipment. ● Increase equipment efficiency during operation. ● Prolong the service life of your equipment. ● Reduce maintenance costs. Always keep this manual nearby and have all personnel involved with any work operations read it periodically. If this manual should become damaged or lost and can not be read, it is advised to request a replacement copy from your SANY distributor as soon as possible. If a copy of the manual is not with the machine at the time of use, do not use the equipment until you have obtained a replacement copy from your SANY distributor. Fig.1-1 SYG5360THB 47 1-4 Introduction If you sell the equipment, be sure to give this manual to the new owner. NOTE:Continuing improvements in the design can lead to changes in detail which may not be reflected in this manual. Always consult your SANY distributor for the latest available information on your equipment or if you have questions regarding information in this manual. 1.1 Manual Section Descriptions This operator's manual covers use and maintenance of your equipment. There are seven sections to this manual, with each section providing information you should be familiar with before performing any operations or repairs. Keep this manual with the machine for your reference at all times. Replace it immediately if it is damaged or lost. NOTE:Due to improvement and updating of products, some information may differ from your equipment. If you have any question on your equipment, contact your SANY distributor before operating or repairing the equipment. 1.1.1 Introduction This section provides an overview of what is covered in the rest of this manual, including machine label information and SANY contact information. 1.1.2 Safety This section covers basic safety information relating to this equipment. Make sure you fully understand all the precautions described in this manual and the safety labels on the machine before operating or maintaining this machine. SYG5360THB 47 1-5 Introduction 1.1.3 System functions This section provides an overview of all the controls and operating systems on your equipment. It is important to study and become familiar with all controls and systems before proceeding with any operations. 1.1.4 Operation This section provides the basic operating procedures for the job. It is important to study and become familiar with all procedures before performing any operations with the equipment. 1.1.5 Maintenance This section provides all general maintenance procedures. It is important to study and become familiar with all the maintenance procedures before performing any maintenance operations on the equipment. 1.1.6 Troubleshooting This section outlines common malfunctions and fault diagnostic procedures for the equipment operating system. Basic mechanical, hydraulic and electrical system troubleshooting is included. 1.1.7 Specifications This information provides overall required operating parameters for the equipment you are using. Some information may vary due to the design of the chassis. NOTE:Some information may vary due to the design changes. 1.1.8 Appendix This section provides the hydraulic basic diagram and the electrical basic diagram. SYG5360THB 47 1-6 Introduction 1.2 Machine Serial Number & Informa- tion The serial numbers and model numbers on the components are the only numbers that your SANY distributor will need when ordering replacement parts or requiring assistance for your equipment. Record the information in this manual for future use. Data Plate See Fig. 1-2 for the Date Plate. Data Plate Location On the top of the main boom mounting turret is the pump unit data plate (a). Fig.1-2 Fig.1-3 3 SYG5360THB 47 1-7 Introduction 1.3 Contact Information Thank you for purchasing a SANY product. In the event that you should need to contact us for any reason, you can reach us as follows: Our address: Sany Industry Town, Changsha National Economic & Technical Development Zone, Hunan, China ● Service Hotline: 0086 4006098318 ● Service E-mail: crd@sany.com.cn ● Web site: http://www.sanygroup.com.cn 1.4 Icons and Symbols Most accidents are usually caused by the failure to follow fundamental safety rules for the operation and maintenance of the machine. To avoid accidents it is important to read and understand all information outlined in this manual before operating or performing maintenance on this machine. The following (ANSI/ISO) signal words are used to inform you that there is a potentially hazardous situation that may lead to damage, personal injury or even death. In this manual and on the machine decals, different signal words or illustrations are used to express the potential level of hazard. DANGER Indicates an imminent hazard which, if not avoided, will result in serious injury or death. WARNING Indicates a potentially hazardous situation which, if not avoided, could result in injury or possibly death. SYG5360THB 47 1-8 Introduction CAUTION Indicates a possible potential hazardous situation which, if not avoided, could result in minor or major injury. NOTICE Indicates a situation which can cause damage to the machine, personal property and/or the environment, or cause the equipment to operate improperly. This is the general warning sign. It is used to alert the user to potential hazards. All safety messages that follow this sign shall be obeyed to avoid possible harm. This symbol indicates that the operation is not in conformity to the safety regulations, is prohibited or may cause injuries or fatalities. This symbol indicates that the operation is in conformity to the safety regulations. SANY cannot predict every circumstance that might involve a potential hazard in operation or maintenance. Some safety messages in this manual and on the machine may not include all possible safety precautions. If any procedures or actions not specified, recommended or allowed in this manual are used, you must be sure that you and others can perform such procedures and actions safely and without damaging the machine, causing injury to yourself or other personnel. If you are unsure about the safety of some procedures, contact your local SANY distributor. SYG5360THB 47 1-9 Introduction WARNING ● All operators or maintenance personnel involved with the use of this equipment must read this manual thoroughly before operating or maintaining this equipment. ● This manual must be kept on or near the equipment for reference and periodically reviewed by all personnel involved with operation or maintenance of this equipment. ● Some actions involved in the operation or maintenance of this equipment could cause a serious accident if they are not performed in the manner described in this manual. ● All procedures and precautions outlined in this manual apply only to intended uses of this equipment. If you use your equipment for any unintended uses that are not specifically prohibited, you must be sure that it is safe for you and others to do so. In no event should you or others engage in prohibited uses or actions as described in this manual. ● SANY delivers equipment that complies with all applicable regulations and standards of the country to which the equipment has been shipped. If this equipment was purchased in another country or purchased from someone in another country, it may lack certain safety features and specifications that are necessary for use in your country. If there is any question about whether your product complies with the applicable standards and regulations of your country, contact your local SANY distributor before operating this equipment. ● Improper operation or maintenance of this equipment can be hazardous and could result in serious injury or even death. SYG5360THB 47 1-10 Introduction BLANK PAGE SYG5360THB 47 2-1 Safety 2 Safety 2.1 Definition of terms .............................................................................................2-4 2.2 Designated use .................................................................................................2-13 2.3 Use contrary to designated use ........................................................................2-15 2.4 Exclusion of liability ...........................................................................................2-17 2.5 Personnel ..........................................................................................................2-18 2.6 Operating Instructions, operating procedures and other regulations ................2-19 2.7 Personal protective equipment .........................................................................2-21 2.8 Before starting work ..........................................................................................2-23 2.9 Danger due to high-voltage ..............................................................................2-24 2.10 Stationary machines .........................................................................................2-27 2.11 Mobile machines ...............................................................................................2-29 2.12 Placing booms ..................................................................................................2-34 2.13 Delivery line systems ........................................................................................2-37 2.14 Pumping operations ..........................................................................................2-39 2.15 Cleaning ............................................................................................................2-42 2.16 Maintenance and special work .........................................................................2-46 2.17 Welding .............................................................................................................2-48 2.18 Working on the placing boom ...........................................................................2-49 2.19 Safety-relevant components .............................................................................2-50 2.20 Software ............................................................................................................2-50 2.21 Protective and safety ........................................................................................2-50 2.22 Electrical power ................................................................................................2-51 2.23 Hydraulic systems .............................................................................................2-53 2.24 Exhaust fumes ..................................................................................................2-55 2.25 Functional fluids ................................................................................................2-55 Safety SYG5360THB 47 2-2 Safety WARNING Always read the Safety section of this manual before attempting to operate this equipment. Failure to do this could result in machine damage, personnel injury or death. SYG5360THB 47 2-3 Safety 2 SAFETY WARNING Make sure you fully understand the precautions described in this manual and the safety labels on the machine before operating or maintaining this machine. Read and follow all safety precautions. Failure to do so may result in equipment damage, serious injury or possibly death. This section corresponds to the contents of the VDMA brochure entitled “Safety manual Concrete delivery and placing machines”. Here you will find a summary of the most important safety regulations. This section is, therefore, particularly suitable as an initial basic instruction for new operators. Naturally, the various rules are also repeated once more at the appropriate points in other sections. NOTE:Special safety regulations may be necessary for some tasks. These special safety regulations will only be found in the description of the particular task. NOTE:Safety regulations referred in this section about line pump is suitable for our product. SYG5360THB 47 2-4 Safety 2.1 Definition of terms The terms used in this safety manual are explained below, along with descriptions of the requirements placed on specific groups of people. 2.1.1 Concrete pump For the purposes of this safety manual, concrete pumps are defined as devices which are designed to deliver concrete to placement sites via pipes or hoses. 2.1.2 Boom pedestal In this safety manual, boom pedestal refers to a device for holding and guiding an arm assembly. 2.1.3 Arm assembly For the purposes of this safety manual, arm assemblies are powered slewing devices consisting of one or more swinging or folding sections for guiding the delivery line. 2.1.4 Placing boom In this safety manual, placing boom refers to a unit comprising the arm assembly and boom pedestal. 2.1.5 Base structure For the purposes of this safety manual, base structures are defined as equipment which is designed to hold a stationary placing boom to give the latter the required stability. 2.1.6 Truck mixer In this safety manual, truck mixers are vehicles with mixing equipment for transporting concrete. SYG5360THB 47 2-5 Safety 2.1.7 Delivery line systems For the purposes of this safety manual, delivery line systems are defined as self- contained pipes or hoses in which concrete is pumped from the concrete pump to the placement site. Devices for shutting-off, diverting or cleaning delivery lines can be integrated into delivery line systems. 2.1.8 Machine In this safety manual, concrete delivery and placing machines refer to: – Truck-mounted concrete pumps (ensemble of truck, concrete pump with and without placing boom). The truck manufacturer’s safety regulations also apply to the truck. – Truck mixer concrete pump (an ensemble of truck mixer, concrete pump and placing boom). The safety regulations issued by the truck mixer manufacturer and by the truck manufacturer also apply to truck mixer concrete pumps. – Stationary concrete pumps – Stationary placing systems (an ensemble of placing boom and base structure) 2.1.9 Operator Authorized representative of the owner of the concrete pumps and/or placing booms. The operator is responsible for the use of these machines. 2.1.10 Machine operator Person trained in and charged with the operation of concrete pumps and placing booms. SYG5360THB 47 2-6 Safety 2.1.11 Hoseman Person instructed by the site management in how an end hose is guided. Hosemen must be able independently to evaluate dangerous situations which may occur in the area of the end hose and react according to the situation. 2.1.12 Signaller and other auxiliary personnel Persons instructed by the site management to help the machine operator in his work if the latter is unable to observe all areas of operation and danger zones. Signallers must be able to independently evaluate all dangerous situations which may occur when working with a concrete pump and/or placing boom, and to react according to the situation. The signaller must have a suitable means of communication with the machine operator. 2.1.13 Truck mixer driver Person who supplies the concrete pump with concrete from a truck mixer. Truck mixer drivers must be instructed by the machine operator to operate the operating elements on the concrete pump provided for their use. Truck mixer drivers must be able to independently evaluate all dangerous situations which may occur when working in the area of the hopper of a concrete pump, and to react according to the situation. 2.1.14 Authorized inspector Authorized inspectors are persons empowered by the relevant government bodies to carry out this task of inspection. The prerequisites for becoming an authorized inspector are: – To have completed a higher education course in engineering or similar. SYG5360THB 47 2-7 Safety – To have at least 5 years’ professional experience in a relevant domain, of which at least six months must have involved participation in the work of an authorized inspector. – To possess thorough knowledge of the relevant health and safety regulations, as well as of directives and the generally recognised rules of engineering. – To have access to the necessary equipment to carry out the inspection. – To be able to carry out the tasks impartially. 2.1.15 Subject expert For the purposes of this safety manual, a subject expert is a person who, through their professional training, their professional experience and their recent professional activity, has the required specialist knowledge to inspect the tools. 2.1.16 Qualified personnel Persons who have completed specialist training for a particular activity which qualifies them to carry out their roles. 2.1.17 After Sales Service personnel Qualified persons employed by the manufacturer who are responsible in particular for maintenance of the machine. 2.1.18 Maintenance Maintenance embraces all measures required for inspection, servicing and repair of a machine. SYG5360THB 47 2-8 Safety 2.1.19 Place of work, working area, danger zone Mobile machines Stationary machines Fig.2-1 Example Fig.2-2 Example SYG5360THB 47 2-9 Safety NO. Designation Explanation 1 Place of work (during pumping operations) Machine operator In normal operation, with the remote control 2 Hoseman At the end hose in the danger zone 3 Signaller In the machine operator’s range of vision 4 Auxiliary personnel As manual placing system operators 5 Truck mixer driver At the hopper in the danger zone 6 Working area Permitted Area with a radius of the reach of the placing boom + end hose length 7 Impermissible The end hose must not be moved backwards beyond the vertical of the placing boom 8 Danger zone At the end hose Risk of injury when pumping is started, during pumping operations, when removing a blockage and during washing out procedures. The diameter of the danger zone is twice the end hose length. 9 Beneath the placing boom Risk of injury from falling items 10 Area of the support legs and feet or area of the base structure Danger of crushing when the machine is set up and when the supports are retracted 11 On the machine Any presence on or below the machine when the pump is in operation is prohibited 12 At the hopper Risk of injury during washing out procedures and when the hopper is being filled using a truck mixer 13 Area of the delivery line systems Risk of lines bursting, risk of injury by crushing or shearing e. g. by gate valves 14 Structure or area being concreted Example SYG5360THB 47 2-10 Safety Place of work The place of work is the area in which people must remain in order to carry out the work. ● Place of work-machine operator The machine operator’s place of work is with the remote control when the pump is in operation. The place of work must be selected so as to allow visual contact with the site of concrete placement, and the truck mixer driver, and so that the working area can be observed at the same time. A signaller must otherwise be used. The operator’s place of work is with the machine when this is being set up or prepared for driving. ● Place of work-hoseman The hoseman’s place of work is within the danger zone of the end hose, but not beneath the placing boom. This requires a greater level of caution. The hoseman and machine operator must have visual contact. ● Place of work- truck mixer driver The truck mixer driver’s place of work is in the danger zone of the hopper and at operating elements for the agitator and truck mixer. This requires a greater level of caution. The truck mixer driver and machine operator must have visual contact. Working area The working area is the area in which work is carried out with or on the machine. Parts of the working area can become danger zones depending on the operation being carried out and the position of the placing boom. SYG5360THB 47 2-11 Safety The working area must be secured and clearly identified. Suitable personal protective equipment is required in the working area. The machine operator is responsible for safety in the working area of the machine whilst the machine is in use. ● Impermissible working area Because of their high manoeuvrability, some placing booms can also be shifted into positions for which they are not designed. This may overload or damage the placing boom. Placing booms must therefore only be moved within the permitted working area. Danger zone The danger zone is the area surrounding the machine, in which people may be at risk of injury from movements required by the work. The danger zone varies within the working area and depends on the activity being carried out and the position of the placing boom. Danger zones must be secured and clearly identified. The machine operator must be capable of seeing the danger zone at all times and under all circumstances. If necessary he must appoint a signaller to supervise the danger zone. Depending on the working situation, workplaces may occasionally fall within the danger zone, especially the workplace of the hoseman and the truck mixer driver. If a workplace falls within the danger zone, increased caution is required and suitable personal protective equipment is prescribed. Persons who are authorized to be present in such a workplace, must use their own discretion to assess the hazards of the situation and be able to react accordingly. SYG5360THB 47 2-12 Safety The machine operator is responsible for safety in the danger zone of the machine whilst the machine is in use. The machine operator must stop work immediately and press the EMERGENCY STOP button if an unauthorized person enters the danger zone. ● Supporting legs and support feet There is a danger of crushing in the swing- out and extension zone for the supports. ● Placing boom The danger zone when working with the placing boom is the zone over which the placing boom is slewed. In this area there is a risk of injury from falling concrete and delivery line components. ● Machine All the time the vehicle is in operation, there is a risk of injury on and below the machine from moving parts and bursting delivery lines or hydraulic hoses, as well as a risk of falling on slippery surfaces or steps. ● End hose The danger zone when pumping is started, during pumping operations, when removing a blockage and during washing out procedures is the area around the end hose in which the hose may swing out. The diameter of the danger zone is twice the end hose length. ● Hopper In the area of the hopper, there is a risk of becoming trapped between the truck mixer and the hopper and of being sprayed with concrete. There is a risk of being crushed and of injury by shearing from the transfer tube. There is a risk of being entrapped by the rotating agitator. SYG5360THB 47 2-13 Safety ● Delivery line systems In the area around the delivery line systems there is a risk of injury from the delivery line bursting if there is an abrupt rise in pressure. There is a risk of crushing and injury by shearing with devices integrated in delivery line systems. 2.2 Designated use The machine must only be operated as intended and in technically perfect condition. All protective and safety-related devices, such as removable protective devices and EMERGENCY STOP devices, must be available and fully functional. The machine is constructed in accordance with the conditions laid down in the EU Machinery Directive (2006/42/EC) and EN 12001. Nevertheless, its use may constitute a risk to life and limb of the user or of third parties, or cause damage to the machine and to other property. The machine is designed exclusively for the delivery and placing of concrete up to a bulk density of 2,400 kg/m 3 . It must only be used for pumping operations on construction sites. The maximum concrete pressure must not exceed that specified on the rating plate or in the check book. Designated use also includes observing the Operating Instructions and complying with the intervals and conditions for inspections and maintenance work. SYG5360THB 47 2-14 Safety 2.2.1 Inspection intervals After it is used for the first time, the operational safety of the machine must be checked regularly by a subject expert. The inspection intervals depend on the age of the machine. The older the machine, the greater the probability of damage. This is why a regular inspection of the machine, appropriate to its age, is an effective means for the early detection of damage. In anticipation of the change to the standard EN 12001:2003+A1:2009, inspection intervals will be established as follows: Machines of up to and including 5 years old: Inspect after every 1,000 operating hours or 1 year, whichever is soonest. The interval is repeated after every inspection. Machines more than 5 years old: Inspect after every 500 operating hours or 1 year, whichever is soonest.The interval is repeated after every inspection. Machines more than 10 years old: Inspect after every 250 operating hours or 1 year, whichever is soonest. The interval is repeated after every inspection. The day of initial commissioning in accordance with the handover report and the machine’s operating hours meter is definitive for the intervals. This operating hours meter records the hours of pumping operations. The operating hours meter must always be kept in good working order. It must not be tampered with. For machines without an operating hours meter, the operating hours must be comprehensibly recorded in writing. SYG5360THB 47 2-15 Safety The operator is responsible for commissioning the inspection. The outcome of the inspections must be recorded in the check book and confirmed by a signature. The check book must always be kept with the machine and must be produced upon the request of the national supervisory bodies. Notwithstanding national legislation, the operator can be liable in the event of damage, if it is proved that the damage has arisen as a consequence of a regular repeat inspection not being properly carried out. 2.3 Use contrary to designated use Any use of the machine which is not described in section 2.2, entitled "Designated use", or which extends beyond the uses described in this section is deemed to be contrary to designated use. The manufacturer accepts no liability for damage resulting from such use. Some examples of conceivable uses that are contrary to the designated use are given below. 2.3.1 Transporting goods The machine may not be used for the transport of goods, except for carrying the accessories used for the machine, such as pipes, hoses, etc. The maximum permissible gross weight may not be exceeded. 2.3.2 Lifting loads The placing boom must never be used for lifting loads. 2.3.3 Removing obstacles The placing boom must not be used under any circumstances to remove obstacles. This would overload the placing boom, causing damage and endangering people. Fig.2-3 SYG5360THB 47 2-16 Safety 2.3.4 Extending the reach It is prohibited to attach an extension (e.g. freely suspended crossbeam) to the end hose or placing boom tip in order to extend the reach or to pump at an angle. Since the boom and the lifting equipment for the extension have differing pivot points and modes of control, it is not possible to coordinate their movements. 2.3.5 Extensions Extension of the placing boom and end hose beyond the length specified on the rating plate is forbidden. 2.3.6 Impermissible end hose The end hose must not be fitted with any extension coupling, spout, “swan neck”, outlet shoes or other dangerous outlet fitting or similar device. 2.3.7 Impermissible working area The end hose must not be moved backwards beyond the vertical of the placing boom. Fig.2-4 Fig.2-5 SYG5360THB 47 2-17 Safety 2.3.8 Climbing the placing boom It is prohibited to climb the placing boom, to stand on top of it or to misuse it as a working platform or aid to climbing. 2.3.9 High-pressure delivery It is prohibited to deliver concrete at high- pressure (concrete pressure greater than 85 bar) through the delivery line of the placing boom. The delivery line and end hose are only suitable for concrete pressures up to 85 bar in their new condition. 2.3.10 Accessories and attachments It is prohibited to fit accessories and attachments to the machine if they have not been expressly approved for use on this machine by the manufacturer. 2.4 Exclusion of liability Where the manufacturer’s delivery conditions are agreed, liability will be as described in the provisions there. We expressly stipulate that the manufacturer is not liable for any damage caused in the cases specified in these conditions. Unless the responsibility of the manufacturer, the warranty will be invalidated in the following situations in particular: – use contrary to designated use – incorrect operation, maintenance and repair – use of spare parts or accessories other than original manufacturer’s spare parts and accessories or their equivalents – conversions, alterations or modifications to the machine – fitting of accessories and attachments not approved by the manufacturer Fig.2-6 SYG5360THB 47 2-18 Safety – adjustment of safety pressures, speeds of movement, power outputs, speeds of rotation and other settings to values other than those set in the works 2.5 Personnel The operator must ensure that only persons who are qualified or have received the necessary instruction work on or with the machine. He must clearly define who is responsible for operation and maintenance of the machine. He must also ensure that only persons commissioned to work on the machine do so. 2.5.1 Requirements Persons operating or carrying out maintenance work on the machine must meet the following requirements: – They must be aged 18 years or over. – They must be physically and mentally capable. – They must be physiologically capable (rested and not under the influence of alcohol, drugs or medication). – They must have been instructed in the operation and maintenance of the machine. – They must have demonstrated their competence to the operator. – They can be expected to reliably execute the tasks with which they are charged. The operating personnel must not wear loose garments or jewellery, including rings. Long hair which is not tied back must be covered by a hair net. Injury may result from hair being caught up in the machinery or from rings catching on moving parts. SYG5360THB 47 2-19 Safety 2.5.2 Qualifications Do not allow persons who have not yet completed training or instruction, or persons taking a general training course, to operate the machine unless under the constant supervision of an experienced person. If you do not have qualified personnel, suitable workshop equipment etc. available, you should commission the manufacturer’s After Sales Department with the maintenance of your machine. 2.5.3 Responsibility of the machine operator The operator must define the responsibility of the machine operator (including in respect to national road traffic regulations) and empower him to reject instructions from third parties prejudicial to safety. The machine operator must be able to reject the site of operations if he has doubts regarding technical safety. 2.6 Operating Instructions, operating procedures and other regulations 2.6.1 Operating Instructions Personnel entrusted with work on the machine must have read the Operating Instructions, in particular the chapter on safety, before beginning work. Reading the instructions after work has begun is too late. This applies especially to persons working only occasionally on the machine, e.g. during setting up or maintenance. The Operating Instructions must always be kept to hand at the site of use of the machine (in the tool compartment or container provided for this purpose). SYG5360THB 47 2-20 Safety As the operator, you must always make sure that the Operating Instructions are available. Have personnel working on the machine confirm in writing their knowledge, understanding and application of the Operating Instructions and Safety Regulations. At regular intervals of at least once a year, check that personnel are conscious of safety and the hazards involved in their work and are taking account of the Operating Instructions. Personnel entrusted with work on the machine must observe all safety notes and hazard warnings. Personnel entrusted with work on the machine must be familiar with the machine itself. You must practice all the operating procedures described in the Operating Instructions (extending the supports, operating the placing boom, shifting the placing boom into the driving position, preparing the vehicle for moving, etc.) under the supervision of a subject expert until you are certain you can execute them safely. Ask questions if there is something you have not understood. Begin operating the machine only once you are familiar with the layout and significance of all the control and monitoring devices and the functioning of the machine in general. 2.6.2 Operating procedures The operator must produce operating procedures for his personnel in accordance with national regulations. These operating procedures must include instructions covering the duties involved in supervising and notifying special operational features, e.g. organization of work, working procedures or the personnel entrusted with the work. SYG5360THB 47 2-21 Safety Furthermore, reference must be made to other generally valid legal and otherwise mandatory regulations relating to accident prevention and environmental protection. Such regulations may also deal with handling hazardous substances, the issuing and wearing of personal protective equipment or with national road traffic regulations. You should familiarise yourself with the site of operations and with how to use fire extinguishers. Observe the fire-alarm and fire- fighting procedures. 2.6.3 Other regulations The current regulations for concrete delivery and placing machines as issued by: – the legal authorities in your country – national supervisory bodies – the responsible commercial liability insurance company are binding on the operator of the machine. 2.7 Personal protective equipment In order to reduce risks to personnel, personal protective equipment must be used in so far as this is necessary or deemed to be so by regulations. All personnel working on or with the machine must wear safety helmets, protective gloves and safety shoes. Personal protective equipment must, as a minimum, comply with the requirements of the specified standards. Safety helmet A safety helmet protects your head against, for instance, falling concrete or parts of the delivery line in the event of a hose bursting. (DIN EN 397; Industrial safety helmets) Fig.2-7 Safety helmet SYG5360THB 47 2-22 Safety Safety footwear Safety footwear protects your feet against falling objects and against penetration by projecting nails. (EN ISO 20345; Safety footwear for professional use; Class S3) Hearing protectors Hearing protectors protect you against the noise generated by the machine when you are standing close to it. (DIN EN 352-1; Hearing protectors – General requirements – Part 1: Earmuffs or DIN EN 352-3; Hearing protectors – General requirements – Part 3: Earmuffs on safety helmet) Protective gloves Protective gloves protect your hands against aggressive or chemical substances, as well as against mechanical effects (e.g. impact) and cutting injuries. (DIN EN 388; Protective gloves against mechanical risks; Class 1111) Protective goggles Protective goggles protect your eyes against injuries from concrete spatters or other particles. (DIN EN 166; Personal eye-protection – Specifications) Safety harness When working at height, use the climbing aids and working platforms provided for reasons of safety or wear a safety harness. The relevant national regulations must be complied with. (DIN EN 361; Personal Protective Equipment Against Falls from a Height –Full Body Harnesses; Category III) Fig.2-8 Safety footwear Fig.2-9 Hearing protectors Fig.2-10 Protective gloves Fig.2-11 Protective goggles Fig.2-12 Safety harness SYG5360THB 47 2-23 Safety Face mask and respiratory protection A face mask and respiratory protection protect you against particles of building materials which could enter your body through your respiratory passages (e.g. concrete admixtures). (DIN EN 149; Respiratory protective devices – Filtering half masks to protect against particles-Requirements, testing, marking; Class FFP1). 2.8 Before starting work 2.8.1 Checking that the machine is ready for operation As machine operator, it is your responsibility to check the machine for external damage and defects before any use of the machine. You must immediately report any changes (including changes in the working characteristics) to the organization or person responsible. If necessary, shut the machine down and secure it against use. 2.8.2 Rendering the machine ready for operation As machine operator, you are responsible for rendering the machine ready for operation. This also includes topping up the functional fluids. Do not fill with fuel in enclosed spaces. Switch off the engine and the heating. Wipe up spilt fuel immediately. Do not smoke or use a naked flame when handling fuel. Set all the control and monitoring devices to the zero position before you change the mode of control (control block, control console or remote control). Press the EMERGENCY STOP button. otherwise the machine might execute unintended movements. Fig.2-13 Face mask and respiratory protection Fig.2-14 SYG5360THB 47 2-24 Safety Never put the remote control down when the machine is ready for operation. If this is unavoidable in exceptional cases, you must press the EMERGENCY STOP button, disconnect the remote control and lock the remote control away (see also page 40). Never leave the machine when the engine is running or when the engine could be started by an unauthorized person. If you need to leave the machine, proceed as follows: – press the EMERGENCY STOP button, – disconnect the remote control and lock it away, – switch off the ignition or the main switch, – lock the control cabinet. 2.9 Danger due to high-voltage 2.9.1 High-voltage lines Whenever you touch a high-voltage line, there is a risk of death for all persons either on the machine or in its vicinity or who are connected to it (via the remote control, end hose, etc.). A spark can jump across from a high-voltage line even if you just approach it and this will energize the machine and the surrounding area. 2.9.2 Discharge voltage pattern In the event of a flash over, what is known as a “discharge voltage pattern” is formed in the vicinity of the machine. The voltage decreases from the inside to the outside in this discharge voltage pattern. If you step within this discharge voltage pattern, you will bridge different potentials. This will cause a voltage corresponding to the potential difference to flow through your body. SYG5360THB 47 2-25 Safety 2.9.3 Clearances Maintain a minimum clearance from high-voltage lines in accordance with the following table. The minimum clearance is measured in the horizontal when the placing boom is fully extended. The specified clearances are minimum requirements. You must observe any greater clearances that may be specified in the country of use. When you set a minimum clearance, the possibility of the high- voltage lines and the placing boom swaying in the wind must also be taken into consideration. You should further note that where air humidity is high, clearances greater than the minimum clearances shown above are always necessary. You must stand as close as possible to the unfolded placing boom if you wish to estimate correctly the movements of the boom and, above all, the clearance between the placing boom and obstacles or high-voltage lines. The same minimum clearances are necessary when driving under overhead cables. In the event that this minimum clearance cannot be maintained under all possible working positions, the power station responsible must be contacted and you must have the high-voltage line switched off. Should you have any doubts, it is better to forego the use of the placing boom and to lay a separate delivery line, for instance. Rated voltage [V] Minimum clearance [m] up to 1kV 1.0 1kV to 110kV 3.0 110kV to 220 kV 4.0 220kV to 380kV 5.0 unknown rated voltage 5.0 Fig.2-15 SYG5360THB 47 2-26 Safety 2.9.4 High-voltage warning devices According to the current rules of engineering, high-voltage warning devices do not meet a safety standard which enables a safe undershooting of the required minimum clearances to high-voltage lines. Previous experience has shown that high- voltage warning devices cannot make all situations in working procedures safe. Flash overs and fatal accidents can occur despite the use of a high-voltage warning device. You must therefore always maintain the minimum clearances mentioned above. 2.9.5 Procedure in the event of a flash over Should a flash over occur, despite all precautions, stay calm, do not move (potential differential), touch nothing. If your machine comes into contact with heavy current lines: – Warn those outside against approaching and touching the machine. – Have the power switched off. – Only leave the machine once you are sure that the line you have touched or damaged has been de-energized. Power stations are always equipped with automatic switch-on devices. If a circuit breaker trips, the short-circuited cable will be switched back on again after a brief interval. Brief intervals when the voltage is absent give rise to a false sense of safety. You should only move and rescue injured persons once a representative of the power station has notified you that the cable has been switched off. A radio remote control system only protects the machine operator if he is standing outside the discharge voltage pattern. Fig.2-16 SYG5360THB 47 2-27 Safety 2.9.6 Earthing in the event of electrostatic charging Faults can be caused in the radio remote control system and dangerous electrical charging of the machine can occur when working in the vicinity of transmitters (radio transmitter, etc.). Persons who bridge the charged parts to the earth are heavily charged on contact. Machines in use in the vicinity of transmitters must be earthed. Secure the earthing cable (at least 16 mm 2 ) to an extra pre-prepared, bright metal point of the machine (e.g. not to a piston rod) and to a conductive metal rod in the ground (minimum insertion depth of 1.5 m). Thoroughly dampen the earth around the metal rod to make it more conductive. Even when the machine is earthed, the safe clearances to high-voltage lines (see page 25) must be maintained and the instructions regarding storms and bad weather (see page 36) must be observed. If you have any further questions about earthing the machine, please contact the construction site management or the operating company of the machine. 2.10 Stationary machines 2.10.1 Set-up site Stationary machines are generally used on a construction site for a lengthy period. For this reason, site management should prepare the set-up site carefully. The site management must deliver the necessary documents in good time in order to be able to prepare the foundations, base plates or similar on time. SYG5360THB 47 2-28 Safety When selecting the set-up site, remember that the machine must be dismantled and transported away again at the end of its use on site. The ambient conditions may change as construction work progresses. 2.10.2 Stationary booms When stationary booms are erected on tubular columns, lattice booms or other base structures, the base frame of the base structure must be secured on the foundation horizontally in all directions. Check the documentation provided by the manufacturer in this regard and the corresponding notes in the operating instructions. 2.10.3 Lifting machines and components Machines which are transported to the set-up site in individual parts or not under their own power must only be lifted with suitable lifting equipment in accordance with the specifications in the Operating Instructions. The lifting gear on the machine must be capable of accepting the lifting gear and lifting the load. No-one should stand under suspended loads. Before work is started, a subject expert must check that the assembled machine is working properly. 2.10.4 Loading and transporting Only use suitable means to load and transport stationary machines. Ensure that no-one can be injured by the machine tipping over or slipping. If there are fixtures provided for transport of the machine or its individual components, only these should be used. The machine or components must be properly lashed down during transport. The transport vehicle and machine must be marked to conform with the road traffic regulations in the country concerned if they are to use the public highway. SYG5360THB 47 2-29 Safety 2.11 Mobile machines 2.11.1 Set-up site It is the machine operator who takes responsibility for setting up the machine safely. He must inspect the proposed set-up site and must refuse to set the machine up at the site of operations if he has any doubts regarding safety. As machine operator, you must familiarise yourself with the working area and surroundings before work is begun. The working area and surroundings include obstacles in the work and travelling areas, the loadbearing capacity of the supporting ground and any barriers separating the construction site from public roads. You must also check the approach route to the site where the machine will be set up. If you are unsure whether the approach route is suitable, prepare the route before work is started. It is especially necessary to walk the approach route once in darkness and at dusk or dawn. You should repeat this exercise again before leaving the construction site. You must always ask for a signaller if you have to reverse into the site where the machine will be set up. If necessary, have the approach route closed off or secured by signallers. Have any materials or equipment that hinder your approach removed. 2.11.2 Supporting ground Check the loadbearing capacity of the supporting ground. The site management will be able to state the permitted ground pressure. SYG5360THB 47 2-30 Safety The supporting ground must be level and even. If necessary, set up a level surface on top of the uneven ground. There must be no voids or other ground irregularities under the support feet. Asphalt, concrete slabs, etc. may have been washed out underneath. Never set the machine up on backfilled ground. The support area must be enlarged as required. Support blocks and timber blocks may be used to increase the support area. The support timbers must be undamaged and free from ice, oil, grease, etc. The support blocks and timber blocks must be laid under the support plates such that the load is distributed uniformly and the support leg cannot slip off the side of the support. Check the stability of the machine regularly during operation. Interrupt the pumping operation if the machine becomes unstable. Factors which reduce stability include, for instance: – modifications to the ground conditions, e.g. caused by rain water or the thawing of frozen ground – the support sinking on one side – fluid losses through leaks in the support hydraulics 2.11.3 Corner bearing loads The corner bearing load is stated on each support leg. This value must always be legible. The force transferred to the ground by each support leg diffuses through the soil in a conical pattern at an angle of 45°. Safe clearance to the pits and slopes must be maintained, and such clearance must be determined in accordance with the nature of the ground. The safe clearance is measured from the foot of the pit. Fig.2-17 Fig.2-18 SYG5360THB 47 2-31 Safety However, for undisturbed, compacted ground, the safe clearance corresponds to pit depth, but must be a minimum of 2 m. For loose or back-filled ground, the safe clearance is twice the pit depth, but a minimum of 2 m. 2.11.4 Supports The placing boom must not be raised until the machine has been supported in accordance with the Operating Instructions. There is otherwise a risk of the machine toppling over. Swing out and telescope the support legs to their end positions in sequence. Intermediate positions are prohibited to guarantee stability. Exceptions are machines which have been equipped by the manufacturer with a device which allows secure erection with a reduction in support. Check the corresponding notes in this regard in the operating instructions. Lock all supports mechanically, if this is provided for in the design. Close all shut-off valves in the support hydraulics. Leaks can cause the supports to sink on one side. The machine must be made level in all directions. The maximum permitted deviation from the horizontal is 3°. Greater deviations from the horizontal overload the slewing gear for the placing boom and jeopardize the stability of the machine. Check stability regularly during operation. The elastic distortions to the machine frame occasionally occurring under extreme positions of the placing boom (one support foot lifts from the ground) must be compensated for by resetting the support cylinders until all support feet are firmly placed on the ground. Fig.2-19 SYG5360THB 47 2-32 Safety 2.11.5 Driving When preparing the machine for driving, you must perform the following tasks in particular: – The placing boom must be folded in fully and positioned on the placing boom support provided. – The support legs and support feet must be fully retracted and secured. – Raised or locked axles must be lowered and released. – Accessories belonging to the machine must be safely stowed away and secured. – The maximum permissible gross weight may not be exceeded. While the vehicle is being driven, the delivery line, pump and hopper must be empty. If there are concrete leavings in the hopper, it must not be possible for the leavings to be thrown out while the vehicle is in motion, thereby creating a risk of injury. You must adapt your driving style to the altered centre of gravity of the machine. You must not exceed the maximum permissible gross weight of the machine. Observe the road traffic regulations and specifications of the machine manufacturer. Maintain a clearance of at least 1 m from the secured edges of construction pits and at least 2 m from slopes. Always make sure that there is sufficient clearance when driving under underpasses, over bridges and through tunnels or when passing under overhead cables. The same minimum clearances apply when driving under high-voltage lines as when working with the placing boom. Be aware of the height of the truck. Only drive over arches, bridges or other supporting structures if the loadbearing capacity is adequate. Fig.2-20 SYG5360THB 47 2-33 Safety Do not drive across uphill or downhill gradients. Be aware of the elevated position of the truck’s centre of gravity when travelling on a slope and on ascending or descending routes. Always adapt your travelling speed to the prevailing conditions on sloping terrain. Never change to a lower gear on a slope but always before reaching it. Observe national road traffic regulations. If necessary, clean the tyres, lights and number plate. Before travelling with the machine, check that the braking, steering, signalling and lighting systems are fully functional. Persons accompanying the driver must be seated on the passenger seats provided for this purpose. Whilst the truck is in motion, the mixer drum on truck mixer concrete pumps must only be rotated at the maximum speed of rotation specified in the Operating Instructions. The truck is at risk of tipping over, particularly when travelling round corners. 2.11.6 Towing The machine must only be towed, loaded and transported in accordance with the Operating Instructions. Only use existing towing hitches for towing and observe the truck manufacturer’s regulations. You must comply with the prescribed driving position, permitted speed and itinerary when towing. 2.11.7 Loading The lifting points fitted to the machine as standard are provided for assembly purposes only. They are not suitable for lifting the complete machine. The lifting points for lifting the entire machine are specially marked. Fig.2-21 SYG5360THB 47 2-34 Safety Use only appropriate means of transport and lifting equipment of adequate loadbearing capacity. Lifting equipment, lifting tackle, support trestles and other auxiliary equipment must be reliable and safe in operation. Use only stable loading ramps of adequate loadbearing capacity for loading. Ensure that no-one is at risk from the machine tipping over or slipping. Secure the machine against rolling, slipping and toppling over on the transport vehicle. 2.12 Placing booms 2.12.1 Unfolding the placing boom Only raise a mobile placing boom from the driving position once the machine has been supported in accordance with the Operating Instructions. Stationary booms may only be raised after the proper set-up has been checked by a subject expert. Only raise the placing boom in the sequence described in the Operating Instructions. The correct sequence depends on the folding system (roll-and-fold system, Z-fold system, etc.). Always ask the site management to supply you with an assistant to act as a signaller. Agree clear hand signals or other signals with the signaller so that you can communicate with each other. You should position the signaller such that he can always observe the whole of the placing boom. Your primary duty as the machine operator is to observe the site of concrete placement. Only slew the placing boom over persons when the end hose is empty. There is a risk of concrete falling out of the end hose. SYG5360THB 47 2-35 Safety Press the EMERGENCY STOP button immediately if the placing boom moves unexpectedly. If this should occur, you must cease working and have the cause of the fault rectified by your qualified personnel or our After Sales Department. Placing booms with placing boom hinges which allow considerable flex angles have a very large potential working area. Because of this high manoeuvrability, various placing booms can, however, also be shifted into positions that are of no interest for the pumping operation. Under certain circumstances it is even possible to overload or cause damage to the placing boom. We have indicated such impermissible working areas by the use of warning signs and information plates on the machine and appropriate notes in the Operating Instructions. 2.12.2 End hose The end hose must hang freely each time you start pumping, when you start pumping again after blockages, and during washing out procedures. No-one should stand within the danger zone of the end hose. The diameter of the danger zone is twice the end hose length. Do not guide the end hose when pumping is started. There is a risk of injury from the end hose swinging out or stones being ejected. There is a risk of injury to the hoseman if the end hose becomes caught in the reinforcement and suddenly jumps out on further movement of the placing boom. Never bend the end hose over. Never attempt to straighten a bent end hose by increasing the pressure. The end hose must not be submerged below the surface of the concrete being delivered, otherwise the concrete may spray upwards. Fig.2-22 Fig.2-23 SYG5360THB 47 2-36 Safety The concrete may also spray from the end hose due to the presence of air in the delivery line. To prevent this from occurring, the hopper must always be filled with concrete as far as the agitator shaft so that no air can be sucked in. The end hose must be secured against falling. 2.12.3 Procedure in storms Return the placing boom to the driving position in the event of storms or bad weather. – Placing booms with a vertical reach of 42 m or more may only be operated in wind forces up to 7 (wind speed 61 km/h = 17 m/s). – Placing booms with a vertical reach of less than 42 m may only be operated in wind forces up to 8 (wind speed 74 km/h = 20 m/s). Wind speeds in accordance with the Beaufort scale are average wind speeds measured over a period of 10 minutes. Higher speed gusts of wind may occur briefly during the measuring period. Higher wind speeds jeopardize stability and safety of the structural elements. There is a risk of lightning strike in a thunderstorm. A lightning strike poses a lethal danger to persons. The machine and the surrounding area will be charged with electricity. Earthing the machine does not reduce this risk. For this reason, you should fold in the placing boom if there is a risk of lightning strike. Tower cranes on construction sites generally have wind speed measuring equipment, so that you can ask about the wind speed at any time. If no wind speed measuring equipment is available, you can ask the nearest meteorological office what the wind speed is, or estimate the wind speed using the following rule of thumb. SYG5360THB 47 2-37 Safety – In winds of force 7 and greater, green leaves break from the trees and there is perceptible resistance when walking against the wind. – In winds of force 8 and greater, small branches break from trees and walking outside is significantly impeded. 2.12.4 Concreting in cold weather The boom must not be used in temperatures below minus 15°C (+5°F) unless the manufacturer has given express approval. There is a danger of damage to the steel (brittle fracture) and the seals throughout the system at such extreme minus temperatures. In addition, such minus temperatures should be considered the realistic lower limit for concrete placement, as it is no longer possible to prepare concrete such that it can achieve its strength without the use of special additives. 2.13 Delivery line systems 2.13.1 Suitable delivery lines Use only perfect delivery lines, end hoses, couplings, etc. suitable for the delivery job and manufactured by the machine manufacturer. Delivery lines are subject to wear which varies according to the pressure and composition of the concrete, the material from which the delivery line is made, etc. 2.13.2 Securing delivery Delivery lines, delivery hoses, end hoses and couplings must be securely fastened and secured against spontaneous opening. Fig.2-24 SYG5360THB 47 2-38 Safety 2.13.3 Tightness and blockages Regularly force water through the delivery line under operating pressure to check that the system is watertight. A properly-cleaned delivery line is the best insurance against the formation of blockages. Blockages increase the risk of accidents. Never attempt to push through a blockage (e.g. by increasing the delivery pressure, using compressed air, etc.). There is a risk of fatal injury from the delivery line bursting or from concrete being ejected from the end of the delivery line. Always try to remove the blockage by reverse pumping and then restarting forward pumping. If the blockage is not removed, relieve the pressure on the delivery line before removing the section of delivery line concerned. 2.13.4 Opening delivery lines You must not open or tap delivery lines while these are pressurized. Concrete exiting under pressure can cause injury. The concrete column must be depressurized by reverse pumping before the delivery line is opened. Never work bending directly over the coupling. 2.13.5 Clearance to delivery lines No-one should remain in the vicinity of separate delivery lines during pumping operations. Cordon off the danger zone. If it is not possible to place a large enough cordon around the danger zone, the delivery line must be covered by suitable means. Fig.2-25 Fig.2-26 SYG5360THB 47 2-39 Safety 2.13.6 Fastening delivery lines Delivery lines, in particular riser lines which are not laid along placing booms, must be securely fastened in order to transfer the forces generated in them into the structure or other structural members. The lines must be laid so as to avoid kinks, sharp bends, stresses and damage during pumping operations. 2.13.7 Continuation delivery lines A continuation delivery line connected to the placing boom must not exert a load on the boom. Devices for shutting- off, diverting or cleaning delivery lines During operation there is a risk of being crushed and of injury by shearing. Hydraulically driven devices are generally supplied with power by a machine’s hydraulic system. It must therefore be possible to see from the devices and the machine with control unit and vice versa. Observe the safety regulations for the machine and the device when connecting and operating a device. Make sure that no-one is in the danger zone before operating devices. Use only suitable, perfectly functioning devices to shut-off, divert and clean the delivery line. Defective and unsuitable devices may cause damage to the whole delivery system and injure persons in the surrounding area due to a malfunction. 2.14 Pumping operations 2.14.1 Place of work The machine operator’s place of work is with the remote control when the pump is in operation. If you operate the machine using the remote control, all operating and control devices on the machine must be closed to prevent unauthorized interventions. SYG5360THB 47 2-40 Safety In the case of stationary placing booms, platforms or similar equipment are only provided for assembly and maintenance work. Use of these platforms as a workplace during operation is prohibited. It is forbidden to climb onto the machine during operation. In the case of stationary placing booms, it is forbidden to climb ladders during operation. 2.14.2 Safety Before switching on the machine, you must make sure that nobody can be injured by the running machine. Refrain from any procedures that may impair the stability of the machine or are prejudicial to safety in any other way. 2.14.3 Remote control You must always carry the remote control on your person when the machine is ready for operation. Only in this way can it be guaranteed that you can press the EMERGENCY STOP button in the event of an emergency situation. The EMERGENCY STOP button may only be unlocked once the cause/emergency has been remedied (see also page 23). You must carry the remote control in such a way that no control element is actuated unintentionally. During breaks in pumping, interruptions, maintenance work or your absence from the machine, you must secure the machine against inadvertently rolling away and to prevent unauthorized use. Press the EMERGENCY STOP button on the remote control and lock the remote control away. SYG5360THB 47 2-41 Safety 2.14.4 Moving machine components and hot surfaces Keep all access covers, maintenance flaps, guards, etc. closed and locked during operation. This also applies to the grille, water box cover, and covers on cylinders, for example. There is otherwise a risk of injury from moving parts of the machine and a risk of burning on hot surfaces. In particular, there is a risk of burns from the engine, attached parts and the exhaust. Never start work unless the grille is closed and bolted down or otherwise secured. Do not touch moving parts of the machine, whether the machine is running or switched off. Always switch off the engine first, and dump the accumulator pressure where an accumulator is fitted. Never poke any objects (e.g. a shovel handle, trowel or similar) into moving machine components. Such objects could become trapped and dragged into the machine. They might then hit you or be torn from your hands and cause you injury. 2.14.5 Constant observation of the machine You should be constantly observing the machine for any damage or faults while it is in use. In the event of faults or malfunctions that impair safety at work, shut the machine down immediately and secure it. Have the faults rectified immediately. If it is not possible to rectify faults which jeopardize the safe operation of the machine, you must suspend operations until the defects are rectified. SYG5360THB 47 2-42 Safety 2.14.6 Truck mixer As the machine operator, it is your role to instruct the truck mixer drivers delivering the concrete to you. Only allow the truck mixer drivers to work alone once you are certain that they have understood your instructions. Make sure that no-one stands between the approaching truck mixer and the machine. There is a danger of being crushed between the truck mixer and the machine. 2.15 Cleaning 2.15.1 General You must drain the delivery line, pump and hopper completely. Concrete leavings in the hopper, in particular, may be thrown out whilst the truck is moving. The machine must not be driven with the placing boom unfolded or the support legs extended, even over short distances. This rule also applies when you have to drive the machine to a different site for cleaning. The placing boom and support legs must be fully retracted and secured. The preferred methods for cleaning the delivery line are reverse pumping or forced cleaning with water. The agitator must be switched on during reverse pumping. Otherwise, the concrete flowing back into the hopper can bend the agitator shaft. Use a catch basket, pipe cleaning head and wash- out ball for forced cleaning to prevent any water from flowing into the formwork. Never spray remote controls or control cabinets with barrier agents (mould oil or similar) to protect them against contamination. This causes significant corrosion damage to the electrical system. Fig.2-27 SYG5360THB 47 2-43 Safety 2.15.2 Cleaning agents Take care when using aggressive cleaning agents. Aggressive cleaning agents may attack materials (e.g. rubber) and painted surfaces. You can use commercially available paint cleaning and care agents, as long as these have a pH value of between 4 and 9. Ask the manufacturer of the cleaning agent to confirm its suitability. Observe the manufacturer’s instructions regarding use and safe handling. Wear protective clothing. Always rinse off cleaning agent thoroughly with clean water; do not allow puddles to form. Do not use sea water or other water containing salt for cleaning purposes. Do not use any highly flammable agent for cleaning; there is a danger of fire. 2.15.3 Hazards There is a risk of injury at all points on the machine from slipping, tripping, bumping into things, etc. Use the handles and steps to climb into and out of the machine. It is forbidden to stand on the grille. Do not jump from the machine. Do not reach into the hopper or any other moving machine components. This rule must also be followed when you are opening the outlet on the bottom of the hopper. Do not remove the grille. Only point the water jet into the hopper or other moving machine components. Do not insert the hose. It could become entangled with moving machine components. 2.15.4 Cleaning with compressed air When the delivery line is being cleaned with compressed air, there is an increased risk of accident from explosively escaping compressed air, spurting concrete and flapping delivery or end hoses if they have not been removed. Fig.2-28 SYG5360THB 47 2-44 Safety Compressed air should only be used for cleaning purposes under the supervision of a subject expert. All persons participating in the cleaning procedure must be instructed in the safety regulations. The manufacturer accepts no liability for damage caused by incorrectly performed compressed air cleaning. If you blow out the delivery line with compressed air, you must observe the following rules without fail: – Individual pipes and short pipe runs up to 10 m in length must not be blown through with compressed air. There is a risk of accident from rebound. – Only blow out delivery lines which have the same nominal diameter throughout their length. Reducer pipes must be drained and flushed out by hand. – No bends, delivery or end hoses may be fitted at the end of the delivery line. – A catch basket must be fastened at the end of the delivery line and a wash-out adaptor must be fitted on the head of the delivery line. Catch basket and wash-out adaptor must fit the delivery line system. – The concrete must be able to flow freely from the end of the delivery line. – No persons may be present in an area of 3 m around the delivery line, at the end of the delivery line and especially in front of the opening in the catch basket. – Care must be taken to ensure that any concrete that might be expelled from the catch basket cannot injure anybody or cause any damage. – The wash-out adaptor must be fitted with a separate, large dump cock and a pressure gauge. SYG5360THB 47 2-45 Safety – The pressure gauge must be kept under constant observation during the cleaning process. The pressure in the delivery line must be rapidly dumped via the dump cock in the event of a sudden drop in pressure (concrete column exiting from the end of the line) or increase in pressure (risk of blockage). – The sponge ball or the plug used to push the concrete out must be sufficiently dense that the air does not pass through it into the concrete. In addition, the delivery line must be sealed to the rear when the sponge ball or plug is caught in the catch basket. – Only work on the delivery line (e.g. open the delivery line) once this has been depressurized. Make sure that the compressed air has been dumped completely. – The dump cock must be opened in such a way that no-one can be injured by concrete residue that might be expelled from the dump cock. 2.15.5 Protection against water Water spraying on the machine from random directions has no damaging effect. The electrical system is protected against spray water, but is not waterproof. You must close/seal all openings into which water/steam/cleaning agent must not penetrate for safety or functional reasons before cleaning the machine with water or a steam jet (high-pressure cleaner) or other cleaning agents. Electric motors and control cabinets are particularly at risk. SYG5360THB 47 2-46 Safety 2.15.6 Post-cleaning procedure After the machine is cleaned, the covers/ tapes must be completely removed and the machine must be checked to ensure that it is ready for operation (see also page 23). Look out for leaks, loose connections, chafe marks and damage during the cleaning procedure. Any identified defects must be rectified immediately. The machine must be greased after it has been cleaned using a high-pressure cleaner. 2.16 Maintenance and special work 2.16.1 Requirements for special work In the capacity of operator, it is your responsibility to provide all the necessary information to the personnel concerned before special work or maintenance work is carried out. Someone should be nominated as the person responsible for this. Carry out the maintenance and inspection operations and comply with intervals specified in the Operating Instructions, including specifications for the replacement of parts and equipment. These activities must be carried out by qualified personnel only. Workshop equipment appropriate to the task in hand is absolutely necessary for the execution of maintenance work. Secure a wide area around the maintenance area as far as is necessary. A machine completely shut down for maintenance and repair work must be secured against being restarted inadvertently: – Lock the main control devices and remove the key. SYG5360THB 47 2-47 Safety – Fix a warning plate to the main switch. Only carry out maintenance work if the machine is parked on level and sufficiently supporting ground and is secured against rolling away. Use specially designed or otherwise safety- oriented climbing aids and working platforms when carrying out assembly work above head height. Never use machine parts as climbing aids. Keep all handgrips, steps, railings, platforms and ladders free from dirt, snow and ice. Carefully secure individual parts and large assemblies to lifting gear when carrying out a replacement operation. Use only suitable and technically perfect lifting gear and suspension systems with adequate lifting capacity. Never stand under suspended loads. The fastening of loads and instruction of crane operators should be entrusted to experienced persons only. The signaller must be within visual range of or in voice contact with the crane operator. Observe national regulations when working with lifting gear. Work on chassis, braking and steering systems must only be carried out by qualified personnel trained for such work. Clean the machine, especially connections and threaded unions, of any traces of oil, fuel or preservatives before carrying out maintenance or repair work. Do not use aggressive cleaning agents.Use lint-free cleaning rags. Bolted connections that you have loosened for carrying out maintenance and repair work must always be retightened to the specified torque. SYG5360THB 47 2-48 Safety Do not open gas-filled spring elements, as used on maintenance flaps, for instance. The spring elements are filled with gas under high pressure which can escape explosively if you attempt to open them. Relieve the tension on systems under mechanical stress. Be aware of hot functional fluids and surfaces (hydraulic fluid, hydraulic fluid radiator, etc.). Ensure that all functional fluids, consumables and replaced parts are disposed of safely and with minimum environmental impact. 2.17 Welding Only qualified personnel commissioned by the manufacturer may carry out welding work on the placing boom, on the supports or on other components which are important for safe operation. The work must be inspected by an authorized inspector. Always attach the earth cable of the welding unit directly to the component which is being welded. The welding current must not flow through hinges, cylinders, etc. Significant damage may be caused by current bridging gaps. Electronic components can be destroyed by stray voltage during arc welding processes. For this reason: – Disconnect the remote control cable from the control console. – Disconnect all cables leading to the receiver of the radio remote control system. – Close connector sockets with caps. – Disconnect the positive and negative leads from the battery. SYG5360THB 47 2-49 Safety Only carry out welding, flame cutting and grinding operations on the machine if this is expressly approved by the manufacturer. Clean the machine and its surroundings of dust and flammable substances and make sure that the premises are adequately ventilated before carrying out welding, flame- cutting and grinding operations (danger of explosion). Only qualified personnel should carry out welding work on the fuel and oil reservoirs in accordance with the manufacturer’s specifications. 2.18 Working on the placing boom Only carry out maintenance and repair work on the placing boom if the placing boom is folded or properly supported, the engine is switched off and the support legs are secured. Support the placing boom arms before starting work on the valves, cylinders or hydraulic lines on the boom. The delivery line was installed without tension with the placing boom in the driving position and can only be replaced without difficulty in this condition. Stresses may be generated on folding if the delivery line is replaced when the placing boom is unfolded. Do not remove the whole delivery line but exchange the delivery arm, e.g boom arm by boom arm. Otherwise, the pivot points of the new delivery line will have to be redetermined using special equipment. Following substantial changes, placing booms must be inspected by an authorized inspector before recommissioning. SYG5360THB 47 2-50 Safety 2.19 Safety-relevant components Some of the manufacturer’s spare parts, such as pumps, valves and controller cards are supplied from the works with a basic setting. These must be adjusted (set) in accordance with the information on the circuit diagram or machine card after installation in the machine. Parts relevant to safety and adjustable devices (pressure limiting valve, potentiometer, fluid flow limiter, hydraulic cylinders, etc.) must only be repaired, replaced or adjusted by After Sales Service personnel. Seals must only be removed by the manufacturer’s After Sales Service personnel. Modifications to the machine ratings (for example, increasing pressures, modifying speeds, etc.) are not permitted. 2.20 Software If a machine is equipped with software, the software may only be used as is provided for in the manufacturer’s Operating Instructions. Only persons authorized by the machine manufacturer may intervene in the machine’s software. This also applies to updates. Unauthorized interventions in the machine’s software may lead to severe damage and accidents. 2.21 Protective and safety Any safety devices removed for maintenance purposes must be refitted and checked immediately upon completion of this work. SYG5360THB 47 2-51 Safety All equipment required for safety and accident prevention (warning signs and information plates, grilles, guards, etc.) must be in place. Such equipment must not be removed, modified or damaged. Keep all warning signs and information plates on the machine complete and in a perfectly legible condition. It is your responsibility as operator to ensure that any warning signs and information plates that have been damaged or rendered illegible are replaced without delay. 2.22 Electrical power 2.22.1 General Work on electrical systems or operating equipment must only be carried out by qualified personnel. For further information on machines operated on the site power supply, see also section 2.22.3, entitled "Power at the construction site". The power supply to machine components on which maintenance work is to be carried out must be isolated, if provided for in the regulations.Before starting any work, you must check the de-energized parts for the presence of power and earth or short-circuit them in addition to insulating adjacent live parts and elements. Disconnect the negative lead from the battery before starting any work on the electrical system. When reconnecting, connect the positive terminal first, and then the negative terminal. Before starting work on high-voltage assemblies and after cutting the power supply, you must connect the supply cable to earth and short-circuit the components such as capacitors with a rod-type earth electrode. SYG5360THB 47 2-52 Safety If work is to be carried out on live parts, the presence of a second person is required who can switch off the power supply to the machine in the event of an emergency. Secure the working area with a red-and-white safety chain and a warning plate. Use insulated tools only. 2.22.2 Electrical components Control cabinet, motor and control elements are protected as standard at least to degree of protection IP 54. IP 54 means: – Complete protection against contact with live components or internal moving parts. Protection against damaging dust deposits. – Water spraying on the equipment from random directions shall not have a damaging effect. Use only original fuses with the specified current rating. The electrical system can be destroyed by overrated fuses or bridging. You must switch off the machine immediately if a fault occurs in the power supply. 2.22.3 Power at the construction site The power on the construction site must be supplied from a special feed point (construction site power distribution point). Machines with an electric motor must not be connected to the mains power supply. Only qualified personnel may work on electrical systems with an operating voltage in excess of 25 volts alternating voltage or 60 volts direct current. Only such qualified personnel may install, connect, disconnect and open electrical control cabinets. An electric shock (possibly with fatal consequences) may be the result of touching machines with electric motors or contact with other electrical cables if the electrical connection has not been made properly or the supply cable is damaged. SYG5360THB 47 2-53 Safety 2.23 Hydraulic systems 2.23.1 General Work on hydraulic systems must only be carried out by qualified personnel. Always wear your personal protective equipment when carrying out work on the hydraulic system. Escaping fluid is toxic and can penetrate the skin. Injection through the skin is a major medical emergency situation. In the event of injuries caused by pressurised oil, inform the company medical officer and call a medical specialist immediately. This also applies for injuries which may seem only slight. Hydraulic fluid which has penetrated underneath the skin must be removed immediately. Otherwise, there is a risk of life-endangering impairment to blood circulation and infections. Parts of the system and pressure lines which are to be opened (hydraulic, pneumatic, and delivery lines) must be depressurized according to assembly descriptions before repair work is started. Work only on depressurized systems. Switch the hydraulic pump drive and the engine off, otherwise there is a risk of injury caused by functional fluids escaping under pressure. Where a hydraulic accumulator is fitted, open the accumulator dump valve to prevent any movements of the machine as a result of the residual pressure. Modifications to the hydraulic accumulator are prohibited. Be aware that enclosed hydraulic fluid can remain under pressure for a certain length of time. Do not open any hydraulic systems if they are under pressure from an external force (e.g. from a raised placing boom). SYG5360THB 47 2-54 Safety Route and install hydraulic lines in accordance with current engineering standards. Ensure that connections are not interchanged. The fittings, lengths and quality of the hoses must comply with technical requirements. You must carefully bleed the hydraulic system after any maintenance work, otherwise there is a risk of injury caused by swinging and telescopic support legs extending rapidly, the placing boom lowering, etc. Open vent valves very carefully until hydraulic fluid starts to escape. You should on no account open vent valves further than necessary or go so far as to remove them. Damaged hydraulic lines must be replaced rather than repaired. You must replace damaged or saturated hydraulic hoses immediately. Spurting hydraulic fluid may cause injury and fire. 2.23.2 Replacing hydraulic hoses During the repeat inspections, a subject expert must check the hydraulic hoses for external damage. The inspection must be recorded in the check book. The operator must have hydraulic hoses replaced if they show signs of external damage. 2.23.3 Noise emissions The place of work in normal operation is with the remote control. For this reason, it is not possible to specify a particular place of work for the machine operator. Take the values for the sound pressure level and sound power level from the machine Operating Instructions. Wear suitable personal protective equipment in the vicinity of the machine. As the operator, you must instruct your personnel to always wear their personal ear protection. You are responsible for ensuring that your personnel comply with this regulation. SYG5360THB 47 2-55 Safety All soundproofing equipment must be fitted and in perfect condition. All soundproofing equipment must be closed during operation. A high sound level can cause permanent hearing damage. 2.24 Exhaust fumes Vehicle exhaust gases contain constituents which can be lethal or carcinogenic. Operate internal combustion engines and fuel- operated heating systems only in adequately ventilated premises. Before starting up the engine in enclosed spaces, make sure that there is adequate ventilation and direct the exhaust gases away from the place of work. Wear personal protective clothing and equipment for all work in which exhaust gases or particles of building material can enter the body through the respiratory passages. Comply with the information issued by the manufacturer of the building material. 2.25 Functional fluids When handling oils, greases and other functional fluids, observe the safety regulations applicable to the product concerned (see the safety data sheet). Oils, fuel and other functional fluids may be hazardous to health upon contact with the skin, etc. You must, therefore, always wear personal protective clothing and equipment when you are handling toxic, caustic or other functional fluids that are hazardous to health and always take note of the manufacturer’s information. Fig.2-29 SYG5360THB 47 2-56 Safety Take care when handling toxic and caustic functional fluids (brake fluid, battery acid, water glass, concrete set accelerating admixtures, cement, etc.). Building materials containing cement have a highly alkaline effect when they react with water (and also with perspiration). Admixtures are toxic and caustic. Cleaning agents, concrete release agents, preserving agents etc. propelled by compressed air can cause very serious damage to the respiratory tract if a respiratory protection mask is not worn. Spray mist enters the lungs very easily. Frequent injuries are eye injuries caused by concrete spatter, water glass or other chemical substances. Take care when handling hot functional fluids and consumables (risk of burning or scalding). Have used operating equipment and functional fluids such as filters, batteries, oil, brake fluid, etc. disposed of properly. Used cleaning rags should also be disposed of properly. Fig.2-30 SYG5360THB 47 2-57 Safety BLANK PAGE SYG5360THB 47 2-58 Safety BLANK PAGE SYG5360THB 47 3-1 System Functions 3 System Functions 3.1 General Overview .............................................................................................3-3 3.2 Boom System ...................................................................................................3-6 3.3 Outrigger System ..............................................................................................3-9 3.4 Truck Chassis ...................................................................................................3-12 3.5 Pumping System ...............................................................................................3-14 3.6 Hydraulic System ..............................................................................................3-17 3.7 Electric Control System ....................................................................................3-24 3.8 Remote Control System ....................................................................................3-48 System Functions SYG5360THB 47 3-2 System Functions WARNING Always read the Safety section of this manual before attempting to operate this equipment. Failure to do this could result in machine damage, personnel injury or death. SYG5360THB 47 3-3 System Functions 3 SYSTEM FUNCTIONS 3.1 General Overview This section of the manual provides detailed information regarding the basic description and overview of all the controls, alerts and operating systems on your equipment. It is important to study and become familiar with all systems before proceeding with any pumping operations. (Some truck chassis information may be included here.) 3.1.1 Main component locations The SANY truck-mounted concrete pump consists of the following main components, see Fig. 3-1. Left side Right side Fig.3-1 General Figure of Truck-mounted Concrete Pump [1] Chassis [2] Boom [3] Outrigger system [4] Hydraulic system [5] Electrical system [6] Body understructure [7]Pumping mechanism [8] Remote control system (in cab) [9] Boom & outrigger backup hydraulics (in cabinet) [10] Outrigger control [11] Maintenance operation box [12] Small operation box 1 7 6 2 3 4 5 8 12 9 10 11 SYG5360THB 47 3-4 System Functions 3.1.2 Main characteristics (1) Stability function with one button The booms can keep stabilization just with one button after action, and the ending-hose can also achieve the position quickly. (2) Automatic stabilization technology The technology mixed with putzmeister, shaking of the booms decrease by 50%. (3) Automatic pumping technology The technology mixed with putzmeister, the changing speed of main cylinder can reach 29~30/min when the pressure of system is 12MPa, the efficiency can increase 25%, and the cost of diesel is 10% lower than before. (4) Function of preventing swing The swinging range of revolving tower can decrease by 60% with this technology, and the precision of the acting also increases a lot. (5) Automatic diagnosing function The system can making diagnosis itself including 150 kinds of malfunction, the driver can repair complex malfunction with the suggesting. (6) Automatic boom system a. Flexing function with one switch:spreading/retracting the booms by pushing/pulling only one switch b. Limiting function of acting area?you will never be worried about the safety when you working in a complex environment if you confirm the area of booms before acting with this function. c. Locking function: the first and the second booms can be locked, and then you can SYG5360THB 47 3-5 System Functions move the other ones, the locking booms will keep their position during the whole process until you unlock them. (7) New technology in damageable structure The life of the damageable structures increases a lot with this new technology and new technics. (8) Safety technology a. Overload safeguard of booms:adding safety valve in balance valve of boom cylinder, it will release the pressure when the booms is over-lord in order to protecting the boom system. b. Safety equipment in Hopper:the equipment in the hopper will stop working (pumping mixing) if the Grille is opened, this function will protect the repairer when the equipment in the hopper are broken and needing repair. c. Safeguard of hydraulic oil: with this function, the system will release the flow of the pumps if the hydraulic oil is lower than one position, Then SYCD show that the equipment need more oil. And the system will stop working if the hydraulic oil is lower than the limiting line until adding enough oil or forcing it. SYG5360THB 47 3-6 System Functions 3.2 Boom System 3.2.1 Boom overview The boom system is used for concrete output and placing. By the extension/retraction of boom cylinder and the rotation of turntable, the concrete can be directly conveyed to the position ( paving site) at the end of boom, via the delivery pipe attached on the boom. The boom of R type is applied, which has compacted structure, can be rapidly folded and unfolded, and requires for small space for folding, see Fig. 3-2. 3.2.2 Boom components The boom system is principally made up of the foldable plane four-connecting rod mechanism formed by articulating the four- arm boom, connecting rod, oil cylinder and connecting piece, see Fig. 3-3. Fig.3-2 Fig.3-3 Boom of Truck-mounted Concrete Pump [1] Oil cylinder of arm (1) [2] Arm 1 [3] Oil cylinder of arm(2) [4][Connecting rod (1) [5] Connecting rod (2) [6] Arm 2 [7] Oil cylinder of arm (3) [8] Connecting rod (3) [9] Connecting rod (4) [10] Arm 3 [11] Oil cylinder of arm (4) [12] Connecting rod (5) [13] Connecting rod (6) [14] Arm 4 [15] Oil cylinder of arm 5 [16] Connecting rod (7) [17] Connecting rod (8) [18] Arm 5 SYG5360THB 47 3-7 System Functions 3.2.3 Boom control There are three methods of boom control: (1) A remote controller that is physically carried by the equipment operator and used during normal pumping operation. See “Remote Control System” on page page 3-47 for details. NOTE:The specific model of remote controller is subject to the real products. The seven-rocker remote controller(Fig. 3-4): ● Rocker (a) controls boom rotation. ● Other rockers controls up/down movement of articulating boom arm 1-5. NOTE:See “Boom components” on page 3-7 to identify articulating boom arm 1-5. ● The Boom Speed Switch (b) is used to selected the boom movement speed. The remote controller of intelligent boom (Fig. 3-5): ● In the manual mode, the five linear rockers a, b, c, d and e are respectively corresponded to arms 1~5. ● In the intelligent mode, the five rockers a, b, c, d and e are used to control the vertical movement of the end of boom. ● Under the intelligent mode, the switch f is used to automatically extend/retract the boom. NOTE:See “Boom components” on page 3-8 to identify articulating boom arms 1,2,3,4 and 5. (2) A hard-wire connection for direct communication with the in-cab receiver. Fig.3-4 f Fig.3-5 SYG5360THB 47 3-8 System Functions NOTE:See page 3-53 for the hard-wire connector port of double-rocker remote controller; NOTE:See page 3-57 for the hard-wire connector port of intelligent boom remote controller. (3) Back-up hydraulics (located in a cabinet on the right side of the chassis) that can be used to manually lower the boom if the system electronics fail, see Fig. 3-6. NOTE:Refer to Charter 4 “Operation” for complete details on boom control. No. Function a Control handle for slewing b Control handle for arm 1 c Control handle for arm 2 d Control handle for arm 3 e Control handle for arm 4 f Control handle for arm 5 Fig.3-6 f SYG5360THB 47 3-9 System Functions 3.3 Outrigger System 3.3.1 Outrigger overview The outrigger system is a part of the revolving tower. The outrigger system supports, stabilizes and levels the entire concrete pumping system during pumping operations. The X-shaped outrigger configuration includes rear outriggers that unfold outwards away from the truck chassis and front outriggers that extend (telescope) out from the truck chassis. 3.3.2 Outrigger components 1 2 3 4 5 6 7 8 9 Fig.3-7 Components of Outrigger [1] Turntable [2] Slewing mechanism [3]Fix revolving tower [4] Right front outrigger [5]Left front outrigger [6]Telescope cylinder of front outrigger [7]Right rear outrigger [8]Left rear outrigger [9]Spread cylinder of rear outrigger SYG5360THB 47 3-10 System Functions 3.3.3 Outrigger control There are three methods of outrigger control: (1) A set of four levers (a) and a momentary safety toggle switch (b) located on the left side of the machine controls all four outriggers, see Fig. 3-8. NOTE:Holding the toggle switch (b) down activates the levers. The levers (a) will not function if the toggle switch is released. Left side (driver side) outriggers control The levers for the left side of the machine control the outriggers as indicated in the table below: Lever Direction Action a Up Lift the left front outrigger Down Descend left front outrigger b Up Retract left front outrigger Down Extend left front outrigger c Up Fold left rear outrigger Down Unfold left rear outrigger d Up Lift left rear outrigger Down Descend left rear outrigger Fig.3-8 Fig.3-9 SYG5360THB 47 3-11 System Functions Right side (nondriver side) outriggers control The levers for the right side of the machine control the outriggers as indicated in the table below: (2) Back-up hydraulics (located inside a cabinet on the right side of the chassis) that can be used to manually retract all four outriggers if the system electronics fail, see Fig. 3-11. With lever (e) in the down position, hydraulic oil flows to the outrigger controls. NOTE:Refer to Charter 4 “Operation” for complete details on outrigger control. 3.3.4 Outrigger pads Outrigger pads (a) are used to support the outriggers after they are in their extended positions. The outrigger pads (a) are stowed on each side of the truck when not in use. Lever Direction Action a Up Lift the right rear outrigger Down Descend right rear outrigger b Up Fold right rear outrigger Down Unfold right rear outrigger c Up Retract right front outrigger Down Extend right front outrigger d Up Lift right front outrigger Down Descend right front outrigger Fig.3-10 Fig.3-11 Fig.3-12 SYG5360THB 47 3-12 System Functions 3.4 Truck Chassis Always keep the truck chassis operator's manual with the truck. Also, you must become familiar with all of the truck chassis operating systems. Damage to or unauthorized modifications to the truck chassis may compromise the ability of the truck chassis to function as originally designed. 3.4.1 Truck chassis overview (1) The chassis of truck-mounted concrete pump is mainly used to provide power for traveling and working of the truck- mounted concrete pump. (2) The shift fork in transfer case, driven by the pneumatic device, can drive the clutch sleeve, so that the power in vehicle's engine can be switched by transfer case. The truck-mounted pump can run if the power is switched to the rear axle of vehicle, and can convey and distribute the concrete if the power is switched to the hydraulic pump. (3) The chassis is composed of the chassis of car, transfer case, oil pump assembly, platform and accessories, etc. The chassis adopted in the truck-mounted concrete pump should conform to the requirements of the local traffic rules and relevant regulations (see Fig. 3-13). SYG5360THB 47 3-13 System Functions 3.4.2 Truck chassis components 1 2 3 Fig.3-13 [1] Vehicle's chassis [2] Transfer case and oil pump assembly [3] Platform and accessories SYG5360THB 47 3-14 System Functions 3.5 Pumping System 3.5.1 Pumping system overview The pumping system conveys the concrete from the hopper at the rear of the truck chassis through the conveying piping of the boom and to the point of application. 3.5.2 Pumping system & related components Pumping system is composed of pumping system (including main oil cylinder, water tank, delivery cylinder, concrete piston, etc.), swing mechanism, S-valve, mixing mechanism, hopper, lubrication system, piping, etc. (see Fig. 3-14). 1 2 5 6 10 9 12 3 4 7 8 11 Fig.3-14 Schematic Diagram of Pumping System [1]Main oil cylinder A [2]Main oil cylinder B [3]Water tank [4]Right conveying tube [5]Left conveying tube [6]Concrete piston A [7]Concrete piston B [8]Swing mechanism [9]S-valve [10]Agitator [11]Hopper [12]Discharge outlet SYG5360THB 47 3-15 System Functions 3.5.3 Pumping system operation The following occurs when the pump is energized. NOTE:The item numbers used here are the same as used in Fig. 3-14 on page 3-14. (1) Hydraulic fluid enters the main oil cylinder (1), forcing that concrete piston (6) forward (towards the hopper) while the other concrete piston (7) retracts (away from the hopper). (2) The swing mechanism (8) positions the S-valve (9) to align with concrete piston (6). (3) Suction created by the retracting concrete piston (7) pulls concrete from the hopper (11) to fill that piston’s conveying tube (4). (4) When the two pump pistons have reached the limit of their travel, the swing mechanism (8) aligns the S-valve (9) with concrete piston (7). (5) Hydraulic fluid enters the other main oil cylinder (2) forcing the concrete piston (7) forward, thus forcing the concrete from the conveying tube into the S-valve, out through the discharge outlet (12) and up through the boom-mounted conveying piping (13) (the number 12 and 13 see Fig. 3-15). (6) At the same time, the other pump piston (6) retracts to pull concrete from the hopper into its conveying tube. (7) When the two pump pistons have reached the limit of their travel, the swing mechanism (8) repositions the S-valve (9) and the process repeats to align with concrete piston (7). 13 12 Fig.3-15 Fig.3-16 SYG5360THB 47 3-16 System Functions The wash tank (3) helps keep the piston rods clean as the piston rods travel within their pumping cylinders. The agitator (10) keeps the concrete mix in the hopper (11) stable, thus ensuring smooth flow from the hopper and into the conveying tubes (4) and (5). 3.5.4 Pumping controls .IThere are two methods of pumping control, see Fig. 3-17. (1) Using the remote controller. ● If you use the seven-rocker remote controller, the toggle switch (9) is used to control the pumping direction and the dial (10) is used to control the pumping flow speed. NOTE:The item numbers here are the same as used in Fig.3-92 on page 3-49 and Table 3-2 on pabe 3-50. ● If you use the intelligent boom remote controller, the toggle switch (4) is used to control the pumping direction and and the dial (5) is used to control the pumping flow speed. NOTE:The item numbers here are the same as used in Fig.3-93 on page 3-51. (2) The pump pressure high / low switch (3), the pumping direction toggle switch (4) and the pumping flow speed switch (6) on the rear chassis switch panel (see Fig. 3-18). NOTE:The item numbers here are the same as used in Fig.3-25 on page 3-24. NOTE:Refer to Charter 4 “Operation” for complete details on pumping control. 9 Fig.3-17-1 Fig 3-17-2 Fig.3-18 3 4 6 SYG5360THB 47 3-17 System Functions 3.6 Hydraulic System 3.6.1 Outrigger controls There are two banks of levers and toggle switches for controlling all four outriggers. ● A set of four levers and toggle switches on the left side of the machine. NOTE:Holding the toggle switch(6) down activates the levers(1), (2), (3) and (4). The levers will not function if the toggle switch is released. 1 2 3 4 5 6 Fig.3-19 No. Name Function 1 Lifting/descending handle for left front outrigger It is used to control the lifting and descending of left front outrigger. By pushing the handle upward, the outrigger is lifted. By pushing downward, the outrigger is descended. 2 Extension/retraction handle for left front outrigger It is used to control the extension and retraction of left front outrigger. By pushing the handle upward, the outrigger is retracted. By pushing downward, the outrigger is extended. 3 Folding/unfolding handle for left rear outrigger It is used to control the folding and unfolding of left rear outrigger. By pushing the handle upward, the outrigger is folded. By pushing downward, the outrigger is unfolded. 4 Lifting/descending handle for left rear outrigger It is used to control the lifting and descending of left rear outrigger. By pushing the handle upward, the outrigger is lifted. By pushing downward, the outrigger is descended. 5 E-STOP button When the button is pressed, the concrete pump will stop working and all operations become ineffective. When the button returns to its initial position clockwise, the concrete pump will work normally. 6 Control switch for outrigger Cooperate with control handles for outrigger to control the extension and retraction of outrigger. Only when the control switch is pressed, can the control handles work. SYG5360THB 47 3-18 System Functions ● A set of handles and toggle switches on the right side of the machine. NOTE:Holding the toggle switch (1) down activates the handles (3), (4), (5) and (6). The handles will not function if the toggle switch (1) is released. Fig.3-20 No. Name Function 1 Control switch for outrigger Cooperate with control handles for outrigger to control the extension and retraction of outrigger. Only when the control switch is pressed, can the control handles work. 2 E-STOP button When the button is pressed, the concrete pump will stop working and all operations become ineffective. When the button returns to its initial position clockwise, the concrete pump will work normally. 3 Lifting/descending handle for right rear outrigger It is used to control the lifting and descending of right rear outrigger. By pushing the handle upward, the outrigger is lifted. By pushing downward, the outrigger is descended. 4 Folding/unfolding handle for right rear outrigger It is used to control the folding and unfolding of right rear outrigger. By pushing the handle upward, the outrigger is folded. By pushing downward, the outrigger is unfolded. 5 Extension/ retraction handle for right front outrigger It is used to control the extension and retraction of right front outrigger. By pushing the handle upward, the outrigger is retracted. By pushing downward, the outrigger is extended. 6 Lifting/descending handle for right front outrigger It is used to control the lifting and descending of right front outrigger. By pushing the handle upward, the outrigger is lifted. By pushing downward, the outrigger is descended. SYG5360THB 47 3-19 System Functions 3.6.2 Outrigger and boom backup hydraulics The hydraulic valve body is located in the fixed revolving tower of truck-mounted concrete pump and used for local control of boom as well as manual control in case that the remote control system is not applied. NOTE:If the system electronics fail, however, this valve can be manually operated to lower the boom and operate the outriggers. The various levers operate as listed below: NOTE:Hydraulic valve configurations may vary, depending on the boom system on your machine. 1 2 3 4 5 6 7 Fig.3-21 No. Name Function 1 Switch handle for outrigger and air cooling system It is used to switch between outrigger and air cooling system. By pushing it upward, the oil circuit of outrigger multi-way valve is put through (can be controlled by the control switch beside the valve), and by pushing downward, the boom pump cooperate with pinion pump to actuate the air-cooling motor, mixing motor or water pump motor. 2 Control handle for slewing It is used to control the actions of turntable. By pushing it upward, the turntable moves clockwise, and by pushing downward, the turntable moves anti-clockwise. 3 Control handle for arm 1 It is used to control the movement of arm 1. By pushing the handle upward, the boom is unfolded, and by pushing downward, it is folded. 4 Control handle for arm 2 It is used to control the actions of arm 2. By pushing the handle upward, the boom is unfolded, and by pushing downward, it is folded. 5 Control handle for arm 3 It is used to control the actions of arm 3. By pushing the handle upward, the boom is unfolded, and by pushing downward, it is folded. 6 Control handle for arm 4 It is used to control the actions of arm 4. By pushing the handle upward, the boom is unfolded, and by pushing downward, it is folded. 7 Control handle for arm 5 It is used to control the actions of arm 5. By pushing the handle upward, the boom is unfolded, and by pushing downward, it is folded. SYG5360THB 47 3-20 System Functions 3.6.3 Pump hydraulics The heart of the concrete pumping system is the main control valve located on a protective bracket (see Fig. 3-22) on the chassis and beneath the boom system. The main control valve is ported to actuate and control the two pumping cylinders. See “Pumping System & Related Components” on page 3-14. The result is a steady supply of concrete from the hopper at any chosen flowrate through the boom-mounted conveying pipes and to the end hose at the point of delivery. See “Main component locations” on page 3-3 for locations of components. 3.6.4 Mixing control valve and mixing cutoff valve The auxiliary valve block with mixing and water pump control valve block is mounted at the left of hopper (see Fig. 3-23). By controlling the reverse mixing electromagnetic valve (single-electromagnetic change valve), the mixer switches over the two rotary directions: When rotating clockwise (the electromagnet is not electrified), the mixer feeds concrete to the delivery cylinder; when rotating anti-clockwise (the electromagnet is electrified), the mixer pushes concrete off the delivery cylinder. Main valve block bracket Fig.3-22 Fig.3-23 [1]Auxiliary valve block [2]Mixing cutoff valve [3]Mixing motor SYG5360THB 47 3-21 System Functions NOTE:The bi-directional electromagnetic change valve mounted on the auxiliary valve block which is shielded by the cover plate as in the figure can change between the oil circuit and water pump system or mixing system over the two directions. Thus, the water pump system can not work with mixing system at the same time, that is, when the water pump is working, the mixing system is not working, or when the mixing system is working, the water pump is not working. 3.6.5 Accumulator and Unloading Ball Valve of Accumulator The accumulator installed at the left rear side of truck-mounted concrete pump is used to provide auxiliary energy for the change circuit and reduce the impact over system. The unloading ball valve of accumulator of truck- mounted concrete pump is installed at the position of tank oil return outlet. When the unloading ball valve is open, the pressure oil of accumulator will be unloaded, so as to make maintenance convenient (see Fig. 3- 24). NOTE:When the load of accumulator relieves but the host still runs, the S-valve and delivery pipe may continue to run, which may lead to danger of crushing or cutting figures when checking the hopper, S-valve and delivery pipe. So, the machine must be stopped before check.If the machine is still running, do not access to the hopper from the discharge port at the lower of hopper or the screen at the upper of hopper and do not throw sundries into the hopper either. Fig.3-24 [1]Accumulator [2]Auxiliary valve block [3]Main valve block [4]Unloading ball valve of accumulator SYG5360THB 47 3-22 System Functions 3.6.6 Self-sealing Device of Main Oil Pump Oil Inlet and Gear Pump Oil Suction Cut-off Valve The oil suction pipeline of oil pump is equipped with oil circuit sealing devices which are mainly used to seal the oil suction pipeline of pump when checking the hydraulic system so as to prevent the hydraulic oil of oil tank from leaking. The oil tank inlet self-sealing device is used for the main oil pump as the oil suction sealing device; the cut-off valves are used for gear pump and boom pump as the oil suction sealing devices. The self-sealing device of oil tank inlet is installed on the oil tank wall. When the adjusting threaded rod is tightened, the oil suction of main pump is smooth; when the threaded rod is released, the oil suction is blocked up, and it is not allowed the main pump to work now to avoid to be damaged(see Fig. 3-25). NOTE:The oil tank inlet self-sealing device and cut-off valve must be open so as to keep the oil suction smooth. Otherwise, the pump might be damaged due to air suction. Do remember to open the cut-off valve of gear pump, and screw down the adjusting threaded rod of the oil tank inlet self-sealing device (the method is pressing and screwing down the threaded rod with hands at the same time) after checking the system. 1 2 3 4 5 Adjusting threaded rod Fig.3-25 [1]Oil tank inlet self-sealing device [2]Oil suction pipe of main pump [3]Oil suction cut-off valve of gear pump [4]Oil suction pipe of gear pump [5]Hydraulic oil tank SYG5360THB 47 3-23 System Functions 3.6.8 Filter Cleanliness is a key factor in maintenance of hydraulic system.If the hydraulic oil is polluted, the hydraulic system will not work normally. The impurity in oil tank can be filtrated by passing through oil intake filter and oil return filter element GP.(see Fig. 3-27 ) For new vehicle, oil return filter element GP must be replaced when running 500h.After that, oil intake filter and oil return filter element GP must be replaced every 1000h. When replacing hydraulic oil, oil intake filter and oil return filter element GP should be changed, either. You should obey local effective regulation when dealing with old filter core Fig.3-27 Oil intake filter Oil return filter element GP 3.6.7 Water pump The water pump is under the platform of truck-mounted concrete pump (see Fig. 3-26). NOTE:The bi-directional electromagnetic change valve mounted on the auxiliary valve block which is shielded by the cover plate as in the figure can change between the oil circuit and water pump system or mixing system over the two directions. Thus, the water pump system can not work with mixing system at the same time, that is, when the water pump is working, the mixing system is not working, or when the mixing system is working, the water pump is not working. 1 2 3 4 Fig.3-26 [1]Water pump motor [2]Mouthpiece of water gun and water pipe [3]Water pump [4]Pressure gauge of water pump SYG5360THB 47 3-24 System Functions 3.7 Electric Control System 3.7.1 Electric Control Cabinet The electric control cabinet of the truck- mounted concrete pump is installed in the right side of revolving tower and mainly consists of operating panel, components & elements and electric control cabinet body (see Fig. 3-28, Fig. 3-29 and Fig. 3-30). NOTICE It is prohibited to wash the electric control cabinet body and elements with water or make them sprinkled. Table 3-1 No. Name Function 1 SYCD Display The display serves to show the various parameters concerning operation of the concrete pump, such as the rotation speeds of engine, pumping time, pumping output, malfunction data, etc. 2 Functional Buttons The buttons F1-F6 can be applied according to the specific prompt on the SYLC display. Fig.3-28 1 Fig.3-29 Fig.3-30 1 2 1 2 3 4 6 5 7/8 [1]Electric control cabinet body [5]Emergency stop [6]SYCD display [3]Central distribution box [4]SYMC special controller [2]Circuit board assembly SYEB [7]SANY Truck pump electric plate SYMCEB [8]SANY Truck pump electric plate SYEB SYG5360THB 47 Power Run Output: E-stop STROKE: Press: 0 times/min SY series truck mounted concrete pump Rotary: Oil TEMP: Info Lang uage Start FOR CE PUMP PAR SET Bug 3-25 System Functions SYCD The SYCD is provided with function of indicating various working conditions. Homepage This page contains the following information: Strokes frequency, flux, rotation angle, pumping press, temperature of oil, force pump, force fan, force eddy, rotation speed of motor and so on(see Fig. 3-31). Functions of the buttons are as follows: ● F1: go to the system function page. ● F2: choose the language. ● F3: no function in this page. ● F4: press this button to start counting the time and the cubic yard, press again to stop. ● F5: force pump ● F6: to set the parameters. Control system function menu On the homepage, press F1 to go to the system function page(see Fig. 3-32), this page contains the following information: ● Realtime Working Info ● Working Statistic Info ● Fuel Consume ● Device Information Query ● I/O State and Feedback Current ● Intelligent Boom Test ● Current Faults ● History Faults Functions of the buttons are as follows: Fig.3-31 Fig.3-32 SYG5360THB 47 3-26 System Functions ● F1: return to home page. ● F2 F3: no function in this page. ● F4: choose the up item. ● F5: choose the down item. ● F6: to confirm the item which you chosen. (1) Realtime Working Info. This screen displays the realtime working information about currently flux, stroke times, engine RPM, pump time, pump cube, pump count and so on. Functions of the buttons are as follows: ● F1: return to home page. ● F2: go to the pre-page. ● F3~F6: no function in this page. (2)Device Information Query This page contains the following information (see Fig. 3-34): Scan the information about the device configuration, such as: SYMC program version, SYCD program version, chassis, delivery volume, hydraulic system etc. Functions of the buttons are as follows: ● F1: return to home page. ● F2: go to the pre-page. ● F4~F6: no function in this page. (3)I/O State and Feedback Current This page displays all of the input and output port information for the device(SYMC). Show as onFig. 3-35 and Fig. 3-36. Press button F1 to return to the home page . F2 and F3 have no function in this page. Press F4 to go to the next page. Fig.3-33 Fig.3-34 Fig.3-35 SYG5360THB 47 3-27 System Functions Press F5 to go to IO-OUT/IN menu. NOTE:This display is mainly used for service engineers when eliminating the fault codes. (4)Current Faults This display will display current fault codes which have occurred. If there is no fault currently, it will display the contents as Fig. 3- 37 (5)History Faults This display shows a record for the preveninet fault for the device,and the engineers just need to follow the prompts to carry out the appropriate troubleshooting Fig.3-36 Fig.3-37 Fig.3-38 SYG5360THB 47 3-28 System Functions . Force pump Press F5 button on the home page to go to the page shown as Fig. 3-40. On this page the display has some notices that pertain to force pump, force fan and force rotate. PAR SET This page contains the following information (see Fig. 3-41): ● Pump Parameter Set ● Boom Damping Parameter Set ● Boom Parameter Set ● Assistant Function ● Device Info Configure ● Turn on Confirm ● Intelligent Diagnose System Fig.3-39 Fig.3-40 Fig.3-41 SYG5360THB 47 3-29 System Functions ● Black Casket Functions of the buttons are as follows: ● F1: return to home page. ● F2: go to the pre-page. ● F3: no function in this page. ● F4: choose the up item. ● F5: choose the down item. ● F6: to confirm the item which you chosen. NOTE:Accessing this item requires a password. (1) Boom Damping Parameter Set Modify the parameters in this page to start the function of boom shock-absorbing. Functions of the buttons are as follows: ● F1: return to home page. ● F2: go to the pre-page. ● F3: no function in this page. ● F4: perform. ● F5: no function in this page. ● F6: to confirm the item which you chosen. NOTE:When you need to modify it, please contact the After-sales Service Engineer 3.7.2 Small operation box The small operation box is on the right side of the chassis frame and in front of the steps beside the hopper. The functions of the switches on the panel are listed below. (1) E-STOP (2) Remote or Local Operation (3) Pump Pressure High / Low Fig.3-42 Fig.3-43 SYG5360THB 47 3-30 System Functions (4) Pumping Forward / Backward (5) Flush Water On / Hopper Agitator On (6) Pump Delivery - Increase / Decrease (7) Horn & Vibrate Hopper Grate (1) E-STOP (see Fig. 3-44) ● Press the button to apply emergency stop, and then the concrete pump stops working and all operations become ineffective. ● Turn the button clockwise to make it return to the initial position, and then the concrete pump works normally. ● Sound the horn before resuming normal operations. CAUTION Failure to sound the horn before resuming normal operations could result in minor or major injury. (2) REMOTE & LOCAL — Two-position toggle switch (see Fig. 3-45). ● Turn the button leftward to apply remote control mode, actuate the remote controller and make the operating panel and control handle for boom fail to work. ● Turn the button rightward to apply local control mode, actuate the operating panel and control handle for boom and make the remote controller fail to work. (3) PRESSURE HIGH-LOW — Three- position momentary toggle switch (see Fig. 3-46). Fig.3-44 Fig.3-45 Fig.3-46 SYG5360THB 47 3-31 System Functions ● Turn the button leftward to apply high- pressure mode and actuate the concrete pump for high-pressure pumping. ● Turn the button rightward to apply low- pressure mode and actuate the concrete pump for low-pressure pumping. CAUTION Always check the pipe pressure rating before operating. If the piping does not indicate it is designed to handle high pumping pressure, do NOT position the switch to the “HIGH” pressure position. Failure to do so will result in equipment damage and could result in personal injury. (4) PUMPING FORWARD & BACKWARD — Three-position toggle switch (see Fig. 3- 47). ● Turn the button leftward to apply forward pumping mode and actuate the concrete pump to convey concrete from hopper to boom end. ● Set the button at middle position to make the pump stopping working. ● Turn the button rightward to apply reverse pumping mode and actuate the concrete pump to suck concrete from boom end to hopper. (5) FLUSH & AGITATE─ Three-position toggle switch (see Fig. 3-48). ● Turn the button leftward to actuate the water pump, and then washing of concrete pump can be carried out. ● Turn the button rightward to actuate the mixing shaft, and then mixing of concrete in the hopper can be carried out. Fig.3-47 Fig.3-48 SYG5360THB 47 3-32 System Functions ● Set the button at middle position to apply standby mode, and then the water pump or mixing system will stop working. NOTE:Always start the agitator before beginning any pumping operations to keep concrete in the hopper over the material cylinder openings. (6) DELIVERY INC & DEC (see Fig. 3-49). ● Turn the button leftward to increase pumping output steplessly, while releasing the button, it returns to neutral position automatically. ● Turn the button rightward to decrease pumping output steplessly, while releasing the button, it returns to neutral position automatically. (7) HORN & VIBRATE — Three-position momentary switch (see Fig. 3-50). Turn the button rightward to make the horn sound once, while releasing the button, it returns to neutral position automatically. 3.7.3 Maintenance and operation box The maintenance and operation box is on the rear boom support pedestal. The functions of the switches are listed below: Fig.3-49 Fig.3-50 Fig.3-51 (2) Agitate reverse (3) Main cylinder forward/backward (4) E-STOP (5) Preheat (6) Speed up/down (7) Swing cylinder forward/backward (8) 24V-3A electrical outlet (1) Piston exit /keep/reset 1 2 3 4 5 6 7 8 SYG5360THB 47 3-33 System Functions (2) AGITATE REVERSE (see Fig. 3-53) After applying the switch, the mixing blade begins to rotate reversely, and then stops reverse rotation after several seconds of delay. CAUTION Never reach into the hopper while the paddles are rotating. Be sure all hydraulic functions are shut down completely and all movement has stopped before reaching into the hopper. Failure to do so may result in serious injury. (3) MAIN CYLINDER FORWARD& BACKWARD (see Fig. 3-54) Two-position toggle switch controls the direction of the pumping cylinders in case the pumping cylinders require service. Leaving the switch in one position results in the cylinders moving in this direction. AGITATE REVERSE Fig.3-53 Fig.3-54 MAIN CYLINDER (1) PISTON EXIT/KEEP/RESET (see Fig. 3- 60) ● It is a three-position toggle switch to access the pump pistons during maintenance procedures. ● KEEP position - Used for normal operation. ● EXIT position - To draw the pump pistons into the wash box for service. ● RESET position - For installing pump pistons. PISTON Fig.3-60 SYG5360THB 47 3-34 System Functions (4)E-STOP (see Fig. 3-56) It is used for emergency situations only, pressing this large, red, round button immediately shuts down all pumping and hydraulic operations, except for the truck engine. When pressed, the button locks in the STOP position until it is released by simply rotating it clockwise as indicated by the arrows on the button. All functions will resume normal operation after the E- STOP button is released. Sound the horn before resuming normal operations. CAUTION Failure to sound the horn before resuming normal operations could result in minor or major injury. (5)PREHEAT (see Fig. 3-57) Apply the switch at low temperature or before operating the machine, so as to preheat the hydraulic oil. NOTICE Switch to the STOP position when the oil has reached operating temperature. Do not leave the switch in the START position. Doing so could cause the hydraulic oil to overheat. Fig.3-56 PREHEAT Fig.3-57 SYG5360THB 47 3-35 System Functions (6) SPEED UP & DOWN (see Fig. 3-58) It is used to adjust the rotation speed of diesel engine and drive the loads through controlling the diesel engine, namely turning it upward for acceleration and turning it downward for deceleration. (7) SWING CYLINDER FORWARD/BACKWARD (see Fig. 3-59) ● It is used to adjust the position of swing cylinder in case of jamming or check. ● Turning it upward for moving forward; ● Turning it downward for moving backward. (8)24-volt Outlet (see Fig. 3-61) It is located on the switch panel shown on. This outlet is always energized and cannot be switched off. Fig.3-58 Fig.3-59 24V 3A Fig.3-61 SPEED SWING CYLINDER SYG5360THB 47 3-36 System Functions 3.7.4 Electromagnetic valves for mixing The electromagnetic valve of mixing valve is installed in the auxiliary valve block (see Fig. 3-62). NOTE:Control the electromagnetic valve for reverse mixing to switch the mixer over the two rotary directions: during forward rotating (the electromagnet is not electrified), the mixer feeds concrete to the delivery cylinder; while reverse rotating, (the electromagnet is electrified), the mixer pushes concrete off the delivery cylinder. 1 2 3 4 ?? ? Fig.3-62 [1]Stamping electromagnetic valve of accumulator [2]Mixing electromagnetic valve [3]Electromagnetic valve for reverse mixing [4]Electromagnetic valve for water pump SYG5360THB 47 3-37 System Functions 3.7.5 Electromagnetic valve of boom This electromagnetic valve of boom is installed in the fixed revolving tower of the truck-mounted concrete pump (see Fig. 3-63). NOTE:The electromagnetic valve of boom is electrohydraulic proportion control valve, which is featured by speed control in accordance with current and stable starting. The normal operations are of remote control mode while the handle only serves for emergent operation. 3.7.6 System gauges & indicators The system gauges enable the equipment operator to monitor the hydraulic system performance, temperature and fluid level. In addition to these system gauges, a water level gauge is located on each outrigger to provide a visual indication of the water level remaining in the water supply system built into each rear outrigger (see Fig. 3-64). NOTICE Know the location and function of these monitoring systems before beginning operation. Failure to do so may result in damage to the machine or a system malfunction. 1 2 3 4 5 6 7 Fig.3-63 [1]Electromagnetic valve for switchover of outrigger and air cooling system [2]Rotary electromagnetic valve [3]Electromagnetic valve of arm 1 [4]Electromagnetic valve of arm 2 [5]Electromagnetic valve of arm 3 [6]Electromagnetic valve of arm 4 [7]Electromagnetic valve of arm 5 1 2 3 4 5 Fig.3-64 [1]Main system pressure [2]Changeover pressure [3]Agitator pressure [4]Hydraulic fluid levels [5]Cleaning water levels SYG5360THB 47 3-38 System Functions (1) Main System (Pump) Pressure (see Fig. 3-65) It activates for 2 minutes each time the Oil Pressure toggle switch (see item 1, on page 3-33 Fig.3-52) on the quick-check panel on the rear boom support pedestal is used and the concrete pump is running. NOTE:Main system (pump) hydraulic pressure is set to relieve at approximately 34 MPa (4,931.3 psi). (2) Change-over Pressure (see Fig. 3-66) It displays the S-tube shift cylinder hydraulic operating pressure during operation. The change-over pressure is the accumulator pressure and it is always active. NOTE:This gauge will pulsate between 152- 117 bar (2,200-1,700 psi) each time the accumulator fires. (3) Agitator Pressure (see Fig. 3-67) It displays the agitator circuit hydraulic pressure. NOTE:Agitator hydraulic pressure is set to relieve at approximately 12 MPa (1,741 psi). Oil Pressure of main system S 10 20 30 40 1000 2000 3000 4000 5000 6000 MPs ? Fig.3-65 Change-over pressure S 10 20 30 40 1000 2000 3000 4000 5000 6000 MPs 0 Fig.3-66 Agitating oil pressure S 1000 2000 1500 500 2500 3000 3500 MPs Fig.3-67 SYG5360THB 47 Fig.3-69 Fig. 3-69) Fig.3-68 (b) (see Fig. 3-68) 3-39 System Functions (5) Hydraulic Fluid Levels & Temps (a) and It indicates the hydraulic oil level and its temperature in the main hydraulic tank. ● (a) is used when the outriggers and boom are in their travel (storage) positions (outriggers folded/retracted into chassis, boom fully collapsed). ● (b) is used when the outriggers are fully extended and in the operating mode, but the boom is still fully collapsed. NOTICE Always check the hydraulic oil levels before you travel to the job site and after the outriggers have been extended. Use (AW46) hydraulic oil. Failure to do so could result in equipment damage if there is a leak in the hydraulic oil circuit. (6) Cleaning Water Level & Temp (c) (see It indicates level of water and its temperature in the built-in water-wash system for cleaning the machine after pumping operations are completed. Use tap water for refilling. WARNING Never use toxic or flammable fluids in the wash system; use only fresh, clean tap water. Using toxic or flammable fluids in this system could cause injury or an explosion resulting in death. NOTE:For operation in cold climate conditions, mixing a nontoxic antifreeze with the water keeps it from freezing. a b SYG5360THB 47 Fig.3-71 (8) Filter Flow Indicator (see Fig. 3-71) Fig.3-70 Hydraulic Pressure (see Fig. 3-70) 3-40 System Functions (7) Main System (Boom & outrigger) It is behind the right valve body boom control door, this gauge is normally off but activates for 2 minutes each time the Oil Pressure toggle switch (see item 1, on page 3-33 Fig.3-52) on the quick- check panel on the rear boom support pedestal is used. NOTE:Boom system hydraulic pressure is set to relieve at approximately 34 MPa (4,931.3 psi). It is on the left side of the deck and in front of the hydraulic cooler on top of the filter near the valve body, this device monitors the hydraulic flow within the filter. ● GREEN indicator in window – Normal ● RED indicator in window –Blocked filter (replacement required) 7 8 Fig.3-72 3-72) (9) Auto-Grease Pressure Gauge (see Fig. It is located on the auto-grease unit near the hopper, this gauge displays the grease pumping system pressure. This gauge pulsates between 0.035 and 0.103 MPa (5 and 15 psi) during normal pumping operations. NOTE:It is normal to see fresh grease around the hopper during pumping operations. 0 10 40 10 SYG5360THB 47 Fig.3-74 Fig. 3-74). Fig.3-73 platform (see Fig. 3-73). 3-41 System Functions 3.7.7 Light The lamps and switches of truck-mounted concrete pump: (1) The side marker lamp is at side of (2) The number plate lamp is at the hopper of truck-mounted concrete pump (See (3) The operation lamp is on the operation valve of outriggers at both sides of truck- mounted concrete pump (see Fig. 3-75). Fig.3-75 SYG5360THB 47 Fig.3-77 (see Fig. 3-77). Fig.3-76 pump (see Fig. 3-76). 3-42 System Functions (4) The width lamp is behind the rear outrigger of truck-mounted concrete (5) The working lamp is at the platform at the rear of truck-mounted concrete pump SYG5360THB 47 Fig.3-80 3-80). Fig.3-79 Fig. 3-79). Fig.3-78 (see Fig. 3-78). 3-43 System Functions (6) The rear fog lamp is at the hopper at the rear of truck-mounted concrete pump (7) The side response reflector is at (see (8) The tail lamp is at rear outrigger of the truck-mounted concrete pump (see Fig. with ISUZU chassis and HINO chassis. Side Response reflector front outrigger of the truck-mounted concrete pump SYG5360THB 47 Fig.3-83 side of steering wheel (see Fig. 3-83). Fig.3-82 panel in the cab (see Fig. 3-82). Fig.3-81 working lamp (see Fig. 3-81). 3-44 System Functions (9) The working lamp switch is behind the (10) From left to right, they are master switch of power supply, pumping position indicator lamp, driving position indicator lamp, which located on the operating (11) The common switch of lamps is at the SYG5360THB 47 Fig.3-85 Fig.3-84 3-45 System Functions 3.7.8 E-STOP buttons There are E-STOP buttons at various locations on the SANY concrete pumping equipment, plus one more on the portable remote controller. Use any of these E-STOP buttons to immediately stop all concrete pump systems (except for the truck engine). Production changes may result in additional E-STOP locations on your machine not shown here. When pressed, the E-STOP button locks in the pressed position until it is rotated clockwise and allowed to spring back to its normal position. WARNING All personnel involved with the job — no matter what their duties — must be aware of all E-STOP button locations before any concrete pumping operations are begun. Failure to do so may result in damage, injury or possibly loss of life. (1) E-stop button on electrical control cabinet. (2) E-STOP button on maintenance and operation box. Power Run Output: E-stop STROKE: Press: 0 times/min SY series truck mounted concrete pump Rotary: Oil TEMP: Info Lang uage Start FOR CE PUMP PAR SET Bug SYG5360THB 47 Fig.3-88 3-46 System Functions (3) E-STOP button on small operation box. (4) E-STOP button nearby the operating rod of left outrigger. (5) E-STOP button nearby the operating rod of right outrigger. Fig.3-86 SYG5360THB 47 Fig.3-87 Fig.3-91 Fig.3-90 The in-cab receiver (see Fig. 3-90) assembly Fig.3-89 3-47 System Functions (6) E-STOP button on the bottom of right side of the remote controller. 3.8 Remote Control System The remote control system is consisted of in- cab receiver and remote controller. 3.8.1 In-Cab receiver consists of the following components: (1) Antenna (mounted on cab exterior during normal operation) (2) Receiver (remains inside cab during normal operation) (3) Main electrical connector NOTE:Equipped with a magnetic base so that it can be conveniently placed on metal surfaces where desired. For maximum reception, it is best to place the antenna on the roof of the truck cab. 1 2 3 SYG5360THB 47 Fig.3-92 92) 3-48 System Functions 3.8.2 Remote controller The remote controller is carried by the equipment operator. Below are descriptions of the control functions on the remote controller (see Fig. 3- and Table. 3-2. Study and become familiar with all functions on this unit before operating the controller. 8 9 10 11 12 [1]Main swcitch [2]Operation Rod for boom rotation [3]Double-way handle 1# [4]Double-way handle 2# [5]Double-way handle 3# [6]Double-way handle 4# [7]Double-way handle 5# [8]Cut off switch [9]Boom speed switch [10]Horn control switch [11]Output adjustment switch [12]Boom speed switch SYG5360THB 47 3-49 System Functions CAUTION Never set the remote controller transmitter down when the equipment is ready for operation. If this must occur, you are required to press the E-STOP pushbutton, disconnect the controller hard wire cable (if used), and lock the remote controller away. Failure to observe and follow this directive could result in personal injury and / or machine damage. Table 3-2 No Name Functions 1 Main swcitch Control the power of remote controller 2 Operation Rod for boom rotation Control the boom rotation. Up:clocwise rotation; Down:inverted hour rotation 3 Double-way handle 1# Control boom 1.Up:unfold;Down:fold 4 Double-way handle 2# Control boom 2.Up:unfold;Down:fold 5 Double-way handle 3# Control boom 3.Up:unfold;Down:fold 6 Double-way handle 4# Control boom 4.Up:unfold;Down:fold 7 Double-way handle 5# Control boom 5.Up:unfold;Down:fold 8 Cut off switch Cut off the chasis 9 Horn control switch Control the horn 10 Forward/reverse pumping switch Control pumping direction. Up:forward pumping; Down:reverse pumping 11 Output adjustment switch Adjust the output of pumping. Inverted hour:reduce output; Clocwise:add output 12 Boom speed switch Out:fast step; In:slow step SYG5360THB 47 Fig.3-93 Remote Controller of Intelligent Boom 3-50 System Functions [1]Undervoltage indicator lamp of battery [2]LCD [3]Page/OK knob (button) [4]Forward/reverse pumpimg switch [5]Output adjustment switch [6]Automatic extension/retraction switch [7]Orientation/reset toggle switch [8]Fast/slow selector switch [9]Boom lock switch [10]Mode selector switch [11]Double-way handle of turntable [12]Double-way handle 1# [13]Double-way handle 2# [14]Double-way handle 3# [15]Double-way handle 4# [16]Double-way handle 5# [17]Cut-off button of remote controller [18]Sound button [19]Emergency stop switch [20]Starting switch [21]Inching button for swing cylinder [22]Standby [23]Hard-Wire connector port [24]Intelligent key of remote controller [25]Flameout button of engine [26]Remote controller display program download interface [27]Battery of remote controller SYG5360THB 47 Fig.3-95 Fig.3-94 3-51 System Functions Intelligent boom remote controller functions (1) Undervoltage indicator lamp of battery It is used to indicate the battery quantity of remote transmitter. ● “Green” meaning normal. ● “Red” meaning insufficient and replacement required. (2) LCD It is used to display the working conditions of pump and query the malfunction. NOTICE The LCD on the remote controller is easy to be damaged, please wear the straps of remote controller well around the neck of the operator when operating. (3) Page/OK knob (button) ● Rotate it to page the display; ● Press it to increase the lighteness of LCD. (4) Forward/reverse pumping switch This is a three-position toggle switch used to control the concrete flow direction. ● Up position - carry out forward pumping ● Down position - carry out reverse pumping ● Center position - No pumping action. (5) Output adjustment switch Calibrated in increments from 1 through 10 to set pump output. SYG5360THB 47 Fig.3-98 Fig.3-97 Fig.3-96 3-52 System Functions (6) (Automatic extension/retraction switch Under the intelligent mode, it is used to automatically extend/retract the boom. ● Push the switch up and keep for at least 2 seconds to start the function of automatic extension; ● Push the switch down and keep for at least 2 seconds to start the function of automatic retraction. NOTE:When the boom is extended or retracted automatically, if it may be blocked by any barrier, please switch to the manual mode to continue to extend or retract the boom fully. (7) Orientation/reset toggle switch It is temporarily unavailable. (8) Fast/slow selector switch Three-position toggle switch used to select the boom movement speed. ● “Rabbit” position - Fast boom speed ● “Snail” position - Slow boom speed ● F3- Unavailable temporarily. SYG5360THB 47 Fig.3-101 Fig.3-100 Fig.3-99 3-53 System Functions (9) Boom lock switch ● Up position - lock the arm 1; ● Down position - lock the arm 1 and arm 2; ● Center position - unlock the arm 1 and 2. (10)Mode selector switch It is used to switch the Manual/Column Plane/ Right Angle modes of boom action. NOTE:Till now the column plane and right angle modes are now opened. (11)Double-way handle of turntable It is used to rotate the turntable. ● Push the handle upward to make the turntable move clockwise; ● Push it downward to make the it move anti-clockwise. NOTE:When under the automatic extension mode, only the arm 1 is lifted can the handle be operated to make the turntable move. When the turntable is moving, the boom will stop to act. SYG5360THB 47 Fig.3-104 Fig.3-103 Fig.3-102 3-54 System Functions (12)Double-way handle 1# ● Under the manual mode, it is used to control the unfolding/folding of arm 1; ● Under the intelligent mode, it is used to control the vertical movement of the end of boom. (13)Double-way handle 2# ● Under the manual mode, it is used to control the unfolding/folding of arm 2; ● Under the intelligent mode, it is used to control the vertical movement of the end of boom. (14)Double-way handle 3# ● Under the manual mode, it is used to control the unfolding/folding of arm 3; ● Under the intelligent mode, it is used to control the vertical movement of the end of boom. SYG5360THB 47 Fig.3-107 Fig.3-106 Fig.3-105 3-55 System Functions (15)Double-way handle 4# ● Under the manual mode, it is used to control the unfolding/folding of arm 4 ● Under the intelligent mode, it is used to control the vertical movement of the end of boom. (16)Double-way handle 5# ● IUnder the manual mode, it is used to control the unfolding/folding of arm 5 ● Under the intelligent mode, it is used to control the vertical movement of the end of boom. (17)Cut-off button of remote controller It is used to cut off the remote transmitter. NOTE:Press the button for 2~3 seconds to turn off the remote controller. SYG5360THB 47 Fig.3-110 Fig.3-109 Fig.3-108 3-56 System Functions (18)Sound button It is used to control the horn of chassis. Always sound the horn to alert others in the area before starting any operation or operating changes. (19)Emergency stop switch It is used to stop the pumping at any condition. NOTE:If the Emergency stop switch on the remote controller is pressed, rotate it up clockwise and then press the start button to unlock the Emergency stop switch. (20)Starting switch Press the switch, so that the truck-mounted concrete pump operates and each switch on the remote controller is available. SYG5360THB 47 Fig.3-113 Fig.3-112 Fig.3-111 3-57 System Functions (21) Page up button It is used to control the movement of swing cylinder. (22) Page down button Unavailable temporarily.. (23)Hard-Wire connector port It is used for direct line hook-up to the receiver. NOTE:It is best to use the direct hard- wire hook-up feature if in an area where radio frequency between the controller and receiver could be hampered. Remove the battery (27) from the battery pack before using the remote controller if a hard-wire hook-up is to be used SYG5360THB 47 Fig.3-116 Fig.3-115 Fig.3-114 3-58 System Functions (24)Intelligent key of remote controller. It is used to lock and unlock the remote transmitter; unscrew it to deactivate the remote controller and screw it down to activate the remote controller. It is used to turn off the engine of chassis. (25)Flameout button of engine It is used to turn off the engine of chassis. (26)Remote controller display program download interface It is used to download the display program for R&D engineer SYG5360THB 47 Fig.3-117 3-59 System Functions (27)Battery of remote controller Power supply of remote controller. (28)Control handle of damping It is used to control boom damping. SYG5360THB 47 3-60 System Functions BLANK PAGE SYG5360THB 47 4-1 Operations 4 Operation 4.1 Pre-operational Checks ....................................................................................4-3 4.2 Set-up Site ........................................................................................................4-5 4.3 Starting Up ........................................................................................................4-7 4.4 Outrigger Set-Up ...............................................................................................4-10 4.5 Function Checks ...............................................................................................4-18 4.6 Boom Movements .............................................................................................4-23 4.7 Hand Signals for Boom and Pump Operations .................................................4-28 4.8 Extending the Boom .........................................................................................4-34 4.9 Pumping Operations .........................................................................................4-39 4.10 Equipment Clean-up ........................................................................................4-53 4.11 Retracting the Boom & Outriggers ...................................................................4-61 4.12 Driving, Towing and Loading ...........................................................................4-62 4.13 Machine Decals ...............................................................................................4-67 Operations SYG5360THB 47 4-2 Operations WARNING Always read the Safety section of this manual before attempting to operate this equipment. Failure to do this could result in machine damage, personnel injury or death. SYG5360THB 47 4-3 Operation 4 OPERATION 4.1 Pre-operational Checks Before starting your work operations, it is important to perform a pre-operational check to be sure your equipment is in safe operating condition. If any problems are found during your pre-operational check, have them repaired immediately. Never operate a machine that is unsafe, damaged or in need of repair. WARNING Never operate a machine that is unsafe, damaged or in need of repair. Using inappropriate equipment can cause accidents or possibly death. Always check the maintenance record for this equipment before operating. Before operating this equipment read and understand the following: ● Look for any obviously missing or damaged marks. ● Inspect the outrigger system for damage or missing components. Be sure the outrigger locks are functional and that the outriggers are properly retracted and locked in place before you travel. ● Inspect the hopper area for loose, missing or damaged items. Be sure this area is clean and functional. ● Be sure all safety and work-related equipment necessary for the job is in place and properly secured for travel. Fig.4-1 SYG5360THB 47 4-4 Operation ● Check the condition of all visible hydraulic hoses. Look for worn or leaking fittings and cuts, scuffed or cracked hose surfaces. Have worn, cracked or leaking hoses repaired or replaced immediately. ● Inspect the boom system for damage, loose or missing parts. Immediately replace any missing or damaged parts and repair or replace loose components that could fall or break during operations. ● Inspect the conveying piping for damage, excessive wear, dents, loose clamps or mountings. Inspect gaskets and hoses, blow-out adapter, sponge (clean-out) ball catchers and any related items. Never use a worn hose or damaged piping. ● Inspect the hydraulic cylinders for damage or leaks. Have damaged or leaking hydraulic cylinders repaired immediately. ● Be sure all safety decals are in place and are not damaged. Be sure they are clean and visible for all personnel to see. ● Be sure the steps, walkways and other areas are clean and not covered with mud, concrete or debris. ● Check the hydraulic tank and cooler. Be sure they are not damaged, loose, leaking or blocked with debris. NOTE: When at the first time to start the new machine, check the piston rod of swing cylinder and oil cylinder of boom (4). If protective sleeves are applied, take off the protective sleeves to prevent the protective sleeves being entangled into oil cylinder during cylinder working. Failure to do so may causing faults. SYG5360THB 47 4-5 Operation 4.2 Set-up Site Awareness of these three basic items displayed in Fig. 4-9 are critical to safe operation when performing concrete thoroughly to be sure it will accommodate your equipment and work operations. Review all set up, pumping and safety rules with the crew before starting. WARNING Failure to observe and follow these directives may result in equipment damage, property damage, personal injury or even death. Overhead power lines Surface conditions Slab to be poured Working clearances Working clearances Building Fig.4-2 SYG5360THB 47 4-6 Operation Surface conditions Always check in with the contractor and talk with the superintendant or foreman regarding where to set up safely. The contractor needs to supply a safe set-up area where the soil and surface are capable of supporting your equipment. Always check for hidden dangers such as voids, pipes or any underground conditions that could cause your machine to tip. Never set up in an area where recent excavations have taken place. Working clearances It is essential to maintain a safe distance between the boom and obstructions such as cranes, scaffolding, buildings or any objects. CAUTION Always study the area thoroughly before unfolding the boom. Never allow yourself to get into a situation where equipment or property could be damaged or personnel could be injured. Overhead power lines Always assume that all power lines are live. Never take the word of someone on the job site that it has been de-energized. DANGER Only a qualified representative of the responsible power company can verify that all electrical systems have been de- energized. Failure to follow this alert will result in serious injury or death. Fig.4-3 Fig.4-4 Fig.4-5 SYG5360THB 47 4-7 Operation 4.3 Starting Up CAUTION Never use starting aids to start the engine. Starting aids are explosive and will damage the engine or possible injury may result. When you take over the machine, you must become so familiar with the equipment that damage and accidents cannot occur. Every time you use the machine, you take on full responsibility for the safety of anyone located in the machine's danger zone. You are therefore under an obligation to ensure that the machine is completely safe in operation. 4.3.1 Test run You must have a test run and function checks before starting work on the construction site. The test run should be made before operation. (1) After the handle brake is applied with the light on, do not move the pump truck (see Fig. 4-6). (2) Put the chassis at the neutral position and turn off the engine. Confirm there is no foreign material in the hopper and clean off. Then, start the engine. Releasing position of hand brake Indicator lamp is on when the hand brake is pulled on P Fig.4-6 SYG5360THB 47 4-8 Operation (3) Check the air pressure for more than 700kPa (see Fig. 4-7). (4) Press down the power button and wait for 10sec, to finish SYMC programme initialization (see Fig. 4-8). (5) Put the chassis at the neutral position and turn off the engine.Press down the oil pump position button to exchange the driving to pumping position of the transfer case, with the indicator on (see Fig. 4-9). NOTE: Press down the oil pump button and remain until the indicator beeping. Barometer 5 5 15 10 0 20 H F Fig.4-7 Fig.4-8 Fig.4-9 SYG5360THB 47 4-9 Operation (6) Start the engine. Step down the clutch to swift the gear per the instructions of the sign in the cab. (7) After stepping down the clutch (at 1:1 gear position with the transfer case), release the clutch slowly, and the pump is in pumping. NOTE: In normal operation of the generator and oil pump, the pumping is made with the hopper screen closed. If the hydraulic fluid temperature is below 15°C, preheating should be made for the system. (8) After pumping, shift empty gear, turn off the engine, press the traveling button, check if the lamp of traveling position is light, if not press the traveling button again till it is light, and then start the engine again and drive with shifting gear (see Fig. 4-10). 4.3.2 Start the machine and engaging the transfer gearbox power take- off CAUTION Be sure the truck chassis is sitting on a firm and level surface. Failure to follow this alert could result in loss of control or possible injury. (1) Set the parking brake on the truck chassis to the park Position. Fig.4-10 PARKING BRAKE Bendin PUSH TO APPLY RELEASE PULL TO Fig.4-11 SYG5360THB 47 4-10 Operation (2) Chock all wheels on the truck. The wheel chocks are stored below the chassis toward the front of the truck. (3) The transfer gearbox is installed after the truck gearbox in the Cardan shaft line. NOTE: The following notes must be abided in order to prevent damage when using the transfer gearbox: ● When the transfer gearbox is engaged and disengaged, the engine must be stopped and the Cardan shaft should not be turned. Furthermore, no gear may be selected. ● The engine may only be restarted after it has been shut down during pumping operations if the concrete pump is switched off and the pumping rate has been turned down to 0". NOTE: Refer to truck chassis operator’s manual for details on starting the engine. 4.4 Outrigger Set-Up You must have read the safety section and have completed the operations for starting up the machine before you begin setting out the machine supports. 4.4.1 Working area See Fig. 4-2 on page 4-5 for the working area. Fig.4-12 SYG5360THB 47 4-11 Operation WARNING People who remain in the working range without authorization can be injured. You should therefore secure the working range. Keep the working range under constant observation. You must cease working immediately and press the E- STOP button if unauthorized person enter the working range. 4.4.2 Danger zone WARNING There is a danger of crushing in the area through which the supports may be swung out or extended. You should secure the danger zone. Keep the danger zone under observation. If anyone enters the danger zone, you must halt work immediately and press the E-STOP button. When the rear outrigger is unfolded or folded, the whole revolving area of the outrigger is dangerous for people may be hurt by clamping (see Fig. 4-13). Fig.4-13 SYG5360THB 47 4-12 Operation When the outrigger is put down, check if there is anything under it to avoid being pressed by the outrigger. The foreign substances under the outrigger must be cleared away (see Fig. 4-14). 4.4.3 Operation of outriggers (1) Unlock the rear outriggers (see Fig. 4- 15). NOTICE Failure to unlock the rear outriggers as directed here may result in machine damage as the control system attempts to unfold the rear outriggers as described later in this procedure. (2) Unlock the front outriggers (see Fig. 4- 16). NOTICE Failure to unlock the front outriggers as directed here may result in machine damage as the control system attempts to extend the front outriggers as described later in this procedure. Fig.4-14 Fig.4-15 Fig.4-16 SYG5360THB 47 4-13 Operation (3) Set the switch (a) on small operation box to the local position to activate the electrical system for the outriggers. See “Main component locations” on page 3-3 for the location of the small operation box. (4) Operation of left outriggers: There is a group of (four) outrigger control handles on both sides of the truck-mounted concrete pump, and the left ones are in charge of the actions of outrigger as follows: 1. lifting/descending of left front outrigger; 2. extension/retraction of left front outrigger; 3. Folding/unfolding of left rear outrigger; 4. lifting/descending of left rear outrigger (see Fig. 4-18). During the operation, turn on the control switch of outrigger 5 (see Fig. 4-18), and then pull the corresponding control handle to operate the outrigger. The order for unfolding outrigger is: 2-3-1-4;The order for folding outrigger is: 4-1-3-2. For supporting, it is necessary to support to the proper positions by two times: the first supporting distance is about 30cm; for the second time it has not supported to the proper position until the tyre of truck-mounted concrete pump is lifted above the ground (see Fig. 4-19). 1 2 3 4 5 Fig.4-18 30cm Fig.4-19 Turn the switch right O O a Fig.4-17 SYG5360THB 47 4-14 Operation (5) Operation of the right outriggers The control handles at the right side are in charge of the actions of outrigger as follows: 1. lifting/descending of right rear outrigger; 2. folding/unfolding of right rear outrigger; 3. extension/retraction of right front outrigger; 4. lifting/descending of right front outrigger. The order for unfolding right outriggers is: 3-2-4-1; the order for folding right outriggers is: 1-4-2- 3. (6) Ensure that outriggers are fully extended or unfolded; the arrow decals markings on both front and rear outrigger mountings must align, indicating they are fully extended and in the proper operating position. See Fig.4-21. WARNING Never operate the equipment with the outriggers partially extended or partially unfolded. Loss of control, serious injury or death may result. 1 2 3 4 Fig.4-20 The arrows of outrigger and lug well aligned The arrows of outrigger extended boom well aligned Fig.4-21 SYG5360THB 47 4-15 Operation 4.4.4 OSS NOTE: OSS is the abbreviation of One-Side- Support which is a type of support for supporting the machine in narrow spaces. (1) This truck-mounted concrete pump is provided with OSS function. (2) When the OSS function is used, the placing scope of boom should be strictly controlled to prevent the truck-mounted concrete pump from overturning. NOTE: The machine can be set up for safe use with outrigger placement on the right or left side only if necessary. Once the boom is elevated and extended, it can then be positioned above the placing area. This operation requires careful planning and continued monitoring of the outriggers. WARNING Never retract the outriggers until the boom is folded into the transport position, even if you will be moving the truck only a short distance. If the truck must be moved for any reason, always retract the boom back to the travel position and lock it securely before retracting the outriggers. Failure to do so may result in loss of control, rollover, personal injury or death. (3) When the OSS function is used, the operation area is as follows: a. With left outriggers retracted and right outriggers fully extended, and taking the central axial line as the origin, rotate the boom rightward from 0° to 120°(see Fig. 4-22); Fig.4-22 SYG5360THB 47 4-16 Operation b. With right outriggers retracted and left outriggers fully extended, and taking the central axial line as the origin, rotate the boom leftward from 0° to 120° (see Fig. 4-23). (4) The working area of the truck-concrete pump depends on the length and rotation angle of boom. Anyone is forbidden to enlarge the working scope by means of addition of spare parts. 4.4.5 Levelling the machine Once the outriggers are unfolded and extended in the proper operating position, it is important to level the chassis. (1) Be sure there is solid, stable ground beneath where the outrigger levelling cylinders will sit. See table 2-2 on page 2- 32 for details on surface conditions. (2) Place the approved factory-approved cribbing pads (1) that came with the pumping unit beneath where the outrigger leveling cylinders will sit. Fig.4-23 Fig.4-24 1 Fig.4-25 SYG5360THB 47 4-17 Operation (3) Hold switch (6) in the down position to operate the outriggers hydraulic control levers (1 and 4). NOTE: Switch (6) is a safety feature to prevent accidental activation once the outriggers are in place during the pumping or boom movement operations. If switch (6) is not held down, the control levers (b and c) will not function (see Fig. 4-26). NOTE: See “Outrigger controls” on page 3-16 for the functions of control levers(1) and (4). (4) Use the levelling gauges to determine when the machine is level (see Fig. 4-27). NOTE: All truck chassis wheels must be slightly off the ground with full weight of the machine resting on the outriggers. CAUTION Always stand clear from the outrigger levelling cylinders during set-up. Failure to do so could result in serious injury. Monitor the cribbing support under the outrigger cylinder foot to be sure it remains central in place and will support the weight of the pump truck chassis. 1 4 6 Fig.4-26 Fig.4-27 Fig.4-28 SYG5360THB 47 4-18 Operation (5) Extend each outrigger levelling cylinder the same amount. Never exceed the 3° range indicated on the levelling gauge (see Fig. 4-29). CAUTION Operation outside the 3° operating range may cause loss of control, a rollover and serious injury. WARNING Never allow any personnel to crawl under any part of the pump truck unit while raising the truck chassis. Serious injury or even death will result if the truck moves or shifts. 4.5 Function Checks You should check the following functions before you begin using the machine on the construction site. 4.5.1 Pump functions The fundamental prerequisite for problem- free use is a fully functional pump. Switch over Check for an unimpeded switch over function of the delivery pistons and the S-valve at various engine speeds. Magnetic switches Check that the drive cylinders switch over automatically once the hydraulic pistons are close to the magnetic switches. When the piston approaches the magnetic switch to change direction, the mark colour of changing direction in the page of SYCD will change for one time. Fig.4-29 SYG5360THB 47 4-19 Operation Stroke time Measure the machine stroke time under no load, i.e. without concrete. ● Set the engine to maximum speed. ● Set the maximum pumping rate. ● Start the measurement at the first switch over of the S-valve. ● The first single stroke is complete with the next S-valve switch over. ● Measure the stroke time in a minute for three times, get the average. The value must match the data of maximal pumping times in the test reading. NOTE: Due to differences in reaction times when using the stopwatch, the value determined may vary from the value stated by approximately 5%. You may have to take the measurement several times and calculate the mean of the values measured. 4.5.2 Filter functions The hydraulic system of truck-mounted concrete pump has one high pressure oil filters. (see Fig. 4-30) The checking processes of the filter is as following: ● Bring the hydraulic fluid up to operating temperature (122 F (50° C)). ● Set the maximum pumping rate. ● Press in the red button on the filter if it is sticking out. NOTE: If the indicator at the top of oil filter turns green, it indicates that the oil filter is in good condition, without any blockage; if it turns red, in indicates Fig.4-30 SYG5360THB 47 4-20 Operation that the filter core is seriously blocked and the operation is stopped, and the filter core must be replaced. Environmental protection Comply with the waste disposal regulations in force for your area when changing the fluid filter. 4.5.3 E-STOP function It is only possible to intervene rapidly in the event of danger if all the E-STOP buttons are functioning. The machine is no longer safe in operation if one of the E-STOP buttons is defective, as you will no longer be able to switch the machine off quickly enough if danger threatens. You must therefore inspect the function of the E-STOP buttons and the lever position for the boom valves before starting work each time. The machine is only switched off electrically when one of the E-STOP buttons is pressed. Although this causes all the electrically actuated hydraulic valves to be switched off, an uncontrolled sinking of the boom caused by leakages in the hydraulic system, for instance, cannot be prevented in this way. In no event should you first press the E- STOP button if the boom starts uncontrolled movements. Should you do this you will have no ability to counteract the movement. Furthermore, the E-STOP circuit has no influence on the accumulator pump and the agitator pump, i.e. the accumulator is filled and the agitator continues to rotate, despite the E-STOP button having been pressed. The way of checking the function of E-STOP buttons is as following: SYG5360THB 47 4-21 Operation ● Switch the pump on. ● Operate a boom function. ● Press one of the E-STOP buttons. The pump and the boom must come to a halt immediately. ● Check all E-STOP buttons on the machine and on the remote control in the same way. 4.5.4 Function check on the boom control block You may only operate the machine if the boom control block is fully functional. ● Switch on remote control. ● Operate the boom control levers briefly several times while observing the levers on the boom control block. ● The lever for the boom valve operated and the lever for the operating mode selector valve must move each time. NOTE: As soon as you release the boom control levers on the remote control unit, the levers for the boom arm valves previously actuated and for the operating mode selector valve must return to the central position (zero position). The reactions of the operating mode selector valve on the boom control block are delayed by some 3 seconds if you use the cable remote control. 4.5.5 Function check on the agitator safety cutout This machine is fitted with an agitator safety cutout. A pressure roller switch is acted on as soon as you open the grille. This causes the agitator to halt and the pressure to be dumped from the accumulator, ie the S-valve will no longer be able to switch over. In SYG5360THB 47 4-22 Operation addition, the delivery pistons return to the end position and the concrete pump halts. WARNING A defective agitator safety cutout can cause you to believe that the machine is safe, even though this is not really the case. This can lead to the agitator continuing to run or the S-valve switching over when the grille is open. You must therefore check the function of the agitator safety cutout before you start each pumping job. Failure to do this could result in damage to the agitator or serious injury to persons. ● Open the grille with the concrete pump running. ● The switching cam acts on the pressure roller switch. ● The agitator must come to a halt immediately. ● The S-valve must no longer switch over. ● The concrete pump must run to the end position and halt. WARNING You must stop work if you open the grille, but ●the agitator continues to run, ●the S-valve continues to switch, ●the concrete pump does not run to its end position. Failure to do this could result in serious injury to persons. NOTE: You must switch the concrete pump off and back on again to restart it. SYG5360THB 47 4-23 Operation 4.6 Boom Movements Prohibited activities You must have read the safety section and completed the operations to set up the machine before you unfold the placing boom. Only unfolding the placing boom once you have set the machine up properly. WARNING Avoid the following actions. They overload the placing boom and may lead to damage or endanger persons: ● Allowing the placing boom to strike an obstacle, see Fig. 4-31; ● Pushing with the placing boom, in order to move an obstacle out of the way, see Fig. 4-32; ● Tearing away a trapped end hose by force. 4.6.1 Restrictions on use Extreme weather conditions, such as gales, storms or low temperatures restrict the use of the boom, or can even make its use impossible. Bad weather and storms Shift the placing boom to the rest position in the event of storms and bad weather, see Fig. 4-33. ● Booms with a vertical reach of 42 m or more (M 42 and larger) may only be Fig.4-31 Fig.4-32 Fig.4-33 SYG5360THB 47 4-24 Operation operated in wind forces up to 7 (wind speed 61 km/h = 17 m/s). ● Booms with a vertical reach of less than 42 m (< M 42) may only be operated in wind forces up to 8 (wind speed 74 km/h = 20 m/s). Wind speeds in accordance with the Beaufort scale are average wind speeds measured over a period of 10 minutes. Higher speed gusts of wind may occur briefly during the measuring period. Higher wind speeds jeopardize stability and safety of the structural elements. There is a risk of lightning strike in a thunderstorm. Tower cranes on construction sites generally have wind speed measuring equipment, so that you can ask about the wind speed at any time. If no wind speed measuring equipment is available, you can ask the nearest meteorological office what the wind speed is, or estimate the wind speed using the following rule of thumb. ● In winds of force 7 and greater, green leaves break from trees and inconvenience is felt when walking against the wind. ● In winds of force 8 and greater, small branches break from trees and progress is impeded. Cold weather The boom must not be used in temperatures below minus 15°C. There is a danger of damage to the steel (brittle fracture) and the seals throughout the system at such extreme minus temperatures. In addition, such minus temperatures should be considered the realistic lower limit for concrete placement, as it is no longer possible to prepare concrete such that it can achieve its strength without the use of special additives. SYG5360THB 47 4-25 Operation 4.6.2 Danger zone CAUTION There is a risk of injury from parts of the delivery line falling beneath the slewing circle of the placing boom. There is a risk of injury from falling concrete beneath the end hose. You should therefore secure the danger zone. Keep the danger zone under constant observation. You must halt work immediately and press the E-STOP button if anyone enters the danger zone. High-voltage lines A spark can jump across from high-voltage lines even if you just approach them and this will energize the machine and the surrounding area. You must therefore always maintain the specified safe clearance. Minimum Safety Distance Between the Boom and Electric Wire Voltage (KV) Minimum Distance (m) 0~1 1.5 1~100 3.5 100~200 4.5 200~300 5.5 >300 0.01(U-50)+3 Fig.4-34 Fig.4-35 SYG5360THB 47 4-26 Operation Overlapping working ranges Take note of the working ranges of other construction plant (e.g. cranes, other concrete placing booms, etc.). Signal boom movements Move the placing boom with cautious operation of the controls. Maintain visual contact with the placing site. Warn by sounding the horn before you move the boom. Hand signals Move the placing boom only if you can see all of the working range. If this is not the case, you must only move the placing boom in response to signals from a signaller. Agree unambiguous hand signals with the signallers giving directions. 4.6.3 Spontaneous retraction of the boom and support cylinders The hydraulic fluid heats up to an average temperature of 60°-70°C during operation because of the friction in the lines. When the hydraulic fluid cools, its volume reduces as cold hydraulic fluid has a smaller volume than does hot hydraulic fluid. This causes the cylinders on the boom, swing-out legs and supports to retract a little and the boom and the outrigger to sink. NOTE: The boom can sink during lengthy pauses in work due to cooling of the hydraulic fluid. For this reason you should never leave the boom in the unfolded position during breaks in working. In addition, you must keep the supports under constant observation whilst the machine is in operation. You may have to readjust the swing-out cylinders and support cylinders. Fig.4-36 Fig.4-37 SYG5360THB 47 4-27 Operation Loss of volume The extent to which the boom and the truck sink depends on the extent to which the various boom and support cylinders have been extended and the magnitude of the temperature difference in the hydraulic fluid. 4.6.4 Uncontrolled boom movements The following defects may be the cause of uncontrolled boom movements: ● Malfunction in the remote control circuit ● Malfunctions on the boom control block ● Lines, threaded unions or boom cylinders leaking ● Defective mono-isolator on the boom cylinder ● Hydraulic system not carefully bled ● Insufficient hydraulic fluid in the reservoir ● Cooling of the hydraulic fluid In this case, the boom may move as soon as the remote control is switched on. Halt work immediately. You can continue working only after the causes have been remedied and perfect functioning of the machine is ensured. NOTE: Whatever the reason for the uncontrolled movements of the boom, you must halt the work on site and have the cause for the breakdown determined and rectified by qualified personnel. DANGER In no event should you first press the E- STOP button if the boom starts uncontrolled movements. Should you do this you will have no ability to counteract the movement. SYG5360THB 47 4-28 Operation Countermeasures You must proceed as follows if the boom starts uncontrolled movement: ● under the uncontrolled movement immediately and attempt to steer the boom out of the danger zone and bring it to rest under control. If the uncontrolled boom movement continues, despite counter-measures: ● Press the E-STOP button. NOTE: Repeated practice is required to ensure that it will be possible to implement the measures described above in an emergency. 4.7 Hand Signals for Boom and Pump Operations 4.7.1 Standard boom hand signals Clear communications are a means for avoiding accidents. In addition to voice communication systems, hand signals are an excellent method for communications between the signal person and the operator (who will be controlling boom extension and boom positioning). A set of one-hand and two-hand signals is presented by the CPMA (Concrete Pumping Manufactures Association). Never begin operations until all signals are clearly understood. If nonstandard signals are used, be sure the operator and signal person agree on them before operations are to begin. The operator shall respond to operating signals from the proper signal person only, but shall obey a stop signal at any time from anybody. The signal person shall be in a clearly visible or lighted location. If signal communications are interrupted at any time, the operator will stop all movement of the equipment immediately. SYG5360THB 47 4-29 Operation CAUTION Always operate the boom slowly and cautiously. Rapid, jerky movements could result in loss of control and possible injury to nearby personnel. OPEN OR EXTEND THE BOOM: Use both right and left hands with the thumbs pointing away from each other. This is the standard signal used by the signal person to indicate to the operator to open or extend the boom system (see Fig. 4-38). MOVE BOOM UP: Use the right or left hand with a thumb-up signal. This is the standard signal used by the signal person to indicate to the operator to raise the boom (see Fig. 4-39). Fig.4-38 Fig.4-39 SYG5360THB 47 4-30 Operation MOVE BOOM DOWN: Use the right or left hand with a thumb-down signal. This is the standard signal used by the signal person to indicate to the operator to lower the boom (see Fig. 4-40). MOVE BOOM TO LEFT: Use the right hand with a thumb pointing in the direction as viewed by the operator you are trying to signal. This is the standard signal used by the signal person to indicate to the operator to move the boom to the left (see Fig. 4-41). MOVE BOOM TO RIGHT: Use the right hand with a thumb pointing in the direction as viewed by the operator. This is the standard signal used by the signal person to indicate to the operator to move the boom to the right (see Fig. 4-42). Fig.4-40 Fig.4-41 Fig.4-42 SYG5360THB 47 4-31 Operation MOVE THE BOOM A LITTLE BIT: Using the right or left hand and opening and closing the thumb and index finger indicates to the operator to move the boom in short or slight movements. This is the standard signal used by the signal person to indicate to the operator to move the boom slightly (see Fig. 4-43). STOP BOOM MOVEMENT: Use the right or left hand with a closed fist to indicate to the operator to stop all boom movements. This is the standard signal used by the signal person to indicate to the operator to stop all boom movements immediately (see Fig. 4- 44). RETRACT OR CLOSE THE BOOM: Use both right and left hands with the thumbs pointing inward towards each other. This is the standard signal used by the signal person to indicate to the operator to retract or close the boom system (see Fig. 4-45). 4.7.2 Pump operation hand signals These one- and two-hand signals presented by the CPMA (Concrete Pumping Manufactures Association) are required during pumping operations by OSHA (Occupational Safety and Health Association). Fig.4-43 Fig.4-44 Fig.4-45 SYG5360THB 47 4-32 Operation Never begin operations until all signals are clearly understood. If nonstandard signals are used, be sure the operator and signal person agree on them before operations are to begin. The operator shall respond to operating signals from the proper signal person only, but shall obey a stop signal at any time from anybody. The signal person shall be in a clearly visible or lighted location. If signal communications are interrupted at any time, the operator will stop all movement of the equipment immediately. START OR SPEED UP PUMPING: Using the right or left hand at waist level, make a fist and move the forearm in and out to indicate to the operator to start pumping operations. Move the forearm in and out at a faster pace to indicate an increase in pumping speed. This is the standard signal used by the signal person to indicate to the operator to start or speed up the pumping speed (see Fig. 4-46). SLOW DOWN PUMPING: Using both hands with the palms facing down at waist level, move the forearms up and down to indicate to the operator to slow pumping operations down. This is the standard signal used by the signal person to indicate to the operator to slow pumping operations down (see Fig. 4-47). Fig.4-46 Fig.4-47 SYG5360THB 47 4-33 Operation CHANGE PUMPING SPEED SLIGHTLY: Using the right or left hand and opening and closing the thumb and index finger, indicates to the operator to increase or decrease pumping speed (flow). This is the standard signal used by the signal person to increase or decrease pumping speed (flow) by a small amount (see Fig. 4- 48). RELIEVE PRESSURE IN PUMP SYSTEM: Use the right hand or left hand to tap twice on your hard hat to indicate to put the pumping system in the reverse mode to relieve pressure on the piping system. This is the standard signal used by the signal person to put the pumping system in the reverse mode (see Fig. 4-49). CAUTION Stop pumping in the forward mode and place the system in the reverse mode immediately if the signal person uses this signal during operations. Failure to do so may result in a sudden rupture in the piping system or hose end-swing and personal injury. ADD WATER TO HOPPER: Using the right hand and thumb pointing toward your mouth, lift the right hand and tilt the head as to indicate drinking. At the same time, hold up the left hand and use your fingers to indicate the amount in gallons (liters) of water to be added to the mix. This is the standard signal used by the signal person to indicate the concrete mix is too thick and needs to be thinned out for better flow (see Fig. 4-50). Fig.4-48 Fig.4-49 Fig.4-50 SYG5360THB 47 4-34 Operation STOP THE PUMP: Use the right or left hand with a closed fist and extended index finger moving the hand across the base of the throat (slashing motion) to signal the operator to stop all pumping operations. This is the standard signal used by the signal person to indicate to the operator to stop all pumping operations immediately (see Fig. 4- 51). NOTICE This signal may be used by other personnel in an emergency. The operator shall obey a STOP signal at any time from anybody. DONE, CLEAN UP: Using both hands with thumbs up motion indicates to the operator that all pumping operations are done and it is time to clean up. This is the standard signal used by the signal person to indicate to the operator that all pumping operations are completed (see Fig. 4-52). 4.8 Extending the Boom Before extending the boom: ● See “Outrigger Set-Up” on page 4-10. ● Be sure your working radius, danger zones and clearances are clear to raise the boom. See “Set-up Site” on page 4- 5. ● Be sure all personnel involved in pumping operations understand all boom hand signals. See “Pump operation hand signals” on page 4-31. Fig.4-51 Fig.4-52 SYG5360THB 47 4-35 Operation ● Be sure all unauthorized personnel are clear of the work area. 4.8.1 Preparing the Remote Controller (1) Be sure the receiver antenna (a) is positioned on the cab roof of the truck for clear communication between the remote controller and in-cab receiver. NOTE: The remote controller system equipment is found inside the truck cab. NOTE: If signal interference will be a problem, you may want to use the hard-wire connector. (2) Set switch (a) on small operation box to the REMOTE position to activate the in- cab receiver. See “Main component locations” on page 3-3 item 12. (3) The controller unit (a) is equipped with straps (b) that must be worn around the neck of the operator during normal operating procedures. See “Remote control system” on page 3-47. Fig.4-53 a b Fig.4-55 a Turn leftward Fig.4-54 SYG5360THB 47 4-36 Operation 4.8.2 Unfolding the boom For details on remote controller joystick functions, see “Remote Control System” on page 3-47. NOTE: See “Outrigger and boom backup hydraulics” on page 3-19 if the electronic control system fails while unfolding the boom. NOTICE Lowering the boom with the hopper in the open position will result in damage to the boom, hopper and hopper cover. (1) Firstly unfold the boom 1 to about 90° position (see Fig. 4-56), or when unfolding the boom 2, it may cause the boom, end base structure and other components to bump. (2) After unfolding the boom 2 to over 70° position, the boom 3 can be unfolded (see Fig. 4-57). (3) After unfolding the boom 3 to over 45° position, the boom 4 can be unfolded (see Fig. 4-58). Fig.4-56 Fig.4-57 Fig.4-58 SYG5360THB 47 4-37 Operation (4) Firstly unfold the boom 5 to over 15° position, and the boom 4 can be unfolded. which avoid arm5 head and tie rods (tie rod 5,6) between arm3 and arm4 to bump (see Fig. 4-59). (5) Unfold the boom 4 and boom 5(see Fig. 4-60). The sequence of folding the boom is the opposition sequence of unfolding the boom. NOTICE When unfolding or folding each boom, it must provide enough height and space for boom movement in order to avoid bump.When turning boom operation handle, don't turn to the dead position once and move slowly to the maximal opposition. WARNING When concrete putting in boom delivery pipe, the total weight of boom increase sharply, and the weight distortion of boom increase, and the the distortion is most at the whole boom horizontal placing state, and the boom end descend sharply, which may cause personnel and equipment damage.Therefore, the minimum distance is over 3 meter from boom and end hose to ground or obstacle before placing. Fig.4-59 Fig.4-60 Fig.4-61 SYG5360THB 47 4-38 Operation 4.8.3 Unlocking the end hose Hold the end hose upward and pull the locking bar (a) downward to release the hose for operation. See Fig. 4-62. NOTE: Don’t unlock the end hose until the boom is in place and ready for pumping operation. 4.8.4 Checking outrigger stability Stability of the unit is very important and must be ensured after the boom is fully extended. Follow the steps below before beginning any pumping operations. NOTICE Lowering the boom with the hopper in the open position will result in damage to the boom, hopper and hopper cover. (1) Slowly slew the extended boom over each outrigger. (2) If you see an outrigger jack sinking or unstable, immediately slew the boom back to its original transport position. (3) Adjust the amount of dunnage under the cribbing pads until you have enough soil contact to hold the unit without sinking. (4) Repeat the procedure for each outrigger. CAUTION Failure to observe and follow these directives could result in machine tipover, equipment damage or personal injury. a Fig.4-62 Fig.4-63 SYG5360THB 47 4-39 Operation 4.9 Pumping Operations Normal pumping operation can begin only after the boom is positioned in the desired location. 4.9.1 Safety precautions NOTICE The pumping system can be started, only after making sure that the change valve of the auxiliary valve group is set at the mixing position, the mixing shaft runs properly, the engine, transfer case and oil pump run normally, the outriggers are supported well and the boom is unfolded as required, and all the examinations are carried out. Failure to do so may result in serious damage to the pumping system, or personal injury. (1) Once the forward/reverse pumping switch is turned to the forward position, the piston will begin to work. Carefully observe whether the main oil cylinder and the swing valve oil cylinder change direction normally, whether the tube clamps are loose, and whether adaptors are leaky. (2) Press reverse pumping button in case of jamming in tube. However, never conduct reverse pumping excessively. Or else, the jamming in tube will become aggravated. (3) In case of emergency, directly press E- STOP button to stop the machine, so that each part of truck-mounted concrete pump stops. SYG5360THB 47 4-40 Operation (4) When starting the truck-mounted concrete pump, accident may be caused by sudden swing of end hose, thus people should be away from the dangerous area of end hose (that may be covered by end hose) during the starting course. The diameter of this area is two times of the length of end hose. If the maximum length of end hose (1) is 4m, the diameter of this area(2) is 8m (see Fig. 4-64). (5) During the operation, you should choose a safe place to stand, and use the appropriate support tools to guide the end hose. Standing on the edge of the building and holding the end hose is forbidden, otherwise, the swing of hose or boom may lead to the fall of operator (see Fig. 4-65). Fig.4-64 Fig.4-65 SYG5360THB 47 4-41 Operation (6) Never allow the rubber hose from bending or jamming, and the end hose cannot be immersed into the concrete. Otherwise, it is easy to cause burst and personnel injury due to the increase of pipeline pressure (see Fig. 4-66). (7) The end hose should be hanged down safely and reliably (see Fig. 4-67). (8) The hopper screen should be closed when the pumping system is running, and it is strictly prohibited to stretch the hands into the hopper or water tank and touch the swing mechanism (see Fig. 4-68, Fig. 4-69 and Fig. 4-70). Fig.4-66 Fig.4-67 Fig.4-68 SYG5360THB 47 4-42 Operation (9) When the pressure is applied, it is prohibited to open or remove the delivery pipes, and it is necessary to decompress the concrete inside the pipe by the reverse pumping. Beware of the wounding by the instant ejection of concrete (see Fig. 4-71). Fig.4-69 Fig.4-70 Fig.4-71 SYG5360THB 47 4-43 Operation CAUTION Do not to use the concrete pump at high pressure (concrete pressure greater than 85 bar) when connected to a pipe suitable only for lower pressure (concrete pressure less than 85 bar). The operator has to make sure that he is using a suitable pipe before switching on the high pressure. SANY does not take any liability for wrong use. (10) Always check weather conditions. Wind speeds in excess of CPMA (Concrete Pump Manufacturers Assn.) and ACPA (American Concrete Pumping Assn.) standard ratings and electrical storms could cause injury or even death. Lower the boom system immediately and take shelter if high winds or an electrical storm should occur during pumping operations. (11) Never allow personnel to stand between the mix truck and pumping equipment when positioning the mix truck with the hopper. Always stand at a safe distance when positioning the equipment. Fig.4-72 Fig.4-73 SYG5360THB 47 4-44 Operation (12) Be sure all pumping material has stopped discharging from the end hose before moving or retracting the boom. Be sure there is no material residue that could fall from the end hose onto the equipment, work site or personnel below. Stop or reverse pumping operations before moving or retracting the boom. 4.9.2 Notes on correct pumping Bouncing boom If the boom bounces very heavily in pumping operations, check the support and correct it as required. If the support is correct, reduce the pump speed or change the boom position. The boom can also bounce if air is taken in and compressed in the delivery line. You should therefore always make sure that the agitator hopper is always filled with concrete to the mixer shaft and that no air is sucked in. Favourable boom position A horizontal position of the last arm is favourable for pumping (see Fig. 4-75). If the last arm is lower than the horizontal, the concrete in this part of the delivery line will flow more quickly as a result of its self- weight. The flow velocity is lower if the arm position is horizontal, and thus the wear on the delivery pipes and the end hose is less. When the pump is stopped, only the content of the end hose flows out if the arm position is horizontal; the content of the delivery line can flow out if the arm position is below the horizontal. Fig.4-74 Last arm horizontal Fig.4-75 SYG5360THB 47 4-45 Operation The strokes of the pump cause forces to act along the delivery line and thus along the boom. If the last arm is vertical, the forces also act vertically on the boom end and move the boom up and down. If the arm position is horizontal, the boom is moved forwards and backwards, which causes a light rocking motion. Damping valve You must close the damping valve when you are pumping soft consistence concrete (snail symbol) as otherwise the S-valve switches over too harshly. You must open the damping valve (hare symbol) when you are pumping stiff consistence concrete as the concrete has a damping effect. 4.9.3 Pre-operational checks Before starting any pumping operations, confirm that: ● All personnel involved are ready for the concrete placing process and that they understand all rules and procedures and know where all E-STOP buttons are located. See “E-STOP buttons” on page 3-45. ● All personnel have an unobstructed view and are able to communicate with the boom operator. ● All hand signals are understood. ● The end hose safety chain (a) is in place and will support the end hose during operations (see Fig. 4-76). NOTE: Never remove this safety chain during pumping operations. Fig.4-76 SYG5360THB 47 4-46 Operation CAUTION Do not use the safety chain to position the end hose. Do not hang onto the end hose or boom during pumping operations. Failure to observe and follow this directive may result in equipment damage or possible injury. ● The auto-grease system is full and operating. It is important that the operator monitor this system during operation. NOTE: Grease build-up under the hopper indicates the system is operating normally. NOTICE Failure to monitor this system may result in component damage or lock-up. 4.9.4 Pumping Priming the system (1) Open the hopper (a) and lock the cover in a safe position using both locks (b) to secure it on both ends (see Fig. 4-77). NOTE: If the boom must be lowered for any reason, be sure to close the hopper cover first. NOTICE Lowering the boom with the hopper in the open position will result in damage to the boom, hopper and hopper cover. a b Fig.4-77 SYG5360THB 47 4-47 Operation (2) Fill the hopper with fresh water and add either a pump priming agent or grout to lubricate the conveying piping. NOTE: Follow the instructions on the priming agent/grout packaging for the amount and mix time. (3) Set switch (a) on the rear chassis switch panel to the AGITATE position to mix the material with the water (see Fig. 4-78). (4) Once the priming agent/grout and water are mixed, signal the personnel at the end hose before engaging the pump. See “Pump operation hand signals” on page 4- 31 for details. Using the remote controller (1) Set switch (b) on the rear chassis switch panel to the REMOTE position and prepare the remote controller for operation (see Fig. 4-78). (2) Move switch (a) to the discharge position while regulating the flow with dial (b) (see Fig. 4-79). Fig.4-79 a b Fig.4-78 SYG5360THB 47 4-48 Operation Using the rear chassis switch panel (1) Set switch (a) to the LOCAL position (turn rightward), see Fig. 4-80. (2) Move switch (b) to the FORWARD position while regulating the flow with switch (c). NOTE: Always sound the horn with switch (d) before you start the pump. The pumping cylinders will begin operation and the mixed priming agent will start moving through the conveying piping. a b c d Fig.4-80 SYG5360THB 47 4-49 Operation Pumping concrete Fill the hopper with concrete when the last of the priming agent is near the bottom of the hopper. NOTE: To avoid concrete build-up on the hopper grate, occasionally use the Switch (a) on either the rear chassis switch panel or the remote controller to shake concrete residue from the grate into the hopper (see Fig. 4-81). NOTICE Always keep more than enough concrete in the hopper during pumping operations to avoid trapping air in the material cylinder openings. 4.9.5 Possible faults Faults may occur even if you have observed all the notes on correct pumping. This section lists the faults occurring most frequently, and indicates how to rectify them. a Fig.4-81 SYG5360THB 47 4-50 Operation Blockages The following faults can lead to blockages: ● delivery line insufficiently wetted; ● S-tube leaking; ● lines leaking; ● concrete leavings in the S-tube and delivery pipes; ● unfavourable concrete composition; ● segregated concrete; ● set concrete. NOTE: In the event of blockages, pump the concrete immediately back into the agitator hopper and mix it up. You can switch over to forwards pumping when the delivery cylinders and the S- valve are switching over automatically again without problem. Begin pumping again with care. Overheating Continuous operation under high loading can lead to overheating of the hydraulic fluid. All pumps have a thermo-electrical cut-out. The pump is automatically shut down if the fluid heats up to over 90 ℃ . Proceed as follows to prevent this: Check that the hydraulic fluid radiator is operating correctly. If not, you can switch it on using the toggle switch on the control cabinet. ● Reduce the output. ● Fill the water box with fresh water as soon as the fluid temperature rises above 80 ℃ . Cooling ● Change the water continuously if the temperature continues to rise. ● Look for the cause of fluid overheating and rectify it. 1 2 3 Fig.4-82 Fig.4-83 SYG5360THB 47 4-51 Operation Additional cooling ● If you absolutely must supply additional cooling, direct the water jet onto the drive cylinders and the piston rods of the drive cylinders. NOTICE Never spray water on the hydraulic fluid reservoir. Damage may be caused to the hydraulic pump. Never use sea water or water containing salt for cooling. Otherwise the chrome layer on the delivery piston rods and delivery cylinders will be destroyed. Restarting after overheating Should the pump have, nevertheless, been switched off because of overheating, you should proceed as follows: ● Switch the pump off. ● Never switch the engine off, as the hydraulic fluid radiator must remain in operation. ● Refresh the water in the water box. ● Wait until the hydraulic fluid has cooled if you are not able to find the fault immediately. ● Once the red indicator lamp has extinguished, switch the pump back on and continue pumping slowly at reduced output. ● Determine the cause of the fluid overheating once pumping operations have been completed and rectify the fault. Fig.4-84 SYG5360THB 47 4-52 Operation 4.9.6 Special cases On some construction sites, it may be the case that the net reach of the boom is not adequate. You then have the option of connecting a continuation delivery line to the boom tip or, if your machine is equipped with a lateral outlet, connecting a delivery line there. Continuation delivery line No forces must be transferred from the fixed delivery line to the boom or vice versa. The stationary delivery line may not place additional loading on the boom. This will prejudice the stability of the machine. The delivery hose may not be bend, nor may be it be stretched. Blockages can occur if it is bent. If it is stretched out, forces may be transmitted which can lead to damage to the structure, delivery hose or boom. The boom can sink during pumping operations and place the delivery hose under tension as a consequence of cooling of the hydraulic fluid in the boom cylinders. This can cause forces to be transferred or the delivery hose to tear. You should therefore keep the delivery hose under constant observation. ● Extend the boom to bring the last arm approximately 1.5-2 m from the stationary delivery line. ● Dismantle the end hose. ● Mount a 3 m long delivery hose in place of the end hose. ● Connect the delivery hose and the fixed delivery line using a SKH attachment coupling. Use an A seal as the seal. ● Fasten the SKH attachment coupling securely to the structure. SYG5360THB 47 4-53 Operation 4.10 Equipment Clean-up After all pumping operations are completed, it is important to remove and clean all concrete material residue from the machine before folding the boom. NOTICE Failure to thoroughly clean the pumping system at the completion of pumping operations will result in equipment damage. 4.10.1Cleaning the Boom Piping Clean the conveying piping before cleaning any other parts of the concrete pump unit. Timing is very important during this operation because concrete can set up and harden very quickly. (1) Fully extend the boom vertically using the joystick controls on the remote controller. This position will aid in the extraction of any concrete within the boom piping (seeFig. 4-85). Fig.4-85 SYG5360THB 47 4-54 Operation (2) Set the Remote/Local switch (a) on the rear chassis switch panel to the LOCAL position (turn rightward) and Pumping Forward/Backward switch (b) to the BACKWARD position to empty the conveying piping as much as possible (see Fig. 4-86 ). See “Main component locations” on page 3-3. NOTICE Use only the rear chassis switch panel when performing cleaning operations to avoid damage to the remote controller. When no additional concrete exits the boom piping, move the Pumping Forward / Backward switch (b) to the central position to stop the reverse pumping operation. (3) Lower the boom to access the end hose. Then soak the sponge ball in water and insert it into the end hose (see Fig. 4-87 ). Fig.4-87 a b Fig.4-86 SYG5360THB 47 4-55 Operation (4) With the saturated sponge ball inserted into the end hose, fully extend the boom vertically once more to extract any residual concrete from the boom conveying piping. (5) Set the Pumping Forward / Backward switch (b) to the BACKWARD position once more to begin reverse pumping flow, draw the sponge ball through the conveying piping and extract any residual concrete from the boom conveying piping. Residual concrete will empty into the hopper and the sponge ball will follow (see Fig. 4-89). NOTE: As the sponge ball gets closer to the hopper, use a wooden mallet to gently tap on the piping to determine the location of the sponge ball. A dull sound indicates the conveying piping is still full. A hollow, ringing sound indicates the piping is clear of concrete and the ball is closer to the end. Fig.4-8 8 b Fig.4-89 SYG5360THB 47 4-56 Operation (6) When the sponge ball is close to the elbow near the hopper, set the Pumping Forward / Backward switch to the center position to stop pumping action; then remove the lock pins (a) and the elbow (b) (seeFig. 4-90). (7) Move the lever (a) at the bottom of the hopper to open the hopper bottom door and allow the hopper to drain (see Fig. 4- 91). When the hopper is empty, retract the boom for additional cleaning if necessary. Retrieve the sponge ball and wash out the remaining conveying piping by hand, then reinstall the elbow and lock pins that secure the elbow to the hopper. NOTE: It may be necessary to repeat steps 4 for 10 several times to ensure that all concrete residue is removed from the boom piping. NOTICE Be sure all conveying piping sections are clean and clear of any concrete residue before performing the final wash of the pump and exterior. Failure to do so may result in equipment damage when the pump is next used. a a b Fig.4-90 a Fig.4-91 SYG5360THB 47 4-57 Operation (8) Move the lever (a) at the bottom of the hopper to close the hopper bottom door after all residual concrete has been cleaned from the boom conveying piping, then retract and lower the boom into place for travel (see Fig. 4-92 ). CAUTION If required, using compressed air to clean the boom piping or a separate pipeline should be done only under the supervision of a trained expert. All hoses must be removed and a ball catcher must be attached to the discharge end. Failure to follow these procedures could result in serious injury. 4.10.2 Hopper, delivery cylinder and S-tube One possible method of cleaning the hopper, the delivery cylinder and the S-valve is described below. NOTE: This machine is equipped with an agitator safety cutout. As soon as you open the grille, the agitator is halted and the pressure is dumped from the accumulator. This means that the S- valve will no longer be able to switch over. In addition, the delivery pistons return to the end position and the concrete pump halts. You must switch the concrete pump off and back on again to restart it. WARNING In no event should you insert the water hose, the spray gun or other objects through the grille into the hopper to spray out the delivery cylinders. Such objects may be trapped by the S-valve as it switches over and become damaged. The objects may be caused to fly about, thereby causing an injury to you or other persons. a Fig.4-92 SYG5360THB 47 4-58 Operation Drain off the leavings ● Place a sheet beneath the hopper. ● Open the hopper flap beneath the hopper and let the leavings flow out of the hopper. ● Switch the pump over to reverse pumping. ● This pumps the leavings out of the delivery cylinders into the hopper and thus out of the hopper opening. Spray out delivery cylinder ● Open the two cross pins on the hinged elbow to take out the sponge ball, open the hinged elbow. ● Allow the concrete pump to run slowly in reverse. ● Spray the S-valve out carefully downwards from the hinged elbow. Slowly insert the hose up to the marking as you do this. ● Hold the water hose in this position, introduced as far as the marking, for several minutes, until only clean water runs out. This will flush out the two delivery cylinders alternately. ● Carefully spray out the hopper using a hose. ● Hose down all components that have come into contact with concrete. Fig.4-93 Fig.4-94 Fig.4-95 SYG5360THB 47 4-59 Operation 4.10.3Truck superstructure and post- cleaning procedure Once the delivery line, hopper, delivery cylinders and S-tube have been washed out, you must then rinse down thoroughly all parts of the machine that have come into contact with concrete. Concrete that is not washed off immediately can attack the paint, especially if aggressive concrete additives have been used. Use the built-in pressure washing system to remove residual concrete from the exterior of the boom parts, hopper and other areas after the boom conveying piping is clear. Water for the pressure-washing system is located in the rear outriggers. (2) Set switch (a) on the rear chassis switch panel to the FLUSH position (turn leftward), see Fig. 4-96 and the water will (1) Connect the water pump and water gun a Fig.4-96 spurt out from the water gun(see Fig.4-97 ). with flush hose at the left side rear of the truck below the chassis. SYG5360THB 47 4-60 Operation NOTICE Be careful not to let the pressure washing system go dry during washing operations. Damage to the pump may result. NOTICE Failure to remove all concrete residue may result in damage to the machine, especially during later operation. (5) Use either of the following two methods to prevent the possibility of freeze-up during cold weather: ● Drain any water residue from the rear outrigger tanks after all pressure-washing operations are complete. Each rear outrigger has a drain cock (a) on the bottom center of the frame (see Fig.4- 99). ● Add non-toxic antifreeze to the water to prevent freezing and reduce cold climate freeze-up. Fig.4-97 a Fig.4-99 (4) Set switch (a) on the rear chassis switch panel to the STOP position (turn middle ) in 30s after close the ball valve of see Fig. 4- t c e f e l l i w t i r o , ) 8 9 a Fig.4-98 water gun ( the lifetime of the water pump. a b (3) Use valve (a) to adjust the water pressure making sure the pressure reading remains within the green zone on the gauge (b) (see Fig. 4-97). SYG5360THB 47 4-61 Operation 4.11 Retracting the Boom & Outriggers WARNING Clear the work area of all personnel and equipment before proceeding. Never retract the outriggers with the boom raised. Always be sure the boom is fully collapsed and secured in place before retracting the outriggers. Loss of control or a rollover may occur, resulting in equipment damage, personal injury or death. (1) Ensure that all clean-up operations are complete. (2) Confirm that the parking brake on the truck chassis is set to the PARK position and that all wheels are chocked. (3) Retract the boom to its fully collapsed position and secure it in place. See “Extending the Boom” on page 4-34 for details. (4) Standing clear of the outriggers, retract each outrigger jack the same amount until each outrigger is fully lowered, never exceeding the 3° range shown on the level indicator during the process. If necessary, use a spotter to help guide you. (5) With all personnel still clear of the work area, retract the front outriggers into the truck chassis, then fold the rear outriggers in place against the exterior of the truck chassis. (6) Ensure that all outriggers are properly locked and secured in place before you travel. Fig.4-100 SYG5360THB 47 4-62 Operation 4.12 Driving, Towing and Loading 4.12.1Driving General travel precautions Before traveling, be sure the boom is properly seated in its cradle, resting in the approved location and locked in place. Never travel with an incorrectly placed boom. Loss of control may result (see Fig. 4-101). Before traveling, ensure that all outriggers and other equipment are secured in place and all road safety devices are present and secured (see Fig. 4-102). Double-check these items before you travel each time. Always be aware of your travel height. Bridges, power lines and overhanging objects pose a hazard when traveling with your equipment (see Fig. 4-103). Check your equipment dimensions in the specifications section of this manual and be sure your route will accommodate the equipment. Fig.4-101 Fig.4-102 Fig.4-103 SYG5360THB 47 4-63 Operation Always travel at a safe, controllable speed. Avoid sudden stops or high speed turns which could cause loss of control or a possible rollover (see Fig. 4-104). Keep in mind, the larger the equipment on the truck body, the higher the center of gravity. Driving on slopes Driving on slopes may pose a hazard. In order to prevent tipping or losing control of the machine, it is important to follow some basic simple rules. Always drive straight up or straight down the slope (see Fig. 4-105). Keep the boom equipment fully retracted and properly locked down. You may have to back the machine up the slope if the slope grade is too steep. Never turn the ignition switch OFF when driving on a slope. Drive in low gear at a slow, controllable speed. Never turn or maneuver the truck on a slope. Due to the high center of gravity in the concrete pumping equipment, loss of control, tipping or a rollover may result (see Fig. 4- 106). Fig.4-104 Fig.4-105 Fig.4-106 SYG5360THB 47 4-64 Operation Driving in reverse Driving in reverse may pose several hazards. Below is a list of some basic rules to follow when driving in reverse: ● Be sure the area behind you is clear of people or objects that might be in the way. ● Sound the horn before moving your machine to warn others in your area you are moving. ● Designate a person to direct your movements when backing in areas that may pose a hazard or where there is poor visibility. ● Do not rely totally on your truck's mirrors; keep in mind there are blind spots when using mirrors. ● Always use a spotter or guide when backing this machine. Parking and securing the equipment When parking or securing your equipment, it is important to follow several basic safety rules. Keep in mind, you are responsible for the security of your equipment when it is parked or shut down. Below is a list of some basic rules to follow when parking your equipment: ● Never leave a machine running and unattended, even for a moment. ● Always park the machine in a flat, stable level location away from moving equipment, pedestrians or traffic. ● Retract all boom work equipment down onto its supports, neutralize all controls and secure boom equipment in place. Retract all outriggers and secure them in place. ● Chock the wheels. ● Remove the ignition key and lock all areas on the machine equipped with a locking security feature. SYG5360THB 47 Fig.4-107 4-107). 4-65 Operation ● Be sure the parking brake is set to the PARK position. ● Lock and secure access panels, truck driver's cab, fuel and oil tanks to prevent tampering while the equipment is unattended. ● If necessary, cordon off the area with security alerts to warn others of the equipment's presence. 4.12.2Towing ● Observe the stipulations of manufacturer of chassis when towing the Pump Truck with other towing machines ● Do not use the pumping parts (for example, hopper) to tow the Pump Truck, but only the towing eye can be used to. The towing eye is at the forepart of the Pump Truck, and it is used to tow the Pump Truck when the later is broken down. ● In addition, you may also use the outrigger drag loop to tow the Pump Truck. But the outriggers shall be retracted and put at the axle of towing direction. When you tow the Pump Truck, if the outrigger swings out or is at an angle to the towing direction, it may cause a serious consequence (see Fig. SYG5360THB 47 Fig.4-109 lift the Pump Truck (see Fig. 4-109). Fig.4-108 Pump Truck (see Fig. 4-108). 4-66 Operation 4.12.3Loading ● Only use the special lifting holes on the outriggers and on the securing turret can you lift the Pump Truck. ● Strictly perform operation specifications and safety regulations of lifting rigs, tools and other devices when lifting. ● Confirm the nameplate of the Pump Truck to make sure the lifting capacity of the lifting rig is more than 1.2 times of weight of the Pump Truck. ● You may use traveling crane, hoist, front- face lifter etc. to lift the Pump Truck. The lifting tool may be the anti-cut nylon sling, D-type shackle or arc-type shackle. You may use shackles to connect the lifting hole and the nylon sling, and lock the lifting tool and adjust the length of sling to guarantee the leveling of the ● Do not use sling to lift the Pump Truck ● Do not use at discretion a lifting point to SYG5360THB 47 4-67 4.13 Machine Decals It is important that all safety, alert and warning decals are in place, not damaged, covered or removed. It is also important for the operator and all personnel involved to be aware of the decal content and locations on the equipment. NOTE:Our SANY dealer can supply you with new replacement decals if the ones on the machine are damaged or missing. Never modify or change existing decal information unless authorized by your SANY distributor. When replacing damaged or missing decals, be sure they are placed in the proper locations. NOTE:Additional safety or warning decals may be added to your machine if necessary. NOTE:The following images are typical representations and will differ from your machine, depending on the model in exact locations of placement, etc. Operation SYG5360THB 47 Fig.4-111 Fig.4-110 4.13.1 Locations of safety marks on the complete vehicle 注意 WARNING 注意 1 2 3 4 5 6 7 8 9 1011 121314 172719202122 2324 26 18 WARNING 注意 28 29 32 33 34 35 3136 37 38 39 40 41 42 43 44 45 Operation 4-68 SYG5360THB 47 Fig.4-112 4-69 Operation Cab and Fixed revolving tower viewed from the roof Front of revolving tower revolving tower One side of outrigger Mudguard of rear wheel Rear outrigger viewed from the roof Cover plate of water tank 警告 警告警告 53 54 55 56 57 58 15 25 59 30 46 47 49 50 5152 16 48 SYG5360THB 47 Mark for Emission 4-70 4.13.2 Mark descriptions Table 4-1 NO. Mark Callout NO. Mark Callout 1 2 3 5 6 10 11 5 3 3 1 16 2 4 0 2 3 4 1 2 4 4 2 2 Warning Mark for Hand Scald Information Mark about Outrigger Pressure Mark on Outrigger Lock 4 Mark for Warning of Anti-falling Directive Mark 1 Smoking Prohibition Warning mark for water pump usage 7 8 Identification Mark on Water Pump 9 Mark for Water Pump Drainage Procedure Mark for lubrication points Mark for left One-sided support Mark for Warning of Electrical injury 12 Mark for Safety Guards 14 Mark for working on equipment Mark for Arrow 15 Mark for CCC Authentication 17 Warning Mark for Accumulator Instruction Mark for Boom Supporting Rack 18 Cautions Mark for boom usage 19 Warning Mark for Delivery tube Mark of Grease Cup 23 Caution mark for safety helmet Warning Mark for Outrigger Activation 24 25 Mark for Concrete Piston Operation Prohibition for Hopper 26 27 Warning Mark for Preventing Boom against Electric Shock Mark for Caution to Splashing Concrete 28 29 Protective Mark on Swing Mechanism 30 31 Caution Mark for Delivery Pipe Breakage 32 Warning Mark on Stair Mark about Agitating Oil Pressure 33 34 Mark about Swing Valve System Oil Pressure Mark about Main-system Oil Pressure 36 Caution scutcheon for protective the pump pipe Instruction Mark for Outriggers 37 38 Mark for right One-sided support Information Mark about Placing Range 39 Instructions Mark for Use 40 41 Mark for Warning of Breakage of Oil Tube Directive Mark 2 Name Mark of Truck-mounted Concrete Pump Marks for Boom Operation Piston Protection Mark Operation SYG5360THB 47 Fig.4-113 4-113) Mark for Greasing 4-71 4.13.3 Detailed explanation to safety marks 47 57 9 5 9 4 52 3 5 Table 4-1 NO. Mark Callout NO. Mark Callout 45 46 Mark at Water Inlet Warning Mark for Hand Injury Due to Tyre Pressing 48 Mark for Gear Oil Draining Outlet Mark 1 on Oil Tank 50 Mark 2 on Oil Tank 51 Instruction Mark for Sealing Oil Tank Mark of Exhaust Valve of Main Oil Pump Identification Mark of Hydraulic Oil Tank Mark at Gear Oil Filler 54 55 Warning Mark for Stepping on the Covering Parts Mark for Benz Cigarette Lighter 56 Mark for Speed Set and Brake 58 Mark for Switchover of Driving and Pumping Mark for Checking Piston Head (1) Warning Mark for Hand Scald (see Fig. ● It warns personnel to beware of scald caused by engine, oil tank or others. Operation SYG5360THB 47 Fig.4-115 (3) Mark on Outrigger Lock (see Fig. 4-115) Fig.4-114 Pressure (see Fig. 4-114) 4-72 (2) Information Mark about Outrigger ● It gives the information about the loads imposed by the working truck-mounted concrete pump with the outriggers laid. ● It indicates that the outrigger must be unlocked before telescoping or extending outriggers. ● It indicates that the outrigger must be locked before moving vehicle. Operation SYG5360THB 47 Fig.4-119 (6) Smoking Prohibition (see Fig. 4-119) Fig.4-118 (5) Directive Mark 1 (see Fig. 4-118) Fig.4-116 4-116) 4-73 (4) Mark for Warning of Anti-falling (see Fig. ● It prohibits climbing the revolving tower during pumping, or the person may slide and fall off. ● It indicates the operation of the handle below is for controlling the retraction or extension of outriggers. ● It is used to prohibit smoking near the machine. Operation SYG5360THB 47 Fig.4-121 Fig. 4-121) Fig.4-120 (see Fig. 4-120) 4-74 (8) Identification Mark on Water Pump (see (7) Warning mark for water pump usage ● Before cleanout , open the water gun before operating the motor of water pump ● It is used to identify Off/On position of the water pump ball valve. ● It is prohibited using alkaline detergent instead of clean water. ● When the temperature is below 0°C, drain the water residue after operations are complete to prevent frost crack which may happen to the water pump. to prevent damage to the water pump. Operation SYG5360THB 47 Fig.4-122 Procedure (see Fig. 4-122). 4-75 (9)Mark for Water Pump Drainage ● It introduce the water pump drainage procedure. ● Note: the time of air pumping should not exceed 30 second after no water draining form water gun. Operation SYG5360THB 47 4 12 124 4-76 (11) Mark for left One-sided support (see Fig. Fig.4- 4- ) ● When the truck-mounted pump is supported only on its left side, i.e. with only the front and rear outriggers spread (fully and properly, as required), it is forbidden to turn the boom to the place as shadowed in the figure below. Its placing scope is confined as regulated. 123) (10) Mark for lubrication points (see Fig. 4- ● It indicates the points where should be added lubrication on the boom and the swing machine. And it also indicates the regulation of adding lubrication. Fig.4-123 Operation SYG5360THB 47 Fig.4-126 (13) Mark for Safety Guards (see Fig. 4-126) 4-77 ● Do not operate the equipment without all safety guards in position. Standing near the running boom or outriggers is forbidden. ● Outriggers must be fully extended and on a firm base before raising boom. Keep the tires off the ground while operate the boom. Fig.4-125 4-125) (12) Mark for Warning of Electrical injury (see Fig. ● It indicates that the personnel is forbidden to operate this equipment within 5 meters of power lines. ● Death or serious injury can result from contacting with any part of this machine or vehicle if they become electrically charged. Operation SYG5360THB 47 4-78 (16)Mark for CCC Authentication ● It is used for authentication. Abbreviated here Fig.4-128 (15) Mark for Arrow (see Fig. 4-128) Fig.4-127 4-127) (14) Mark for working on equipment (see Fig. ● It warns personnel to stop engine before working on equipment in order to prevent any injury on the vehicle. ● Manual controls on the machine must not be used for standard operation, but only in emergency and for assembling, dismantling cleaning, maintenance and servicing. ● It requests personnel to extend or retract the four outriggers to the required positions, setting where the arrows of outriggers and lug, and the arrows of front outrigger boom and front outrigger boom well aligned. Operation SYG5360THB 47 1 13 ) 1 3 1 - 4 4-79 (19) Caution mark for boom usage Fig.4- (see Fig. ● It is shown to avoid the truck-mounted concrete pump being used to lift loads and prohibit persons standing below the boom. ● It requests operators to stand outside the range of boom to control the end hose. It is forbidden to stand under the boom, or else, the casualty may occur due to the falling of parts. 0 13 130) - 4 9 12 9 2 1 (18)Instruction Mark for Boom Supporting (17) Warning Mark for Accumulator (see Fig. Fig.4- 4- ) ● It indicates this accumulator can only be inflated with nitrogen rather than any other gas and the nitrogen inflation pressure should range from 7 MPa to 8 MPa. Fig.4- Rack (see Fig. ● After using period of time, the last section of boom would have natural lateral movement to the boom supporting rack. Please adjust the lateral position of the boom supporting rack in time to ensure the boom entirely contacting with the supporting rack. Operation SYG5360THB 47 Fig.4-134 (22) Mark of Grease Cup (see Fig. 4-134) 4-80 ● It reminds personnel to add butter full every week working hours. Fig.4-132 4-132) (20) Warning Mark for Delivery tube (see Fig. ● It warns that concrete delivery pipe is not allowed to be mounted on the end hose. Fig.4-133 (21) Mark about Emission (see Fig. 4-133) ● It indicates that cement dust is toxic, and the lung protection should be used when exposed to the dust. Operation SYG5360THB 47 Fig.4-137 Fig. 4-137). 4-81 (25)Mark for Concrete Piston Operation (see ● It warns to follow the operating procedure when changing concrete piston, otherwise it will cause physical injury. ● It indicates the operating procedure of changing concrete piston. Fig.4-136 (see Fig. 4-136) Fig.4-135 4-135) (23) Caution mark for safety helmet (see Fig. ● It is used to remind personnel to wear safety helmet. (24) Warning Mark for Outrigger Activation ● It warns the personnel to clear area when activating outriggers and take caution to crushing hazard. Operation SYG5360THB 47 Fig.4-139 against Electric Shock (see Fig. 4-139) 4-82 (27) Warning Mark for Preventing Boom ● It requests personnel to make sure the truck-mounted concrete pump is away from electric wires. When passing through a high-voltage wire area or working nearby such area, the machine should keep a certain distance away from the high-voltage wire. Fig.4-138 (26) Prohibition for Hopper (see Fig. 4-138) ● It is used to prohibit personnel from opening the screen during pumping, there is a risk of injury during concrete agitation. ● It is used to prevent personnel from stepping on the hopper. Operation SYG5360THB 47 4-83 Fig.4-141 (see Fig. 4-141) Fig.4-140 (see Fig. 4-140) (29) Protective Mark on Swing Mechanism (28)Mark for Caution to Splashing Concrete ● It asks personnel to beware of splashing concrete during pumping. ● It prohibits personnel to touch the swing mechanism when pumping. Fig.4-142 (30) Piston protection mark (see Fig. 4-142) ● It prohibits personnel to touch the moving piston. Operation SYG5360THB 47 5 14 4-145) 4-84 (33) Mark about Agitating Oil Pressure (see Fig.4- Fig. ● It indicates the data displayed by corresponding gauge is of agitating oil pressure. Fig.4-144 (32) Warning Mark on Stair (see Fig. 4-144) Fig.4-143 (see Fig. 4-143) (31) Caution Mark for Delivery Pipe Breakage ● It instructs personnel to only use pipes bearable for the max. delivery pressure of the concrete pump, there is a risk of injury from cracked pipes under a pressure too high. ● It asks personnel to stay off machine while it is in operation. Operation SYG5360THB 47 4-85 4-148) 7 14 4-147) 6 14 4-146) (35) Mark about Main-system Oil Pressure (34) Mark about Swing Valve System Oil Fig.4- Pressure (see Fig. ● It indicates the data displayed by corresponding gauge is of change-over oil pressure. Fig.4- (see Fig. ● It indicates the data displayed by corresponding gauge is of main-system oil pressure. Mark for protective the pump pipe (36) (see Fig. ● on the surface of the delivery pipe. as stone,hammer,levering tools,etc.) knock It is forbidden to use the hard objects (such age protection ring.(see Fig. 8-15) ded to dismantle the front pipe to remove If there is a blockage, it is not recommen- the blockage with quite some force.If must adopt this method,please install the block- ● 8 14 Fig.4- Operation SYG5360THB 47 4-86 Fig.4-150 Fig. 4-150) Fig.4-149 4-149) - (38) Mark for right One-sided support (see (37) Instruction Mark for Outriggers (see Fig. ● It suggests that outrigger should be fully extended when the boom will be used, and the forces transmitted to the outriggers should be absorbed by the outrigger reinforcements. ● Never extend the boom over retracted outriggers. ● When the truck-mounted pump is supported only on its right side, i.e. with only the front and rear outriggers spread (fully and properly, as required), it is forbidden to turn the boom to the place as shadowed in the figure below. Its placing scope is confined as regulated. Operation SYG5360THB 47 4-87 Fig.4-152 (40) Instructions Mark for Use (see Fig. 4-152) 1 1 (39) Information Mark about Placing Range (see Fig. 4-15 ) ● It shows the working range of the truck- mounted concrete pump, which should not be changed by any means. Fig.4-15 ● It provides instructions for general use and warns personnel to comply with what indicated in the manual. Operation SYG5360THB 47 4-88 Fig.4-155 Pump (see Fig. 4-155) Fig.4-154 (42) Directive Mark 2 (see Fig. 4-154) 153 53 (43) Name Mark of Truck-mounted Concrete (41 Fig.4- Tube (see Fig. 4-1 ) )Mark for Warning of Breakage of Oil ● It warns personnel not to touch the leaking hydraulic oil. Get medical examination immediately if oil splashing on skin. ● It indicates the operation of the handle below is for controlling the retraction or extension of outriggers. ● It shows the basic technical parameters of the truck-mounted concrete pump, including model , product brand , max. theoretical output, max. theoretical output pressure, max. vertical reach, max. horizontal reach, engine model, max. net power of engine, gross mass kerb mass , overall dimension , date of production and number. 3 Operation SYG5360THB 47 4-89 Fig.4-158 (46) Mark at Water Inlet (see Fig. 4-158) Fig.4-157 (45)Mark for Greasing (see Fig. 4-157). Fig.4-156 156) (44) Marks for Boom Operation (see Fig. 4- ● The marks indicate the control actions of pump boom and turntable. ● It indicates to add butter regularly on the corresponding position on revolving tower. ● It indicates in the corresponding position is a water inlet. Operation SYG5360THB 47 Fig.4-162 (50) Mark 2 on Oil Tank (see Fig. 4-162) 4-90 ● It gives the lowest allowable oil level when the truck-mounted concrete pump is pumping. If oil falls below this oil level, stop operating the boom, and fill oil above this oil level before pumping concrete. Fig.4-161 (49) Mark 1 on Oil Tank (see Fig. 4-161) Fig.4-160 Fig. 4-160). 9 15 4-159) (47 Tyre Pressing (see Fig. )Warning Mark for Hand Injury Due to ● It calls attention to potential hand injury caused by tyre crush. Fig.4- (48)Mark for Gear Oil Draining Outlet (see ● It indicate the location of gear oil draining outlet. ● It gives the lowest oil level allowable when the boom is extended. If oil falls below this oil level, stop operating the boom, and fill oil above this oil level before extending the boom. Operation SYG5360THB 47 Fig.4-166 (54) Mark at Gear Oil Filler (see Fig. 4-166) 4-91 ● It indicates the corresponding part is a gear oil filler. Fig.4-165 165) Fig.4-163 Fig. 4-163) (51)Instruction Mark for Sealing Oil Tank (see ● It instructs how to seal the hydraulic oil during overhauling the truck-mounted concrete pump and how to keep it clean. (53) Mark for Hydraulic Oil Filler (see Fig. 4- Fig.4-164 (see Fig. 4-164) (52) Mark of Exhaust Valve of Main Oil Pump ● It indicates the “OFF” and “ON” position of the exhaust valve of main oil pump. ● The exhaust valve of main oil pump should be remained shut off, and only can be opened during main oil pump exhausting. ● It indicates the corresponding part is a hydraulic filler. Operation SYG5360THB 47 4-92 Fig.4-167 Covering Parts (see Fig. 4-167). (55)Warning Mark for Stepping on the ● Do not step on the covering parts of revolving tower. Fig.4-168 (56) Mark for Benz Cigatette Lighter ● It 68 (see Fig. 4-1 ) indicates the special interface for cigarette lighter should not be connected with other electric equipment. Operation SYG5360THB 47 169 69 57 ( ) Mark for Speed Set and Brake (see Fig. 4-1 ) ● The symbols indicate setting on 14th speed at oil pump place and stopping and parking at driving position. Fig.4- 4-93 Fig.4-171 4-171) 0 7 70 ) (59) Mark for Checking Piston Head (see Fig. 8 (5 )Mark for Switchover of Driving and Pumping (see Fig. 4-1 ● It requests personnel to stop engine before switch over of driving and Fig.4-1 ● It reminds personnel to check piston head before pumping each time and when water is getting turbid. pumping. Operation SYG5360THB 47 4-94 BLANK PAGE Operation SYG5360THB 47 5-1 Troubleshooting 5 Troubleshooting 5.1 General .............................................................................................................5-3 5.2 Troubleshooting Mechanical System ................................................................5-3 5.3 Troubleshooting Hydraulic System ...................................................................5-6 5.4 Troubleshooting Lubrication System ................................................................5-10 5.5 Troubleshooting Electric System ......................................................................5-11 Troubleshooting SYG5360THB 47 5-2 Troubleshooting WARNING Always read the Safety section of this manual before attempting to operate this equipment. Failure to do this could result in machine damage, personnel injury or death. SYG5360THB 47 5-3 Troubleshooting 5 TROUBLESHOOTING 5.1 General SANY truck-mounted concrete pumps are designed for continuous pumping and dispensing of liquid concrete to locations within reach of the placement boom configured to the pump at various elevations, both above and below the location of the pump itself. 5.2 Troubleshooting Mechanical System No. Malfunction Cause Troubleshooting 1 Abnormal sound of boom and turntable Insufficient lubrication at the connection of axis pin and bearing Check lubrication at the connection of axis pin and bearing. If there is slight abrasion, coat lubricating oil; if there is serious abrasion, replace the axis pin or bearing. Abrasion between end faces of delivery pipe after the boom is properly extended or retracted. Replace it with a delivery pipe with standard length. 2 Abnormal sound during extension/ retraction of front outriggers Abrasion of bimetallic bearing shell of contact roller assembly Replace the bearing or add lubricating grease. Big sliding resistance between telescopic booms Add lubricating grease between telescopic booms. 3 Improper extension of front outriggers (the outriggers are driven by chain) Incorrect position of drive chain joint in the chain drive system Re-install the drive chain. Powerless drive motor Replace the drive motor. 4 Short service life of piston Insufficient lubrication Check, clean and unblock the lubricating pipeline and holes. The concrete piston is worn out at one side. Adjust the axiality of oil cylinder and delivery cylinder. Polluted water in the washing room as a result of not replacing the water in time. Check the washing room frequently and fill clean water timely. Corroded concrete seal body resulting in pyrohydrolysis of piston Replace it with a new concrete seal body. SYG5360THB 47 5-4 Troubleshooting 5 Quick abrasion of cutting ring The cutting ring itself has quality problem. Replace it with a new cutting ring. Serious abrasion of the spectacle wear plate Replace it with a new spectacle wear plate. The cutting ring is not of good assembly quality. Replace the cutting ring or spectacle wear plate. 6 Distortion of spectacle wear plate Abrasion of spectacle wear plate itself Replace it with a new spectacle wear plate. Too long transitional bushing Replace the transitional bushing or grind it on-site. Too big processed bottom diameter of spectacle wear plate thread, resulting in distortion of spectacle wear plate due to loose threaded connection when ramming material Replace it with a new spectacle wear plate. Improperly assembled hopper and transitional bushing Grind the transitional bushing on- site or replace the spectacle wear plate. 7 Disalignment between cutting ring and spectacle wear plate Improper reversing of hydraulic valve Ask hydraulic service engineer for onsite adjustment. Serious abrasion of the small shaft spline teeth of S-valve Replace the S-valve. Serious abrasion of lower ball bearing seat of swing cylinder mechanism Replace the lower ball bearing seat of swing cylinder. 8 Tube blocked The slump or formula of concrete is in no conformity with the requirement. Adjust the slump or formula of concrete Large clearance between the spectacle wear plate and cutting ring resulting in large pressure loss Check the clearance between the spectacle wear plate and cutting ring, if it is too large, screw down the locking nut of S-valve. Concrete solidified in the S-valve or delivery pipe Conduct reverse pumping and then forward pumping to get it through. If it doesn’t work, knock and get it through after finding out the blockage location. Insufficient pressure or constant power in the main system of truck- mounted concrete pump Ask electrical service engineer for onsite adjustment. No lubrication of pipeline by using water or mortar before concrete pumping It is necessary to lubricate the pipeline before concrete pumping. No. Malfunction Cause Troubleshooting SYG5360THB 47 5-5 Troubleshooting 9 Difficult switchover of the transfer case Malfunction of cylinder and pneumatic change valve Check the piston seal of the cylinder for damage. If any, replace the seal ring. Malfunction of electrical appliance Take off the electrical plug of the pneumatic change valve and conduct reversing by hand. If the result shows that it is normal, then it proves that the electrical appliance has malfunction. Ask electrical service engineer for onsite troubleshooting. Insufficient pressure of chassis Increase the pressure of chassis to over 700 kPa before switchover. 10 Severe jutter and large noise of transfer case Big tolerance of dynamic balance of the transmission shaft and big radial run-out Replace the transmission shaft Damaged gear in the transfer case Replace the gear. Damaged bearing in the transfer case Replace the bearing. Damaged spline of connecting disc Replace the connecting disc spline. Damaged shock pad Replace the shock pad. 11 Huge vibration of complete machine Big tolerance of dynamic balance of the transmission shaft and big radial run-out Replace the transmission shaft. Damaged universal joint Replace the universal joint. No. Malfunction Cause Troubleshooting SYG5360THB 47 5-6 Troubleshooting 5.3 Troubleshooting Hydraulic System No. Malfunction Cause Troubleshooting 1 The main system without pressure or with the pressure not up to the setting 31.5MPa Valve core of insertion valve of main overflow valve jammed at upper location Clean or replace the insertion valve of main overflow valve. Abrasion of valve core of main overflow valve Replace the insertion valve of main overflow valve. Abrasion of valve core of DT1 electromagnetic change valve Replace DT1 electromagnetic change valve. Loose plug of proportional valve of main oil pump or abrasion of constant pressure valve core Screw down the plug or replace the constant pressure valve. 2 No reversing of the pumping system (with normal pressure of main system) The control electromagnets DT2~DT5 not electrified or get blocked Check circuit or replace DT2~DT5 control electromagnets. The main four-way valve or swing cylinder four-way valve blocked or damaged Clean or replace the main four- way valve or swing cylinder four- way valve. Seizure of small oil controlled valve Clean the small oil controlled valve. 3 When pumping at low pressure, concrete piston reverses more and more frequently before backing to the set stroke closed to the washing room of delivery cylinder Abrasion between the cones of valve cores of insertion valves 22.1 and 22.2 leads to hydraulic oil of main system leaking into rodless connecting chamber from cone of valve core, which results in increase of hydraulic oil of rodless connecting chamber. Replace insertion valves 22.1 and 22.2. Abrasion between valve core and valve sleeve for insertion valves 22.10 and 22.11 leads to hydraulic oil of accumulator leaking into rodless connecting chamber at idle speed. Replace insertion valves 22.10 and 22.11. Damage of piston seal that has retracted out of oil cylinder leads to hydraulic oil leaking into rodless connecting chamber. Replace the sealing element of piston that has retracted out of oil cylinder. SYG5360THB 47 5-7 Troubleshooting 4 When pumping at high pressure, concrete piston steers more and more frequently before backing to the set stroke closed to the washing room of delivery cylinder Abrasion between valve core and valve sleeve of insertion valve of rod-side connecting chamber of main oil cylinder (insertion valve 22.9) leads to hydraulic oil of rod-side connecting chamber leaking into oil tank, which results in diminishment of hydraulic oil of rod-side connecting chamber. Replace insertion valve 22.9. Blockage of damping holes of cover plates of high pressure change insertion valves 22.1~22.4 leads to abnormal oil- adding during reversing of main oil cylinder, which results in diminishment of hydraulic oil of rod-side connecting chamber. Check or replace the damping holes of cover plates of insertion valves 22.1~22.4. 5 Weak reversing of the swing cylinder Insufficient nitrogen pressure of accumulator Check it and fill nitrogen. The plug of the main four-way valve or swing cylinder four-way valve broken off Check it and mount the plug. The shuttle valve in the main oil pump blocked, resulting in the pressure in the accumulator fled to the main system Check and clean or replace the shuttle valve in the main oil pump. The one-way valve at the oil inlet of the accumulator blocked, resulting in no pressure preservation Check and clean or replace the one-way valve at the oil inlet of the accumulator. Damaged dual-gear pump Replace the dual-gear pump. Internal leakage of swing cylinder Replace the swing cylinder seal or the swing cylinder. 6 Random reversing of the pumping system Blockage of the damping hole in the oil-drain valve Get it through with airflow. The valve core of small oil controlled valve of the swing cylinder blocked Check or replace the small oil controlled valve of the swing cylinder. 7 The hydraulic oil temperature rising abnormally The main overflow valve with overflow during pumping Replace the main overflow valve. No rotation of the air-cooled motor or with low rotation speed due to decline of volume efficiency Replace the air-cooled motor. No. Malfunction Cause Troubleshooting SYG5360THB 47 5-8 Troubleshooting 8 The boom only rotates leftward or rightward The slewing limit electromagnetic valve coil burned out or the core blocked Check or replace the slewing limit electromagnetic valve coil or the whole electromagnetic valve. The slewing balance valve core blocked or damaged Replace the slewing balance valve. 9 No action of boom and outrigger The by-pass valve of the multi- way valve not electrified Check the lines, if it is the harness causes the problem, replace the harness; if it is the blocked valve core, then dismount it for cleaning or replace the electromagnetic valve. The three-way flow valve of the multi-way valve blocked or the damping adaptor broken off Clean or replace the three-way flow valve. For the truck-mounted concrete pump with boom switchover valve, possibly it is the coil burned out or the valve core blocked Check and replace the boom switchover valve coil or the whole electromagnetic valve. For the truck-mounted concrete pump with variable boom pump, possibly it is the load sensitive valve, constant-pressure valve or constant-power valve of the boom pump blocked Check, clean and replace the control valve of the variable boom pump. 10 The boom cannot act or rotate, or one outrigger cannot move, while the remaining work normally The reversing slide valve sheet of the multi-way valve with electrical malfunction, and the correspondent electrical proportional valve not electrified Check the lines, if it is the harness causes the problem, replace the harness; if it is the blocked valve core, then dismount it for cleaning or replace the electromagnetic valve. The two-way flow valve of the reversing slide valve sheet of the multi-way valve blocked or its damping adaptor broke off Check and replace the two-way flow valve. 11 The boom extends or retracts slowly The reversing slide valve sheet of the multi-way valve damaged Replace the single sheet valve. The pressure of the boom balance valve is set too high. Lower the pressure of the boom balance valve. The damping hole of the boom balance valve blocked Clean and get it through. No. Malfunction Cause Troubleshooting SYG5360THB 47 5-9 Troubleshooting 12 The hydraulic oil temperature abnormally rises, although the pumping and air cooling systems work normally. The pressure of the boom multiway valve main overflow valve is set too low, resulting in overflow when the boom acts Increase the pressure of the boom multi-way valve main overflow valve. Abrasion of the three-way flow valve of boom multi-way valve Check and replace the three-way flow valve (the method: check the unloading pressure when the boom is not acting under local control state. If there is no indication basically on the pressure gauge, then the three- way flow valve is in normal conditions; if the indication on the pressure gauge is 3 MPa or above, then the three-way flow valve is in abnormal conditions.) No. Malfunction Cause Troubleshooting SYG5360THB 47 5-10 Troubleshooting 5.4 Troubleshooting Lubrication System No. Malfunction Cause Troubleshooting 1 The lubricating grease distribution valve doesn’t act and each part is subject to poor lubrication. Pipeline malfunction Check the pressure gauge of lubricating grease pump. If the pressure is abnormal (over 10 MPa), it indicates pipeline malfunction. Clean the pipeline for troubleshooting. Blockage of lubricating grease distribution valve In case of seizure, clean and unblock the lubricating grease distribution valve. Malfunction of hydraulic synchronizing lubrication pump Check the pressure gauge of lubricating grease pump. If the hand fails to move, remove the lubricating grease pump plunger and clean it with kerosene. Check the pressure gauge of lubricating grease pump. If the hand fails to move, remove the lubricating grease pump plunger and clean it with kerosene. Check the pressure gauge of lubricating grease pump. If the hand fails to move, remove the lubricating grease pump plunger and clean it with kerosene. Blockage of one or more lubricating points on the seats of big and small bearings and mixing bearing Remove the lubricating grease pipe at each lubricating point on the seats of big and small bearing and mixing bearing in turn to locate the malfunction. Clean and unblock the oil duct and pipeline. Blockage or damage of sheet oil separator Clean or replace the sheet oil separator; clean the grease filter. Unclear lubricating grease or foreign substances in the pump, leading to blockage of pipeline and valve Clean the lubricating grease pump, pipeline and valve; replace the lubricating grease with new lubricating grease. SYG5360THB 47 5-11 Troubleshooting 5.5 Troubleshooting Electric System No. Malfunction Cause Troubleshooting 1 The display screen with abnormal speed Poor contact of signal wire Re-lay wires. Low base resistance Check and treat it in line with the drawings. The dynatron works abnormally Replace the dynatron. Poor contact of ground wire Re-lay the wires. Malfunction of speed sensor Replace the sensor. 2 The display screen not indicating the relevant information Improper connection of display screen and SYMC Re-connect the plug and screw down the screw Damage of display screen Replace the display screen. Poor contact of power line Re-connect the power line of display. 3 The display screen indicating “Emergency stop” The emergency stopping button pressed Check and release the emergency stopping button. Poor contact of intermediate relay KA18, and the normally closed contact not really disconnected Check the relay and its wiring. Malfunction of remote controller Check the power of remote controller and replace the remote controller. 4 The display screen indicating idle speed but no response after acting The transfer case is not at the position of oil pump actually. Switch the transfer case to oil pump position. Malfunction of proximity switch of transfer case Adjust the installation position of proximity switch or replace the proximity switch. 5 The display screen indicating “Incorrect rotation angle” Malfunction of proximity switch of turntable encoder Adjust the installation position of proximity switch or replace the proximity switch. Incorrect zero Reset the zero. SYG5360THB 47 5-12 Troubleshooting 6 After pressing down the forward/reverse pumping button, the engine cannot accelerate. No signal detected by SYMC Check the toggle switch and wiring. The transfer case not at the position of oil pump Switch the transfer case to oil pump position. Malfunction of proximity switch of transfer case Adjust the installation position of proximity switch or replace the proximity switch. No startup of the engine or the engine with malfunction in speed measurement Start the engine or check the speed sensor and the relevant wiring. Wrong gear engagement Engage a correct gear. Under “Emergency stop” state Check the emergency stopping switch and wiring. Poor contact of connectors on the vehicle control modules (applicable to BENZ chassis and VOLVO chassis) Check, treat the wiring or replace it. Abnormal output signal of circuit board (applicable to ISUZU chassis) Check if the voltage value is within the normal range (when idling, the voltage for wire 82 to 80 is 0.8V, and when accelerating, it will rise to 3V slowly). 7 After pressing down the forward/reverse pumping button, no pumping The speed doesn’t rise to the specified value. Check if the voltage value is within the normal range (when idling, the voltage for wire 82 to 80 is 0.8V, and when accelerating, it will rise to 3V slowly). No output from SYMC Check and replace the SYMC Central distribution box relay burned out Check the relay and its wiring. Fuse of central distribution box damaged or ejected Replace the fuse or reset it. 8 The odometer with indication when pumping The proximity switch at the location of oil pump not well installed Adjust the proximity switch. Poor contact of intermediate relay tripping the odometer Check or replace the relay. No. Malfunction Cause Troubleshooting SYG5360THB 47 5-13 Troubleshooting 9 No action of cooling blower or display screen indicating “Too high/low temperature” Temperature sensor damaged Replace the temperature sensor or relay wires. Malfunction of air-cooled electromagnetic valve Clean or replace it. 10 Water pump not working No water in the water tank or damage of float switch Fill water into water tank or replace the float switch. No input signal of water pump control Replace the wiring. 11 The output cannot be adjusted when pumping Q0.0 damaged Replace the SYMC. Malfunction of electromagnet Replace the electromagnet. The differential pressure sensor with signal all the time Replace the differential pressure sensor. 12 No reversing for the truck-mounted concrete pump provided with electric control reversing due to pressure suppression Damage of SQ1-SQ4 proximity switches or malfunction of wiring Replace the proximity switch or re-lay wires. No. Malfunction Cause Troubleshooting SYG5360THB 47 5-14 Troubleshooting BLANK PAGE SYG5360THB 47 6-1 Maintenance 6 Maintenance 6.1 Routine Maintenance & Mandatory Overhaul ...................................................6-3 6.2 General Tightening Torques .............................................................................6-8 6.3 Lubrication ........................................................................................................6-11 6.4 Visual Checks ...................................................................................................6-20 6.5 Pumping System ...............................................................................................6-25 6.6 Slewing Mechanism ..........................................................................................6-62 6.7 Transfer Case and Drive Shaft .........................................................................6-67 6.8 Hydraulic System ..............................................................................................6-71 6.9 Accumulator ......................................................................................................6-75 6.10 Oil Filter ...........................................................................................................6-79 6.11 Air Filter ..........................................................................................................6-81 6.12 Hoses ...............................................................................................................6-82 6.13 Electrical System .............................................................................................6-84 Maintenance SYG5360THB 47 6-2 Maintenance WARNING Always read the Safety section of this manual before attempting to operate this equipment. Failure to do this could result in machine damage, personnel injury or death. SYG5360THB 47 6-3 Maintenance 6 MAINTENANCE In order to guarantee normal operation of the machine and avoid malfunctions affecting construction, all inspection and maintenance work should be earnestly carried out. Only in this way, can the failure rate of product be decreased, the service life of the machine be prolonged, and the repair cost be reduced, thus greater profits be achieved. Fill the inspection card for future reference, when carrying out maintenance work. 6.1 Routine Maintenance & Mandatory Overhaul The routine maintenance and inspection is of great importance for the normal operation of the pump. Follow the Safety Inspection Intervals (Table. 6-1), Maintenance Intervals (Table. 6-2) and Mandatory Overhaul (Table. 6-3) during the maintenance process. WARNING You must follow the Safety Inspection Intervals (Table 6-1), Maintenance Intervals (Table 6-2) and Mandatory Overhaul (Table 6-3) during the maintenance process. The Manufacturer accepts no liability for any safety accident arising from the failure to perform due mandatory overhaul. SYG5360THB 47 6-4 Maintenance Table 6-1 Safety Inspection Intervals Assembly Action Every … Hours of Operation Daily 50 100 250 500 1000 Revolving tower Check outrigger for stuck rotation and abnormal noise ● Check outrigger chain or its protection function ● Check limiting function of rotary encoder ● Check slewing bearing bolts for looseness and break ● Check slewing mechanism idler pin-shaft for axial play and abnormal noise ● Check spread cylinder, telescopic cylinder connecting axis pin for looseness and break off ● Check outrigger cylinder bolts for looseness ● Check slewing head, fixed revolving tower, outrigger for abnormal deformation and break ● Check main shaft of reducer for axial play ● Boom Check boom for stuck slewing and abnormal noise ● Check boom for interference ● Check fixed bolt for conveying pipe end hose clamp and safety chain for looseness ● Check bolts at boom end for looseness ● Check boom axis pin for wear and tear ● Check delivery pipe for thickness ● Check boom, linkage for abnormal deformation and break ● Hydraulic system Check main system pressure (28~32MPa) ● Check switching pressure (8~16MPa) ● Check agitator overflowing pressure (12Mpa) ● Electrical system Functional check on E-STOP button, warning lamp and horn ● Check boom limit switch, outrigger limit switch and hopper grill limit switch for abnormity ● SYG5360THB 47 6-5 Maintenance Table 6-2 Maintenance Intervals Assembly Action Every … Hours of Operation Daily 50 100 250 500 1000 Chassis In accordance with the maintenance specifications specified by chassis manufacturer Drive shaft Check bolts for looseness ● Transfer case Check transfer switch for abnormity ● Check oil level ● Change gear oil ●first Revolving tower Clean out sundries for rotary bearing and gear surface, and baste lubricating grease ● Change reducer gear oil ●first Pumping system Wear check of concrete piston and dustproof ring ● Check water tank for water level, mortar leakage, hardness eyewinker, excessive hydraulic oil in water ● Check agitator motor for oil leakage, agitator shaft for mortar leakage and agitator paddle for wear ● Check swing position for swing cylinder ● Wear check of spectacle wear plate and cutting ring ● Check clearance between cutting ring and end face of S-valve (≤ 4mm) ● Check delivery cylinder for abnormal wear ● Wear check of transitional bushing (not lower than delivery cylinder) ● Lubrication system Check grease level in lubricating grease pump ● Check oil distributor and lubrication point for abnormity ● Check delivery cylinder lubrication for abnormity ● Fill grease to boom shaft ●or weekly Fill grease to slewing bearing? pinion and slewing mechanism idler axis pin ●or weekly Fill grease to outrigger shaft, outrigger bearing roller, outrigger lock, oil cylinder joint bearing ●or weekly Fill grease to 66/72M front outrigger linkage mechanism connecting axis pin and joint bearing ●or weekly Fill grease to extension part of drive shaft, and cross bearing ●or weekly ● ● SYG5360THB 47 6-6 Maintenance Hydraulic system Check hydraulic oil level, oiliness ● Check indicator on hydraulic oil filter ● Check hydraulic elements for oil leakage ● Drain off accumulated water in water pump ● Drain off condensed water in hydraulic oil tank ● Triple rubber hose ● Check and clean radiator blade ● Clean filter of water pump ● In case of Shenlong water pump, check water level in pump ● In case of Shenlong water pump, change water pump oil ● Change hydraulic oil filter core ●or red indica tor Clean oil suction filter core (new oil tank) ● Change oil suction filter core (new oil tank) ● Change oil return filter core (new oil tank) ●first ● Change all hydraulic oil ● Clean oil tank ● Electrical system keep transmitter panel clean and check transmitter rocker casing for damage ● Check such threaded connectors as toggle switch for looseness ● Check such connectors as fuse and relay for looseness ● Check water tightness of small control box, maintenance control box and outrigger control box ● Check wiring for damage ● Check mechanical encoder sensor mounting bolts for looseness ● Check electromagnetic valve for abnormity ● Table 6-2 Maintenance Intervals Assembly Action Every … Hours of Operation Daily 50 100 250 500 1000 Check the socket of oil cylinder proximity switch for looseness ● ● Check the socket of boom obliquity sensor for looseness ●first SYG5360THB 47 6-7 Maintenance NOTE: The actions in Mandatory Overhaul shall be carried out by professional maintenance personnel in workshops or 6S shops authorized by SANY Heavy Industry Co., Ltd. Table 6-3 Mandatory Overhaul Assembly Action Every … Hours of Operation 1 year 2 years 5 years Chassis In accordance with the maintenance specifications specified by chassis manufacturer Revolving tower Check gear clearance of slewing mechanism ● Check pre-tightening torque of slewing bearing bolts ● Overhaul of rotary reducer, change bearing of output shaft and sealing parts ● Defect detect or overhaul of welds on turntable, fixed revolving tower and outrigger ● Boom Defect detect or overhaul of boom, linkage and axis pin ● Pumping mechanism Replace seals of main oil cylinder ● Hydraulic system Check and adjust balance valve, multi-way valve pressure ● Check and adjust main oil pump, boom pump pressure ● Check accumulator pressure and charge nitrogen ● Replace seals of all oil cylinders (main oil cylinder excluded) ● Replace all hoses ● Replace all O-rings ● Electrical system Check wiring ● Replace all harness of complete vehicle ● SYG5360THB 47 6-8 Maintenance 6.2 General Tightening Torques NOTICE Looseness or breakage could occur if fasteners, hose or line couplings are not torqued to the specified value. If you will be doing any repairs or service procedures on this machine, always refer to this chart if the tightening torque value is not listed or specified in the procedure. Failure to do so could damage the machine, shorten machine life or cause premature system failure. (1) Table. 6-4 gives the pre-tightening torques of bolts with lubrication. (2) Table. 6-5 gives the pre-tightening torques of bolts without lubrication. NOTE: One bolt should be replaced with a new one of the same size and grade. The above pre-tightening torques for bolt connection are not applicable to hydraulic pipe connectors. Table 6-4 Pre-tightening Torques of Bolts (with lubrication) Thread Specification Strength Grade(8.8) Strength Grade(10.9) Strength Grade (12.9) Pretightening torque T (N·m) Pretightening torque T (N·m) Pretightening torque T(N·m) M8 23±2 34±2 39±2 M10 45±5 67±5 78±5 M12 85±5 118±8 137±8 M16 210±10 290±10 339±15 M20 408±15 568±18 666±18 M24 710±18 984±20 1147±25 M30 1410±25 1956±25 2280±25 M36 2470±30 3412±30 3988±30 SYG5360THB 47 6-9 Maintenance (3) Don't apply excessive force when disassembling pipe connectors. When tightening pipe connector, the pre-tightening torques should be moderate, and just ensure there is no leakage. Table. 6-6 gives the pre-tightening torques of common pipe connectors (rubber hose and steel pipe). Table 6-5 Pre-tightening Torques of Bolts (without lubrication) Thread Specification Strength Grade(8.8) Strength Grade(10.9) Strength Grade (12.9) Pretightening torque T (N·m) Pretightening torque T (N·m) Pretightening torque T (N·m) M8×1 27±2 39±2 46±5 M10×1.25 52±5 76±5 90±5 M12×1.25 93±5 135±8 160±10 M12×1.5 89±5 130±8 155±10 M14×1.5 215±15 215±15 255±15 M16×1.5 225±15 330±18 390±18 M18×1.5 340±18 485±18 570±20 M20×1.5 475±20 680±25 790±25 M22×1.5 630±20 900±25 1050±30 M24×2 800±25 1150±30 1350±30 M27×2 1150±30 1650±30 1950±30 M30×2 1650±30 2350±30 2750±30 Table 6-6 Pre-tightening Torques of Pipe Connectors No Metric Thread Preheating Torque(N.m) No Metric Thread Preheating Torque(N.m) 1 M12×1.5 15~25 8 M26×1.5 85~125 2 M14×1.5 30~45 9 M30×2 115~155 3 M16×1.5 38~52 10 M36×2 140~192 4 M18×1.5 43~85 11 M42×2 210~270 5 M20×1.5 50~65 12 M45×2 255~325 6 M22×1.5 60~88 13 M52×2 280~380 7 M24×1.5 60~88 SYG5360THB 47 6-10 Maintenance Table. 6-7 gives the pre-tightening torques of common pipe connectors (oil port). NOTE: The allowable tolerance for the pre tightening torques in the two tables above is ±10%. L refers to light low-pressure pipe connector; and S refers to heavy high-pressure pipe connector. Table 6-7 Pretightening Torques of Pipe Connectors (close to oil port) Series Thread G Type A Seal (Metal Washer) Type B Seal (Metal Plain Washer) Type E Seal (Elastic-ED) Type F Seal (O-ring) Pretightening Torque (N·m) Pretightening Torque (N·m) Pretightening Torque (N·m) Pretightening Torque (N·m) L M10×1.0 9 18 18 15 M12×1.5 20 30 25 25 M14×1.5 35 45 45 35 M16×1.5 45 65 55 40 M18×1.5 55 80 70 45 M20×1.5 65 140 125 60 M27×2 90 190 180 100 M33×2 150 340 310 160 M42×2 240 500 450 210 M48×2 290 630 540 260 S M12×1.5 20 35 35 35 M14×1.5 35 55 55 45 M16×1.5 45 70 70 55 M18×1.5 55 110 90 90 M20×1.5 55 150 125 80 M22×1.5 65 170 135 100 M27×2 90 270 180 170 M33×2 150 410 310 310 M42×2 240 540 450 330 M48×2 290 700 540 420 SYG5360THB 47 6-11 Maintenance 6.3 Lubrication 6.3.1 Lubrication Method The correct lubrication method should be adopted during operation in order to reduce the machine depreciation. The lubrication system comprises automatic and manual lubrication. Automatic lubrication Through the double power lubrication pump, the automatic lubrication system can realize the lubrication of mixing bearing and the large and small bearing of s- tube. At the same time, the lubrication center can realize the lubrication of concrete seal in the delivery cylinder. This system is characterized by simple structure and good lubrication efficiency. The key diagram of automatic lubrication system is shown in Fig. 6-1. Before every restarting machine, check and add grease in the tank of automatic grease pump. If the grease pressure is too low, clean the overflow valve for pressure adjustment, check valve at the outlet or discharge air. Pressure oil Double-line distribution valve Concrete piston Big bearing seat of S-valve Mixing bearing seat Sheet oil separator Mixing bearing seat Small bearing seat of S-valve Big bearing seat of S-valve Pressure oil Double power lubrication pump Fig.6-1 SYG5360THB 47 6-12 Maintenance CAUTION The double power lubrication pump should be always clean and free of dust and other foreign matters. In addition, it should not contact acid or alkali substances.The adopted grease should comply with specification and must be clean and free of foreign matter. Failure to do so may result in instability in operating positions or serious damage to the machine. Discharge air in the double power lubrication pump, as shown in Fig. 6-2. When the double power lubrication pump can not pump grease for a long time due to the air absorbed caused by the initial use of grease pump, the depletion of grease or other reasons, unlock two exhaust valves by half turn anti-clockwise until air is discharged completely, the grease flows out continuously and no air pocket is found. Then lock them again. Manual lubrication The manual lubrication system has two types. The first is adopting the forced filling grease cup, wherein the grease is manually pressed on the friction surface with the grease gun, e.g. the pin shaft between booms has a grease cup; the second is adopting the grease cup with screw cover, wherein the sufficient grease should be filled in the grease cup first, and then press the grease on the friction surface through the pressure generated by the screw cover, e.g. each swing valve oil cylinder seat has a grease cup with screw cover, as shown in Fig. 6-3. (1) Swing valve oil cylinder seat Fig.6-2 Fig.6-3 Synchronizing lubricating grease port Circular lubricating grease port Air-bleed valve Drive oil port handle Pressure regulating overflow valve SYG5360THB 47 6-13 Maintenance Both swing valve oil cylinder seat respectively has a lubricating grease cup. Before the pumping work, the grease cup must be fully filled with grease. Then rotate the cup cover and add grease for lubrication. During pumping operation, the screw cover should be lubricated every four hours so that the ball friction surface of swing valve oil cylinder can be in good lubrication status. (2) Boom, rotary table and outrigger The hinged adaptors on various booms of this pump truck, connecting shaft between oil cylinder with four outriggers and base, the slewing bearing of rotary table, the gear shaft of reducer, etc., should be manually lubricated. Lubricating points of boom, rotary table and outrigger, as shown in Table 6-8, Fig. 6-4 and Fig. 6-5. The maintenance work of this part requires the grease gun and lithium-based grease. Unless different time is specified, grease should be refilled in various lubricating points every week or every 50 hours of operation. Add grease in lubricating point until grease flows out or grease can not be added. NOTE: The calcium-based grease/butter is not preferred to the lubrication system because it is easily stuck and blocks the lubrication line. SYG5360THB 47 6-14 Maintenance Table 6-8 The Grease Cup of Swing Valve Oil Cylinder No Part to Be Lubricated Quantity of Lubricating Point Lubricating Grease 1 Each articulated joint of boom 27 2# extreme pressure lithium-based lubrication grease 2 Outrigger cylinder seat 4 3 Articulated shaft of rear outrigger and revolving tower 4 4 Articulated shaft of outrigger spread cylinder 4 5 Contact roller of front outrigger telescopic boom 8 6 Slewing bearing 1 7 Rotary reducer and gear 2 8 Drive shaft 8 “00” or “000” lithium- based lubrication grease 9 Swing-valve cylinder seat 2 Fig.6-4 SYG5360THB 47 6-15 Maintenance 6.3.2 Lubricant Recommendation Gear oil The rotary reducer adopts the APIG14 gear oil with the viscosity grade of SAE 85W90. The transfer case adopts the Shell 150 gear oil or Mobil 629 gear oil. Grease Fig.6-5 SYG5360THB 47 6-16 Maintenance Lithium-based lubricating grease is adopted for both the automatic lubrication system and manual lubricating points. It is recommended to use “00” lithium-based lubricating grease when the working ambient temperature is higher than 10° C; to use “000” lithium-based lubricating grease when the working ambient temperature is lower than 10° C. CAUTION Do not use grease mixed with foreign matters; otherwise the valve core of distribution valve will be easily stuck and lead to faults in the lubrication system. Thus the abrasion of parts of pumping system will be aggravated. Failure to do so may result in instability in operating positions or serious damage to the machine. The special lithium-based grease for SANY is preferred, as shown in Fig. 6-6. Engine oil Under most climatic conditions, the SAE15W40 engine oil is preferred to water pump. (1) Quality level The quality of engine oil has different standards: According to the API (American Petroleum Institute) grading standards, common engine oils include: CF-4, CG-4,CH-4. According to ACEA grading standards (European engine oil sequence), common engine oils include: E1-E3-96+E4-98. S A N Y SP E CIA L G RE ASE N O. 00 G E N UI NE P A R T S Fig.6-6 Special Lubricating Grease of SANY Heavy Industry Co., Ltd. SYG5360THB 47 6-17 Maintenance (2) Viscosity The selection on the viscosity grade of engine oil is shown in Fig. 6-7. The ambient temperature determines the viscosity grade of engine oil. Hydraulic fluid The recommended hydraulic fluid types for different ambient temperatures (see Table. 6- 9). (1) The hydraulic fluid used in the hydraulic system is mineral hydraulic fluid (HLP46) or biologically degradable hydraulic fluid (HLP- E46) or non-readily flammable hydraulic fluid (HFC46). The original hydraulic fluid used in this pump truck is the special top grade anti- wear hydraulic fluid Equivis ZS 46S.. (2) As to the places in hot weather (the temperature is higher than 35°C), the special top grade anti-wear hydraulic fluid 68 for SANY Heavy Industry is preferred. Fig.6-7 Table 6-9 Recommended Hydraulic Oil -40 -30 -20 -10 0 10 20 30 40 50 32# SANY special high-grade anti- wear hydraulic oil Equivis ZS 46S 68# SANY special high-grade anti- wear hydraulic oil SYG5360THB 47 6-18 Maintenance (3) As to the places in cold weather (the temperature is lower than 10°C),before pumping concrete, pre-heat the hydraulic fluid and adopt the special top grade anti- wear hydraulic fluid 32 for SANY Heavy Industry is preferred. (4) Do not mix hydraulic fluid with different characteristics. (5) Preheating of hydraulic fluid (6) The temperature of hydraulic fluid is lower than 20°C; therefore it should be preheated so as to ensure the safety of hydraulic system. Start the engine and let it run idly for 5-10 minutes without load, turn the preheating switch on the maintenance operation box to the "preheating" position, increase the speed of engine to 1700rpm and let it run for 10 or more minutes, and raise the temperature of hydraulic fluid to above 20°C. The preheating time should be appropriately adjusted as per local condition. Only after the preheating of hydraulic fluid is completed, the pumping operation can be carried out. NOTE: If the hydraulic fluid temperature is lower than 20°C, the display will show: As the hydraulic fluid temperature is too low, preheat or operate with small capacity. SYG5360THB 47 6-19 Maintenance Recommended capacities of lubricating oil/ grease NOTE: Capacities in table are for reference. During every replacement of lubricating oil and grease, the oil level must be checked at specified checking points and with inspection plug, oil ruler and oil level meter. Storage of lubricants Do not store oils and greases in the open air. Water may be absorbed through the bung hole in the event of changes in the exposure to the weather. Only ever store the barrels lying on their side and supported on timber blocks, with the bung hole facing upwards. Table 6-10 Recommended Capacities of Lubricating Oil / Grease No Part to Be Lubricated Adding Capacity (L) Lubricating Oil / Grease 1 Rotary reducer 8 SAE85W90 gear oil 2 Transfer case 8 SHELL 150 gear oil or MOBIL 629 gear oil 3 Water pump 0.5 SAE 15W-40 engine oil 4 Hydraulic oil tank 650 46# SANY special anti-wear hydraulic oil 5 Automatic lubricating grease pump 4 “00” lithium-based lubricating grease SYG5360THB 47 6-20 Maintenance 6.4 Visual Checks Before you commence any maintenance work, you must carry out visual checks that this maintenance card describes. The service intervals can be find in the maintenance summary. The check should be carried out by qualified personnel and the results should be carefully recorded and kept. The potential risk of equipment found in checking process should be handled. DANGER You should particularly closely and carefully check the electrical cables. There is a danger of overvoltages from defective cables, especially in high air or ambient humidity. There is a danger of fire and explosion through the formation of sparks in a potentially explosive atmosphere. 6.4.1 General check WARNING Be sure the truck parking brake is in the PARK position and all wheels are chocked before proceeding with any service. Failure to do so may result in unexpected movement of the truck causing injury or possibly death. The followings items must always be checked before operation of this machine. Hydraulic tank oil level (1) Locate the oil level gauges on the front of the tank, each side. (2) Check the hydraulic oil level. a. Outriggers and boom in travel position. b. Outriggers are fully extended and in the operating mode. (Boom is not extended).(see Fig. 6-8) Fig.6-8 SYG5360THB 47 6-21 Maintenance Lubricating oil level in transfer case (1) Position the truck chassis on a flat level surface. (2) Remove plug (a) and visually check to see if the oil level reaches within 10 mm (0.4 in) of the bottom of the plug hole. (3) If necessary, add the correct amount of oil as needed, see Table. 6-10, on page 6- 19 for the type of oil. (4) Reinstall plug (a) and torque to 68 N.m (50 lbf.ft). NOTE: See Fig. 6-9 for the location of plug (a) . Rotary reducer oil level Pressure washer pump oil level Remove plug (a) and insert your index finger tip into the fill port to check the washer pump oil level. If oil is found on your finger tip, then the washer pump oil level is correct. If oil needs to be added, see table6-9 on page 6-17 for the type of oil. NOTE: See Fig. 6-11 for the location of plug (a). Fig.6-9 Fig.6-10 a Fig.6-11 Min NOTE: See Fig. 6-10 for the location of Min level. . (1) Position the truck chassis on a flat level surface. (2) Visually checking if the oil level reaches the Min level of the oil cup. (3) If it is, add the correct oil as needed, see Table. 6-9, on page 6-17 for the type of oil. SYG5360THB 47 6-22 Maintenance The grease amount in the lubricating device Check the auto-grease hopper to see if it is full to the top with grease. If grease needs to be added, unscrew lid (1) and add grease to the hopper (2). (See Fig. 6-12 for the locations of lid(1) and hopper (2)). ● Use "00" lubricating grease in the summer; ● Use "000" lubricating grease in the winter. Check the wash box (1) The wash box is located on the chassis deck in the center between the pumping cylinders and the hydraulic cylinders. (2) Unscrew knobs (a) and open cover (b) to check the water condition. If water level is low, add water. NOTE: See Fig. 6-13 for the locations of knobs (a) and cover (b). (3) If wash box needs to be cleaned, remove safety guard screws (d) and lift off safety guard (c) (if equipped with a safety guard). NOTE: See Fig. 6-14 for the locations of knobs (c) and cover (d). NOTE: If excessive amounts of concrete, grout or sand are found in the wash box, this is an indication that the pumping cylinder piston is near the end of its life cycle and additional service is required. For details on replacing the pumping cylinder piston, see “Pumping cylinder piston seal service” on page 6-27. Fig.6-12 Fig.6-13 Fig.6-14 SYG5360THB 47 6-23 Maintenance (4) Drain and clean the wash box. ● The wash box drain is located in the wash box on the right side. ● Rotate the drain valve knob (e) to the left to open the drain port (f).(See Fig. 6-15 for the locations of knob (e) and the drain port (f). (5) After cleaning, close drain (f), install safety guard (c) and fill with fresh water. Install cover (b). See Fig. 6-13, Fig. 6-14, and Fig. 6-15 for the locations of (b), (c) and (f). CAUTION If your machine is equipped with a safety guard, be sure this safety guard is reinstalled before operating the pumping system. Failure to install the safety guard could result in possible injury to persons. Rear outrigger tanks (1) Locate the water level gauges on the front part of each rear outrigger. (2) Check the water level (a)l NOTICE If you will be operating in a cold climate, you may want use an environmentally approved antifreeze solution to prevent the water from freezing. Failure to do so may cause damage to your machine. (3) If required, remove cap (c) and add water until the outrigger water tank is full to level Fig.6-15 a Fig.6-16 SYG5360THB 47 6-24 Maintenance gauge (a).(See Fig. 6-16 and Fig. 6-17 for the locations of gauge (a) and remove cap (c).) Check all safety equipments Check if all safety equipments are available and in fully functioning condition. (1) Check if all warning signs are sound. (2) Check if all safety auxiliary devices are complete (e.g. if the safety chain of the hose at the end is correctly connected, if the screen of hopper can be continuously used, if the cover of water tank is good, if the outrigger is extending to the desired position and supported by the bearing plate as required, etc.) 6.4.2 Check the hydraulic system (1) Check all hydraulic rubber hoses for leakage. (2) Check all hydraulic adaptors secured by screws for tightness or leakage (3) Check if the oil filter is blocked. Start the machine, allow the hydraulic system to run without load, and observe the indicator of oil filter. When the indicator is pointing to red, the oil filter has been blocked, and it should be immediately replaced. (4) Check the oil cooler for contamination and deposits. (5) Check all hydraulic threaded unions for tightness and leaks. (6) Check all hydraulic hoses for leaks. Fig.6-17 SYG5360THB 47 6-25 Maintenance 6.4.3 Check the electrical system (1) Check all electrical adaptors for tightness and rust. (2) Check electrical cables for open circuit. (3) Check the insulator on electrical cables for aging and peeling. 6.5 Pumping System Before every pumping operation, check if the hopper has foreign matter and put down the screen; fill sufficient clean tap water in the cleaning room, when the ambient temperature is lower than 10°C, it is practicable to add hydraulic fluid of about 1/3 capacity to improve the lubrication efficiency. After every pumping operation, open the water drain plug to completely drain off water in the cleaning room and draw out the piston head to conduct cleaning and checking. The cleaning room should be clean and no deposit is allowed on the piston rod of oil cylinder. During forward pumping or reverse pumping, if water in the cleaning room is muddy, immediately stop the machine and check the concrete seal. During pumping, if the water temperature in the cleaning room is too high, timely replace with fresh water. For construction in cold weather, e.g. winter, completely drain off water in the cleaning room to avoid icing. Do not add lithium-based grease in the cleaning room; otherwise the hydraulic system is easily be polluted and faults will frequently occurs. SYG5360THB 47 6-26 Maintenance 6.5.1 Pumping cylinder piston Overview connecting rod, bayonet adaptor and various seals, as shown in Fig. 6-18 . Fig.6-18 Structural of Piston Head 1 2 3 4 5 6 7 [1] Screw [2] Washer [3] Connecting rod [4] Guide ring [5] Concrete seal body [6] O-ring [7] Pressure plate SYG5360THB 47 6-27 Maintenance Pumping cylinder piston seal service Pre-inspection procedures Remove the wash box cover and safety guard (if equipped). For details on accessing the wash box and cleaning, see “Check the wash box” on page 6-22. NOTE: Do not fill the wash box after cleaning. (1) Pull the pumping cylinder piston into the wash box. Hold the switch (a) in the EXIT position as shown in illustration until the pumping cylinder piston is completely in the wash box. See Fig. 6-19 for the location of switch (a). NOTE: This function will position the pumping cylinder piston in the wash box for inspection or removal. (2) Once the pumping cylinder piston is in the wash box, release switch (a) and allow it to return to the KEEP position. See Fig. 6- 19 for the location of switch (a). (3) Inspect the condition of the piston seals (b) for extensive wear or damage. If extensive wear or damage to the piston seals (b) are found, the piston assembly needs to be replaced. Follow the replacement procedures listed below. (See Fig. 6-20 for the location of (b).) NOTE: When inspecting piston seals, always keep in mind both pumping cylinder pistons must be inspected. Follow the procedures outlined underlying for each pumping cylinder piston. Fig.6-19 Fig.6-20 a SYG5360THB 47 6-28 Maintenance Replacement procedures (1) Shut the truck engine OFF. (2) Remove the hydraulic control system housing cover. (3) Locate the circuit dump valve (c) as shown in the illustration. See Fig. 6-21 for the location of (c). (4) The circuit dump valve will be in the CLOSED position for normal operation. Move the circuit dump valve to the OPEN position as shown in the illustration to relieve any excess pressure in the accumulator circuit. WARNING Failure to set the circuit dump valve in the OPEN position could result in unexpected movement of the pumping cylinder piston during service procedures. Unexpected movement of a component could result in serious injury. (5) Loosen the pumping cylinder piston locking collar fasteners (d) and remove the top section of the locking collar (e), see Fig. 6-22. Fig.6-21 d d e Fig.6-22 SYG5360THB 47 6-29 Maintenance (6) Lift the worn or damaged pumping cylinder piston assembly out of the wash box. See Fig. 6-23. (7) Install a SANY approved new or refurbished pumping cylinder piston assembly. (8) Reinstall the pumping cylinder piston locking collar top section (e) and fasteners (d). Torque all fasteners using the torque values listed on page 6-8. (9) Close the wash box drain valve and fill the wash box with fresh clean water. Rotate the circuit dump valve to the CLOSED position as shown in Fig. 6-21. (10) Start the truck engine. Using the rear boom quick-check switch panel, hold switch (a) in the RESET position to insert pumping cylinder piston back into the pumping cylinder bore. (11) Once the pumping cylinder piston is in the cylinder bore, release switch (a) and allow it to return to the KEEP position. See Fig. 6-24. (12) Fill the wash box with fresh clean water. (13) Reinstall the wash box safety guard (if equipped) and cover, see “Check the wash box” on page 6-22 for details. If necessary, contact your SANY distributor for repair procedures. Fig.6-23 Fig.6-24 a SYG5360THB 47 6-30 Maintenance 6.5.2 Agitator shaft and leaf Check the agitator shaft for tightness daily through the viewport on the agitator motor seat. Check the abrasion of agitator blade, which will result in the unsatisfied material absorption efficiency and increment in deposit at the bottom of hopper. Replace the agitator blade (see Fig. 6-25) timely or reinforce it. NOTE: For overlaying welding of agitator blade, the distance between the blade and any position on hopper wall should not be less than 5cm; otherwise the hopper will be worn out. During installation of left and right agitator blades, pay attention to the correct installation direction of agitator blades. Fig.6-25 agitator shaft and agitator blade [1] Agitator shaft [2] Left agitator blade [3] Right agitator blade [4] Bolt [5] Spring pad [6] Flat washer [7] Nut SYG5360THB 47 6-31 Maintenance 6.5.3 S-valve Assembly Overview Checking the S-tube and wear ring Inspect the S-tube and wear ring for signs of looseness, wear, damage or any abnormal conditions. The S-tube and wear ring assembly should be replaced if the following conditions are found: (1) Excess wear or damaged to the surface (1) or swing mechanism (2) are found. (2) The thickness of S-tube surface (1) is less than 10 mm (0.4 in). NOTE: See Fig. 6-27 for the items (1) and (2). Fig.6-26 S-valve Assembly (I) [1] Transitional bushing [2] O-ring [3] Screw [4] Washer [5] Spectacle wear plate [6] Cutting ring [7] Rubber spring [8] S-tube Fig.6-27 1 2 SYG5360THB 47 6-32 Maintenance If you find excessive wear, damage or abnormal surface conditions on the S-tube, contact your SANY distributor for repairs. If concrete flow is weak at the end hose outlet or abnormal concrete leakage is found in the hopper during pumping operations, check the clearance between the spectacle wear plate (3) and S-tube (4). If the clearance (1) is less than 4 mm (0.2 in) the wear ring (2) is at the end of its service life and should be replaced. Contact your SANY distributor for repairs. If the clearance (1) between the spectacle wear plate (3) and S-tube (4) is greater than 4 mm (0.2 in) adjust the clearance until 4 mm (0.2 in) is achieved between the spectacle wear plate (3) and S-tube (4). NOTE: See Fig. 6-28 for the items (1),(2), (3) and (4). Adjustment If concrete flow is weak at the end hose outlet or abnormal concrete leakage is found in the hopper during pumping operations, check the clearance between the spectacle wear plate (3) and S-tube (4). If the clearance (1) is less than 4 mm (0.2 in) the wear ring (2) is at the end of its service life and should be replaced. Contact your SANY distributor for repairs. If the clearance (1) between the spectacle wear plate (3) and S-tube (4) is greater than 4 mm (0.2 in) adjust the clearance until 4 mm (0.2 in) is achieved between the spectacle wear plate (3) and S-tube (4). Follow adjustment procedures be-low. To adjust the clearance (1), rotate nut (5) clock-wise or counterclockwise. Fig.6-28 Fig.6-29 SYG5360THB 47 6-33 Maintenance Clockwise - decreases the clearance between the spectacle wear plate (3) and S-tube (4). Counterclockwise - increases the clearance between the spectacle wear plate (3) and S- tube (4). NOTE: See Fig. 6-28 and Fig. 6-29 for the items (1),(2), (3),(4) and (5). Removing spectacle wear plate and wear ring (1) Unloading, stop and switch off the power supply Open the unloading ball valve of accumulator to unload the pressure oil of accumulator. Close the engine, take out the start key, and switch off the power supply to avoid the unauthorized starting. (2) Remove the limit screw of rocker arm and abnormal nut as shown in Fig. 6-30, unlock the abnormal nut but do not loosen it completely, wherein 2-3 turns of threads should be left. (3) Remove the coupling which connects the delivery line with the hinge elbow; take out the split pin on the axle pin of the hinge elbow. Take out the axle pin, and then remove the hinge elbow as shown in Fig. 6- 31 Fig.6-30 Abnormity Nuts and Limiting Screws [1] Abnormity Nuts [2] Limiting Screws SYG5360THB 47 6-34 Maintenance . (4) Disassemble the material outlet by loosening connecting screw between material outlet and bearing seat. (5) Hoist the S-tube with crow bar to move the S-tube towards the material outlet about 30mm. At this time, there will be about 30mm clearance between the spectacle wear plate and wear ring. (6) For replacement of wear ring, knock the flange edge of wear ring with a brass rod, take out the wear ring and then take out the rubber spring. For replacement of spectacle wear plate, remove the fastening screw of spectacle wear plate and hopper, and take out the spectacle wear plate. 6 1 5 4 9 8 10 3 11 7 Fig.6-31 Hinge Elbow and Discharge Outlet [1] Axis pin [2] Pin [3] Plug-in board [4] Hinge elbow [5] Supporting bolt [6] Protective sleeve [7] Nut [8] Discharge outlett [9] O-ring [10]Locknut [11]Cross pin stud SYG5360THB 47 6-35 Maintenance (7) Clean and care the installation positions of spectacle wear plate and wear ring. NOTICE When loosening the abnormal nut, do not remove it completely so that the hoist stroke of S-tube can be limited. If the S- tube removes unlimitedly when hoisting, and drops in the hopper, the installation position of S-tube can be recovered after disassembling the front and rear bearing seats and swing cylinder system. NOTE: Pay special attention to the cleaning of concrete at the installation position of rubber spring. Fitting the spectacle wear plate and wear ring Fig.6-32 Spectacle wear plate and wear ring (I) [1] Bolt [2] Washer [3] Spectacle wear plate [4] Cutting ring [5] Rubber spring [6] S-tube SYG5360THB 47 6-36 Maintenance (1) Install the lubricated spectacle wear plate in the corresponding positions of hopper. Note that the spectacle wear plate must be flat, and the clearance between the spectacle wear plate and the fitting surface of hopper should not be more than 0.1mm. (2) Check the O-rings in the intermediate rings on which the spectacle wear plate is placed. (3) Clean the mounting surfaces and grease them. CAUTION The spectacle wear plate rests only against the O-rings of the intermediate rings. There is a small clearance between the spectacle wear plate and the hopper wall. The outer fastening bolts should therefore initially only be tightened finger- tight, as otherwise the spectacle wear plate may be broken. (4) Fit the new spectacle wear plate. (5) Put the new spectacle wear plate in place and fasten it with the outer fastening bolts. Tighten these only to finger-tightness initially. (6) Bolt down the spectacle wear plate with the top and bottom and tighten them to the appropriate tightening torque. (7) Tighten the outer fastening bolts to the tightening torques given in the accompanying spare parts sheet. The spectacle wear plate may only be distorted by a maximum of 0.5mm when the bolts are tightened. SYG5360THB 47 6-37 Maintenance Replacing the wear ring Replace the wear ring in the event of heavy visible wear, if concrete is leaking or if there is inadequate pressure buildup in the delivery line. (1) Remove the old wear ring and the thrust ring. (2) Fit a new thrust ring and a new wear ring in the S-tube. Checking the agitator motor Check the agitator motor mounting for loose or missing fasteners (a), leaking hydraulic lines (b) or concrete leakage between the motor and hopper mounting. If missing fasteners are found, replace then with SANY factory approved fasteners. See Fig. 6-33 for the locations of (a) and (b). If loose fasteners or hydraulic lines are found, torque the fasteners or hydraulic lines using the torque values in Table. 6-4,Table. 6-5 and Table. 6-6on page 6-9. If any damage, excessive wear or abnormality is found, contact your SANY distributor for repairs. Removing the agitator motor (1) Stop, switch off the power supply and unloading. Open the unloading ball valve of accumulator to unload the pressure oil of accumulator. Close the engine, take out the start key, and switch off the power supply to avoid the unauthorized starting. (2) Remove the screen, unlock the installation screw of agitator blade and remove the agitator blade. (3) Disassemble three oil pipe adaptors and lubrication pipe (see Fig. 6-34) connecting to Fig.6-33 a b SYG5360THB 47 6-38 Maintenance the agitator motor. Seal the oil pipe and adaptor with plug to prevent the dust entering the hydraulic system. (4) Loosen the fastening screw between the agitator motor seat and hopper, remove the motor seat and motor, and then remove the waterproof plate (see Fig. 6-35, Fig. 6-36). (5) Loosen the fastening screw of end cover at both ends outside hopper and remove the end cover. (6) Loosen M5 screw at both ends inside hopper, remove the pressure ring and allow the seal retainer ring to contact with the shoulder. (7) Loosen the fastening screw of seal cover and hopper at both ends outside hopper. (8) On the side of motor, knock the agitator shaft with a brass rod to move the agitator shaft towards another end. With the force of shoulder, push the seal cover at another end out from hopper hole and remove the seal cover. (9) Push out the seal cover with the same method at the another end. (10) Push the agitator shaft towards one end and take out the agitator shaft from the top of hopper. Fig.6-34 Mixing Motor and Oil Tube SYG5360THB 47 6-39 Maintenance Fig.6-35 agitator device (1) [1] Screw M10 [4] Blot M12 [2] Motor [6] Motor seat [7] Water catcher [8] Felt ring [10] End sealing cover [11] Packing plate [12] Retainer ring [13] Roller bearing [14] Base ring [23]Packing plate (2) [19]O-ring 150 x 3.55 [21]Bolt M8x16 [22]Seal cover [24]J-type dust-proof ring [25]Shaft sleeve [26]Screw M5×8 [27]O-ring 46.2×2.65 [28]Seal retainer ring [29]Pressure ring [30]Screw M5×12 [9] Screw M8×20 3 5 15 4 5 9 24 22 21 20 11 10 8 7 6 2 1 5 16 26 27 25 14 13 12 19 18 17 31 30 29 28 23 [3] Spline housing [5] Washer 12 [15] Screw M12x20 [16] Screw M12x35 [18] Seal Ring [20] Oil Seal B [31] Rubber plug [17]Bearing seat SYG5360THB 47 6-40 Maintenance Fig.6-36 Agitator device (2) [17]Bearing seat [15]Bolt M12x20 [21]Shaft end pressure plate 26 25 24 23 22 21 20 19 7 5 6 18 16 17 14 13 11 12 10 2 1 4 3 8 9 16 15 [24] Packing plate [19]Base ring [9]Packing plate (2) [13]O-ring 150 x 3.55 [11]Bolt M8x16 [10]Seal cover [8]J-type dust-proof ring [7]Shaft sleeve [6]Screw M5×8 [5]O-ring 46.2×2.65 [4]Seal retainer ring [3]Pressure ring [2]Screw M5×12 [26]Screw M8×20 [16] Washer 12 [18]Blot M12x35 [14] Seal Ring [12] Oil Seal B [1] Rubber plug [20]Rolling Bearing [22]Washer [23]Blot M8x25 [25]End cover SYG5360THB 47 6-41 Maintenance Remove the coupling which connects the delivery line with the hinge elbow; take out the split pin on the axle pin of the hinge elbow. Take out the axle pin, and then remove the hinge elbow as shown in Fig. 6- 31 on page 6-33. Disassemble the material outlet Disassemble the material outlet by loosening connecting screw between material outlet and bearing seat. S-tube bearing seal set Fig.6-37 S-valve Assembly (II) [1] Screw M8×20 [2] Pressure ring [3] Rubber pad [4] Wearing sleeve [5] J -type dust-proof ring [6] YX-type seal ring [7] Bearing seat [8] Nylon bearing [9] O-ring [10]Discharge outlet [11]Bolt SYG5360THB 47 6-42 Maintenance (1) Remove two grease pipes on the bearing seat. (2) Loosen the screw of pressure ring in hopper and remove the pressure ring. (3) Hoist the S-tube with crane and flexible cable. (4) Push the bearing seat out with two long bolts and remove the bearing seat. Removing the rocker arm and small bearing seat (1) Remove the ball head baffle and limit baffle. Take out the piston rod of swing valve oil cylinder from the spherical bearing. Fig.6-38 Swing Mechanism [15] Bolt M16x20 [6] Limit baffle [1] Bearing plate [5] Lower ball bearing [7] Left swing valve cylinder [8] Ball head baffle [12] Upper ball bearing [9] Rocker arm [13] Right swing valve cylinder [2] Screw M8x16 [4] Washer 8 2 1 3 4 5 6 7 8 9 10 11 14 12 13 14 15 3 8 15 14 2 6 4 3 1 5 4 [3] Screw M8x16 [10] Conversion joint [11] Washer 16 [14] Oil cup M8x1 SYG5360THB 47 6-43 Maintenance (2) Loosen the limit screw of rocker arm and abnormal nut and remove the abnormal nut. (3) Remove the ball head baffle which connects the rocker arm and swing valve oil cylinder. (4) Remove two grease pipes on the bearing seat. (5) Loosen the screw connecting the bearing seat at the end of rocker arm and hopper, push out the bearing seat with two bolts and remove the bearing seat. Checking other wear parts Fig.6-39 S-valve Assembly (III) [1] Transitional bushing [2] O-ring [3] Screw [4] Washer [5] Spectacle wear plate [6] Cutting ring [7] Rubber spring [8] S-valve SYG5360THB 47 6-44 Maintenance (1) Move the S-tube toward the material outlet with a crow bar until the small shaft is detached from the hopper. (2) If necessary, unlock the bolt of scraper at the bottom of S-tube and remove the scraper. (3) Adjust the position of S-tube at the small end and hoist S-tube from the hopper. (4) Knock the flange edge of wear ring with a brass rod, remove the wear ring and then take out the rubber spring. (5) Unlock the fastening bolt of spectacle wear plate and remove the spectacle wear plate. (6) Check the reducing bushing connecting to the delivery cylinder and replace as per abrasion degree. (7) Check the wear sleeve at the material outlet end of S-tube and replace as per abrasion degree. Replacing the wear sleeve The wear sleeve can be replaced without the requirement to replace the S-tube if the wear sleeve is heavily worn. The S-tube must be removed to do this. (1) Carefully cut the wear sleeve at two opposing points using an angle grinder and remove the two parts. NOTICE Do not damage S-tube when cutting the wear sleeve. (2) Heat the wear sleeve with heater and keep the heating temperature at 200-210°C for about 10 minutes. Fig.6-40 S-valve and Wearing Sleeve [1] S-tube [2] Wearing sleeve SYG5360THB 47 6-45 Maintenance (3) Place the heated wear sleeve over the tube outlet and allow the wear sleeve to cool. (4) Replace the S-tube. NOTE: When heating the wear sleeve, the temperature can not be too high. If no heater is provided, the wear sleeve can be put into an appropriate vessel and heated after diesel oil is added. The oil level should exceed the wear sleeve. The heating temperate is kept at 200-210°C for about 10 minutes. Note that the heating temperature should not be too high and firing should be avoided. Never directly use flame to ignite the wear sleeve. NOTE: When assembling the wear sleeve, note that the inner bevel of the wear sleeve should face towards the large end of S-tube and the outer bevel should face towards the small end of S-tube. Fitting the S-tube (1) Install the wear sleeve into the straight pipe position of S-tube. (2) Hoist the S-tube with crane and flexible cable, put rubber pads on both ends, set the S-tube to the inclined position, put the outlet port of S-tube in the installation hole for material outlet of hopper, push it into the end position and put the small end of S-tube in the installation hole of hopper. Apply grease on the rubber spring and wear ring and install them on S-tube. (3) Replace the Yx-type seal ring, J-type dust ring, dust ring and seal ring with new one, apply grease on the inner and outer of SYG5360THB 47 6-46 Maintenance seal, bearing and bearing seat; install the nylon bearing, Yx-seal ring and J-type dust ring onto the large bearing seat at the outlet. Install the bearing, dust ring and seal ring onto the small bearing seat. NOTICE During installation, pay attention to the correct installation direction of seal ring and dust ring. Failure to do so may result in oil leaking and the dust crushing into the containers or pipes. (4) Install the large bearing seat of seal between the hopper hole and S-tube, set both grease inlets at 15°included angle to the horizontal surface, and then install the lubricating oil pipe and adaptor. (5) Install the small bearing seat of seal in the hopper hole; install the lubricated O-ring in the end bearing sleeve, then install the spline teeth, and then install the end bearing sleeve at the small shaft end into the bearing seat hole from outside of hopper with a brass rod. (6) Install rocker arm on the shaft end of S- tube. SYG5360THB 47 6-47 Maintenance NOTICE When installing the rocker arm, allow the S-tube to hang down freely. The center lines of gravity of S-tube and rocker arm must be overlapped when viewed from the right behind the hopper (see Fig. 6-41). Or fit the key way, which is located on rocker arm and symmetrically coincides with the center line, on the spline teeth located on the shaft end of S-tube and has a center line symmetrically coincides with that of S-tube. If the installation positions of S-tube and rocker arm is not correct, S-tube can not swing to the desired position. (7) Install the swing valve oil cylinder and then install the ball head baffle and limit plate. (8) Install the O-ring into the key way at the end face of abnormal nut, screw the abnormal nut in the spline shaft of S-tube Fig.6-41 Assembly Requirements for Rocker Arm and S-valve [1] S-valve [2] Rocker arm SYG5360THB 47 6-48 Maintenance until the distance between the end face of S-tube and the wear ring is about 4mm, align the notch on the abnormal nut with the thread hole on the rocker arm and install the limit screw. (9) Install the pressure ring in the hopper, tighten the screw of pressure ring and press the rubber pad tightly. (10) At last, secure the material outlet from outside of hopper with screw M24×160 and spring pad, and the tightening torque is 650±18N.m. (11) Install the hinge elbow, insert the cross pin and split pin and then install the coupling. Fitting the agitator (1) Apply the grease on O-ring, insert two O- rings into the key way at both ends of agitator shaft, install seal retainer ring on the shaft shoulders at both ends, and put the agitator shaft in the related hole of hopper. (2) Install the lubricated lip-Like seal ring with inner frame and dust ring in the seal cover, install the assembled seal cover into the hole of hopper and secure it with bolt M8×16 on the hopper. (3) Install two shaft sleeves on the shaft, align the notch with screw hole M5 on the shaft and secure it with screw M5×8 (applied with sealant). (4) Install the O-rings, seal ring and base ring applied with grease on both bearing seats, and secure the bearing seat on the end face of shaft hole with bolt M12×35 applied with sealant and washer. The lubricating oil hole of bearing seat should be Installed towards the lower-rear section. SYG5360THB 47 6-49 Maintenance (5) Install the roller bearing into the left and right bearing seats with the assembling tools for bearing. (6) At the end without motor, secure the pressure plate at the shaft end with screw and then install the end cover; at the end with motor, apply grease on the seal ring and then install the seal end cover, then install the seal end cover and waterproof plate on the agitator shaft. (7) Install the motor seat: install the motor seat on the dome of the right plate for hopper, set the installation groove of grease inlet pipe towards the lower-right side, secure it with bolt M12×40 and spring pad, and tighten bolt in strict accordance with the tightening sequence. (8) Measure the run out: measure the run out of installation hole and end face of motor seat to the center line of agitator shaft, wherein the maximum permissible radial run out is 0.32mm, and the maximum permissible end run out is 0.16mm. This can be ensured through adjustment. (9) Install the hydraulic motor and its hydraulic fluid pipe align the hydraulic motor with the spline, then install it on the motor seat, and secure it on motor with screw M10×90. Tighten bolt in strict accordance with the tightening sequence. (10) At last, install the agitator blade. Secure the screw blade on the agitator shaft with bolt M16×65, spring pad and nut, where in the threads of said bolt should be cleaned, dried and applied with sealant. SYG5360THB 47 6-50 Maintenance NOTE: During replacement of said parts, all related rubber seals should be replaced. The clearance between the spectacle wear plate and wear ring should not be too large or small, and the clearance between the wear ring and the end face of S-tube should be 4mm. 6.5.4 Hopper Frequent inspection and maintenance of the hopper and related parts (see Fig. 6-42) can effectively avoid the abnormal abrasion of hopper. (1) After pumping, clean the hopper and no deposit is allowed; otherwise the lower section of S-tube will be easily worn and even out of service. (2) After every pumping, the recession in the S-tube must be cleaned to avoid blockage in next pumping. (3) The transition section between the spectacle wear plate and delivery cylinder is furnished with transition sleeve and should be frequently checked. In the event of severe abrasion, when its height is lower than delivery cylinder, the transition sleeve should be timely replaced; otherwise the service life of delivery cylinder will be influenced. (4) The agitator motor must not be packed. Check if there is slurry leakage via the observation hole on the agitator motor seat every day. When conducting the inner cleaning, checking and maintenance work of hopper, close the agitator shutoff valve (see Fig. 6-43) and press the E-STOP button synchronously; otherwise there will be injury to person. Fig.6-42 Hopper Fig.6-43 Agitator control valve and agitator shutoff valve [1] Auxiliary valve block [2] Agitator shutoff valve [3] Agitator motor SYG5360THB 47 6-51 Maintenance 6.5.5 Delivery cylinder Because the working conditions of delivery cylinder (see Fig. 6-44) are adverse and there is long-term friction between the concrete and delivery cylinder, if slurry leakage not caused by the damage of concrete seal is found, check if the delivery cylinder is damaged or broken during pulling. The broken position and damage degree of delivery cylinder must be inspected with light when the engine and agitator shutoff valve are closed. 6.5.6 Delivery line All metal pipes and pipeline components should be checked for wall thickness and condition at frequent intervals and all results of such inspections must be recorded. Any used components in storage should be tested before being returned to service. Delivery pipe that has a wall thickness less than the recommended thickness for the pump’s designed maximum concrete pressure should not be used. Hoses that are used to pump concrete should be visually inspected before concrete pumping operations. Damaged or worn hoses shall not be used. Overview The delivery line is composed of tube assembly and boom tube. The tube assembly comprises the tube from the hinge elbow to the slewing center of rotary tower. Boom pipe comprises the tube from the slewing center to the top of boom. The delivery line mainly comprises straight tube, elbow, tapered tube, coupling, tube support, etc. The straight tube mainly comprises the standard 3m straight tube and matching straight tube with customized length. The delivery line of boom is attached at outside Fig.6-44 Delivery Cylinder SYG5360THB 47 6-52 Maintenance place of boom, and its length matches with the boom length through adjusting the matching straight tube. (1) Clearance There must be 3mm clearance between various tubes (see Fig. 6-45) of delivery line. This clearance can be automatically gained through installation a seal ring. (2) Matching straight tube The lengths of matching straight tubes for platform and boom are different. Before replacing the matching straight tube, according to the related information on matching tube assembly and matching tubes of boom in the Spare Parts Drawing Volume, confirm the positions and lengths of all matching tubes. The related dimensions of pipelines produced by SANY Heavy Industry Co., LTD can be gained from the specifications. Use of delivery line Proper use of delivery line can effectively prolong the service life of delivery line. (1) Straight tube Turning the straight tube by 120o or 180 o every pumping 5000 cubic meters can lead to even distribution of abrasion and increment in service life of straight tube. Especially to the delivery line with longer service life (generally the service life is not less than 2 cubic meters), the efficiency is more obvious. (2) Elbow a. Turning the elbow by 180 o every pumping 5000 cubic meters can lead to Fig.6-45 Mounting Clearance of Pipeline [1] Pipe clamp [2] Seal ring [3] Delivery pipe Fig.6-46 Elbow SYG5360THB 47 6-53 Maintenance even distribution of abrasion (see Fig. 6- 46). The outside abrasion of an elbow is larger than the inside abrasion or the abrasion of straight tube. Therefore, when measuring the wall thickness of an elbow, special attention should be paid to the wall thickness at the side of external arc. b. As to the same type of elbow, since they are installed at different positions of boom, their service lives are also different. Generally, the service life of the second last elbow is the shortest. In addition to the general flow friction wear, the elbow at this place also is subjected to the impact of the gravity of concrete when working, which increases the abrasion of pipeline (see Fig. 6-47) In order to uniform the service lives of the whole set of delivery pipeline, SANY Heavy Industry Co., LTD has specially produced thickened elbow for this place. The detailed specifications for this elbow refer to the Spare Parts Drawing Volume. SYG5360THB 47 6-54 Maintenance NOTE: The replacement of the whole set of pipeline is more economic than replacement of the worn tube Fig.6-47 Delivery Pipe [1] Elbow [2] Matching straight tube [3] 3m standard straight tube [4] Boom (5) [5] Elbow (thickened) [6] End hose [7] Seal ring [8] Clamp [9] Fixing clamp [10]Rubber pad SYG5360THB 47 6-55 Maintenance . Measuring the wall thickness Wall thickness testing should be tested using an ultrasonic test instrument or other suitable approved methods. All testing shall be carried out by competent authorized personnel. The test equipment shall be calibrated regularly and maintained according to the manufacturer's requirements. Pipe must not be used if the wall thickness is less than that recommended by the pipe manufacturer for the maximum concrete pressure of the pump. The suppliers of pipes for concrete pumps should be able to provide data on the minimum pipe wall thickness for differing pump pressures. The minimum wall thickness of single wall pipe is dependent on the grade of pipe, the maximum working concrete pressure of the pump and the diameter of the pipe. Where the supplier's information is not available, minimum wall thickness shall be calculated using the formula in AS 4041. The table below is calculated using the formula in AS 4041 which provides default minimum pipe wall thicknesses for 108 mm & 133 mm (4.3 in. & 5.2 in.) outside diameter seamless steel pipes at different concrete pressures. SYG5360THB 47 6-56 Maintenance These minimum thickness values cannot be used for pipe with diameters greater than those specified, nor can the table be extrapolated for other grades of pipe. The min. wall thickness of delivery line (see Fig. 6-48). (1) Follow the Operating Instructions supplied with the test instruments when carrying out measurements. Do not measure the wall thickness of the delivery line at just one point, but around the entire circumference of the delivery pipes. The minimum wall thickness is shown in the graph below. (2) When the wall thickness of delivery tube reaches the min. value, immediately replace it. Especially before pumping concrete with large cubic meters, the pipelines with wall thicknesses approaching the min. value must be replaced. Otherwise, explosion may occur during construction, the progress of engineering will be influenced, and even the life will be threatened. Table 6-11 Minimum Pipe Wall Thickness Minimum Pipe Wall Thickness/mm (in.) Max.Pressure Outside Diameter Of Pipe Grade 200 Grade 250 Grade 350/ST-52 KPa psi 108mm(in) 133mm(in) 108mm(in) 133mm(in) 108mm(in) 133mm(in) 4.500 653 2.2(0.1) 2.7(0.11) 1.7(0.06) 2.1(0.88) 1.3(0.05) 1.6(0.06) 6.000 870 2.9(0.2) 3.5(0.14) 2.3(0.1) 2.8(0.11) 1.7(0.06) 2.1(0.08) 8.000 1.160 3.8(0.15) N/A 3.0(0.12) 3.7(0.15) 2.3(0.10) 2.8(0.11) 10.000 1.451 N/A N/A 3.8(0.15) N/A 2.9(0.12) 3.5(0.14) 12.000 1.741 N/A N/A N/A N/A 3.4(0.13) N/A Fig.6-48 Minimum Wall Thickness SYG5360THB 47 6-57 Maintenance NOTICE Pipes and bends must be replaced as soon as the wall thickness has declined to the value for the minimum wall thickness. It should be specially noted that the influence on delivery line caused by the impact of dynamic load during pumping can not be accurately calculated. It depends on many factors in the procedure of pumping; therefore, the delivery line may break even if the working pressure is within the permissible range. In the event of blockage, the working pressure also will fluctuate. If the wall thickness can not reach requirements, the delivery line will also break. (3) If no test instrument is available, a hard wood hammer or rubber hammer can be used to knock the delivery line when the line is empty, and judge the wall thickness through the sound (see Fig. 6-49). The method has large error and requires rich practical experience. NOTICE No not use metal substances to knock the delivery line; otherwise dent will occur and lead to acceleration in abrasion as well as the inner peeling of the reinforced layer on the high-strength compound wear-resistance tube. Fig.6-49 Check of Delivery Pipe Wall Thickness by Knocking SYG5360THB 47 6-58 Maintenance CAUTION Never increase the wall thickness, outer diameter and length of delivery line; otherwise the service life of boom will be reduced, influencing the stability of this pump truck and potentially leading to breaking of boom and tilting of pump. Checking the pipe coupling Check the concrete pipe couplings for signs of leakage, damage, loose fasteners, wear or any abnormal condition. If a coupling is found to be damaged, worn or in an abnormal condition, replace it with a new SANY approved coupling. If a coupling is leaking or has loose fasteners, torque the fasteners using the torque values in “Pre-tightening Torques of Bolts (without lubrication)” on page 6-8. Replacing the delivery line The delivery line is subdivided into two sections: boom delivery line; pump-boom delivery line. Wall thickness The starting points for laying the pipe on the boom are the hinge pivot points. The straight delivery line run from pivot point to pivot point. They are no more than 3 m long. The delivery line is matched to the arm length concerned by means of the adapter pipes. The length of the pump-boom delivery line is also adapted by means of adapter pipes. Fig.6-50 SYG5360THB 47 6-59 Maintenance NOTICE Do not exceed the delivery line wall thickness specified on the rating plate and in the machine card. The machine’s stability can be impaired by additional weight. NOTICE Should you wish to re-equip your machine to a delivery line of greater wall thickness, the machine’s stability will have to be recalculated and checked and approved by an authorized inspector. Untensioned assembly The boom delivery line must be fully fitted with the arm assembly relieved of tension: the arm assembly is not under tension in the transport position if each arm is lying freely on the rest provided for this purpose; when unfolded if each arm is supported, the arm assembly is not under tension. CAUTION If the tension on the arm package is not fully relieved during assembly, stresses may occur in the delivery line on movement of the placing boom and consequential damage may be caused to the pipe brackets and to the placing boom. Furthermore, the boom may swing up and down causing the end hose to swing and strike out during pumping operations. Clearance A clearance of 4 mm must be maintained between the delivery pipes over the whole of the delivery line, so that the welding neck SYG5360THB 47 6-60 Maintenance rings can butt against the couplings without play. This clearance is achieved either: ● automatically, through the use of a C seal (triple-lip seal), or ● manually, by adjustment, using a feeler gauge. seal C seals (triple-lip seals) are used where the delivery line runs in a straight line and there is no rotational movement. The 4 mm clearance is created automatically. NOTE: No triple-lip seals may be used in the pivot joints in the pipe bends. A seals are used: ● if the delivery line does not run in a straight line; ● in the pivot joints; and at the assembly coupling at the tip of the boom. The spacing of 4 mm must be set using the feeler gauge. Coupling Couplings with a threaded closure are closed using self-locking nuts. These nuts may not be re-used, but must be replaced each time the coupling is fitted. Fitting an A seal ● Push the A seal over the fixed delivery line pipe. ● Lay the pipe to be attached in the pipe bracket and push it up to the fixed pipe. ● Set the clearance of 4mm between the pipes using a feeler gauge. ● Fix the pipe to be attached in the pipe brackets. ● Push the A seal over the two weld-on rings. SYG5360THB 47 6-61 Maintenance ● Fit the coupling and secure it. Fitting a triple-lip seals ● Push the triple-lip seals over the welded- on ring of the fixed delivery line pipe. ● Lay the pipe to be attached in the pipe bracket and push it up to the fixed pipe. ● Push the pipe to be attached as far as the stop in the ring seal. ● Fix the pipe to be attached in the pipe brackets. ● Fit the coupling and secure it. Boom delivery line The starting points for laying the pipe on the boom are the pivot points. ● Grease all couplings and seals well internally before assembly. NOTE: Use a multipurpose grease based on lithium soap marked K2K. Install the bends in the fitting couplings at the pivot points. ● Align the bends such that the straight pipes can be connected without tension. Fix the bends. ● Install the fixed length delivery pipes. ● Install the adapter pipes last. Pump boom delivery line The pressure pipe is the starting point for assembly. NOTE: You should use only high-pressure pipes when replacing these delivery line pipes. Only C seals (triple-lip seals) are used throughout the pump- boom delivery line. SYG5360THB 47 6-62 Maintenance ● Grease all couplings and seals well internally before assembly. NOTE: Use a multipurpose grease based on lithium soap marked K2K. ● Fit the reducer pipe to the pressure pipe with a coupling. The coupling must be capable of rotating with the pressure pipe. The reducer pipe, which must be located in a vibration absorber, may not turn either. ● Fit the boom connection pipes as far as the bend on the riserpipe. 6.6 Slewing Mechanism 6.6.1 Overview The slewing mechanism is a transmission mechanism composed of the ball-bearing slewing ring, Slewing gear transmission and gear, as shown in Fig. 6-51. SYG5360THB 47 6-63 Maintenance . Fig.6-51Slewing Mechanism [1] Rotary reducer [2] Gasket [3] Washer [4] Bolt [5] Dust-proof ring [6] Gear [7] Gear [8] Copper mat [9] Double metal bearing [10]Pin [11]Slewing bearing [12]Nut [13]Washer [14]Bolt [15]Bolt [16]Rubber protective bush [17]Washer [18]Screw [19]Washer [20]Washer [21]Bolt [22] Oil cup [23]Tube connector [24] Screw plug [25]Annular plate [26] Screw [27]Pin [28]Shaft sleeve component [29]Oil cup [30]Sealing plate [31]Lubricating grease tube [32]Cycloid motor [33]Screw [34]Washer [35]Washer [36]Oil cup SYG5360THB 47 6-64 Maintenance 6.6.2 Slewing gear transmission Overview The structure of Slewing gear transmission (see Fig. 6-52), check and maintenance intervals. Checking slewing gear transmission brake function Below is the procedure outlining how to test the performance of the braking function for the slewing gear transmission. (1) Set up the machine in a clear area for normal concrete pumping operations. (2) Extend the boom as shown in the illustration. See “Extending the Boom” on page 4-34 for details on operating the boom system. (3) Carefully slew the boom in both directions while monitoring the brake function stopping distance. ● If the stopping distance is unusually long or slow to stop, the slewing gear transmission braking system may be at the end of its life cycle. ● If the stopping distance is normal the slewing gear transmission braking system is functioning properly. (4) After testing procedures are complete, retract the boom and outriggers and shut the truck engine OFF. Fig.6-52 Structure of Slewing gear transmission [1] Shaft Output [2] cup oil [3] plug vent [4] elbow vent [5] Reducer [6] [7] Nameplate [8] [9] Oil drain [10] [11] [12] Rubber hose brake Brake Oil drain Fender cover 8 9 10 11 12 plug vent for SYG5360THB 47 6-65 Maintenance (5) Remove the drain plug (a) from the slewing gear transmission and inspect the drained fluid condition.(see Fig. 6-53) ● Dark colored fluid with a strong, unusual odor indicates the fluid is probably burned. As a result, the braking system has been overheated and should be replaced. ● Chunks or small fragments of braking material in the fluid indicates that the braking material is failing or the brakes are simply worn out and in need of replacement. ● Contact your SANY distributor if the braking system needs repair. Changing the slewing gear transmission oil (1) Position the truck chassis on a flat level surface. (2) Place a suitable container under the drain plug to catch the oil. Remove plugs (a) to allow reducer case to properly drain. (3) Once drained, install plug (a) and fill case through oil cup (b) until oil level reaches Min level of the oil cup. (4) For correct oil and amount. See Table 6- 9 on page 6-17 for the type of oil. (5) Torque plugs (a) to 15 N.m. Fig.6-53 Fig.6-54 a a b Min SYG5360THB 47 6-66 Maintenance 6.6.3 Ball-Bearing Slewing Ring Overview The structure of ball-bearing slewing ring (see Fig. 6-55), maintenance interval (see Table. 6-1 on page 6-4, Table. 6-2 on page 6-5 and Table. 6-3 on page 6-7 ). Checking the ball-bearing slewing ring (1) Grease the ball-bearing slewing ring through the filling seat of ball-bearing slewing ring every 50 hours of operation or every week. As to the lubrication of ball- bearing slewing ring, apply grease on Fig.6-55 Structure of Ball-bearing Slewing ring [1] Slewing bearing [2] Ring plate [3] Screw [4] Gear [5] Washer [6] Screw [7] Oil cup [8] Plug [9] Pipe connector [10] Lubricating grease tube SYG5360THB 47 6-67 Maintenance various lubricating points of bearing through the delivery line of grease. (2) Check if foreign matter exists between gears. If any, immediately remove them. (3) Check the gear surface of reducer for abrasion every three months and apply grease on the gear surface. NOTE: After long-term stop of pump, apply sufficient grease on the ball-bearing slewing ring. Checking the connecting bolts on the ball- bearing slewing ring (1) Check the torque condition for the fasteners (a) on the rotary tower system every 1000 hours of operation or every year. (2) The tightening torque for the slewing bearing fasteners is 1,210 N.m (892 lbf.ft). Visually inspect all connecting bolts on the ball-bearing slewing ring for looseness, ware or damage. Any missing bolts should be replaced. NOTE: The loosened connecting bolt of ball- bearing slewing ring should not be directly tightened. Replace it with new high-strength bolt of the same size. Oil the thread and the head bearing surface and tighten the replacement bolts. 6.7 Transfer Case and Drive Shaft The transfer case is used to switch the power output, and transfer power to the chassis during traveling as well as the oil pump during concrete pumping. SYG5360THB 47 6-68 Maintenance 6.7.1 Transfer case The structure of transfer case is as shown in Fig. 6-56. Daily inspection and maintenance of transfer case Check the lubricating oil for transfer case and the pre-tightening torque for the bolts for connecting the drive shaft and transfer case as well as the bolts of the transfer case hanger, and fill lubricating grease to the extension section of drive shaft once every week or every 50 working hours. (1) After the pump is placed horizontally, close the engine and cut off the power supply to avoid unauthorized starting. (2) Check two stroke switches and cables on the transfer case for readiness, water resistance and insulation. (3) Check the tightening torques of bolts connecting the drive shaft and transfer case and transfer hanger bolt for looseness. If any, tighten them. 1 2 3 Fig.6-56 Transfer Case [1] Oil filler connector [2] Plug at oil level checking port [3] Plug at oil-drain outlet SYG5360THB 47 6-69 Maintenance CAUTION When the lubricating oil level in the transfer case exceeds the required position, the transfer case will easily generate heat when working, so as to make the lubricating oil easily get bad, affecting the lubrication of inner gear and bearing of the transfer case. In case of serious situation, the bearing and tooth surface of gear will be burnt out due to bad lubrication. Changing the transfer case oil Change the lubricating oil of transfer case every 500 hours of operation or every half year and clean the transfer case. Remove dirt and hazardous substance to ensure the reliable operation of transfer case. (1) Park the truck-mounted concrete pump flatly, shut down the engine and cut off the power to avoid unauthorized startup. (2) Screw off the plug at oil-drain outlet to drain the lubricating oil in the transfer case. (3) Screw off the breathing cover and fill appropriate volume of diesel oil into the transfer case to remove the deposits and dirt inside. The breathing cover of transfer case filler pipe is at the inner side of the revolving tower (see Fig. 6-57). (4) Collect the drained lubricating oil with a proper container, and then dispose it according to the relevant environmental protection regulations. (5) Mount the plug at the oil-drain outlet. (6) Fill gear oil of the appropriate grade from the oil filler at the breathing cover till it reaches the bottom of oil level checking port of the transfer case and some oil overflows. Breathing cover Fig.6-57 Schematic Diagram of Breathing Cover of Transfer Case Filler Pipe SYG5360THB 47 6-70 Maintenance (7) Mount the plug at oil level checking port and the breathing cover. (8) Start the truck-mounted concrete pump and check if the transfer case works normally. 6.7.2 Drive shaft Use a grease gun to apply lubricating grease to the extension section of the front/rear drive shaft and the cross bearing of the transfer case once a week (See Fig. 6-58). Check the pre-tightening torque for the connecting bolts of drive shaft and transfer case, gearbox and differential, etc. Check if the seal rings of cross bearings at both ends of drive shaft are in good condition. Connecting to transmission Connecting to rear axle Fig.6-58 Drive Shaft SYG5360THB 47 6-71 Maintenance 6.8 Hydraulic System The hydraulic system is composed of the hydraulic pump, valve bank, accumulator, hydraulic motor, oil cylinder, line, etc. When pumping, carefully observe the working status of hydraulic system, e.g. if the hydraulic fluid temperature is normal, the operation of radiator is normal and if the oil pump and motor have abnormal noise, etc. 6.8.1 Overview Fig.6-59 Structural Drawing of Hydraulic Oil Tank [1] Air filter [2] Oil-drain valve [3] Oil level gauge [4] Oil filler [5] Hydraulic oil tank 3 1 4 5 2 SYG5360THB 47 6-72 Maintenance 6.8.2 Changing the hydraulic fluid NOTE: Cleanliness is of the greatest possible importance in the maintenance of hydraulic systems. You must make it impossible for dirt or other impurities to enter the system. Even small particles may cause valves to be scored, pumps to seize and choke and control bores to become blocked. Hydraulic fluid drums must stand for some time before the fluid is taken from them. Never roll the barrels to where you will be drawing off the fluid. Clean bungs, filler caps and their surroundings before opening them. If possible, you should use a filler unit to fill up the hydraulic system. Never leave the tank lid open longer than necessary. Preparation The following work must be completed before starting the full fluid change: (1) Switch off the remote control. (2) Switch the hydraulic pumps off. (3) Reduce fluid pressure completely. (4) Check the contamination indicator on the vent filter of the fluid reservoir. When the red check ring is visible in the inspection glass, you must replace the filter element for the vent filter .Close the engine. (5) Switch the drive engine off. (6) Secure the system against unauthorized starting. (7) Secure your working area and fix notices to the blocked controls and setting devices. SYG5360THB 47 6-73 Maintenance WARNING The accumulator pressure in pressurized systems must be released. Failure to do so may result in a sudden rupture in the accumulator or even endanger persons. Changing the fluid NOTICE You must make sure you collect the old hydraulic fluid and dispose of it in accordance with the regulations. Biologically degradable hydraulic fluids must also be disposed of separately from other waste, just like mineral hydraulic fluids. Failure to do so will result in pollution to the environment. (1) Remove a hose from the hydraulic system tank and drain off the fluid. Position of the drain valve. (2) hen disconnect all hoses from the tank. (3) Wipe out all the openings with a lint-free cloth. Wipe as far into the tank as possible when doing this. You should also remember that there may also be separate apertures intended for tank cleaning. (4) Remove all filter inserts. (5) Change all filters and refit the filter elements. SYG5360THB 47 6-74 Maintenance NOTICE Only fill the tank through the mesh in the filler inlet. Fill up the tank up to the Maximum" marking after bleeding and a test run. Use only the hydraulic fluids specified in the lubrication recommendations. Failure to do so may result in instability in operating positions or serious damage to the machine. (6) Replace any defective hoses. (7) Fill the tank with new fluid. (8) Remove the dirt deposits from the oil cooler. (9) Check all screwed joints and tighten where necessary. Check all flared screwed joints. (10) Check the electrical connections. (11) Carry out all function checks. (12) Bleed hydraulic system. (13) Carry out several test runs. (14) Refit all the safety equipment, markings and notices you have removed. Draining the hydraulic oil tank (1) Remove the vent filters (b) from the hydraulic tank fill port (a). (2) Locate the drain locations (c) below the pump chassis hydraulic tank on the left side of the unit. See Fig. 6-61for the position of (c). (3) Place an appropriate container under the drain port. NOTE: For proper container size, see Table. 6-10 on page 6-19 for details. Fig.6-60 Fig.6-61 c e d 52 b a SYG5360THB 47 6-75 Maintenance (4) Remove plug (d) and open valve (e) to drain the hydraulic oil from the tank. See Fig. 6-61 for the position of (d) and (e). Cleaning and inspecting the hydraulic tank (1) Remove covers (f) to inspect or clean the inside of the tank sections after it has been emptied. NOTICE Never use water or toxic liquids to clean the inside of the tank. These chemicals could damage the system. (2) If you will be cleaning the tank, it is recommended to use mineral spirits to wash the inside of the tank. (3) Once the tank is clean and dry, reinstall access covers (f). (4) Close valve (e) and reinstall plug (d). See Fig.6-61 for the location of e and d. (5) Refill hydraulic tank with fresh oil through the vent fill ports on the top of the tank. NOTE: For fluid type and amount, see table 6-9 on page 6-17 and table 6-10 on page 6- 19. (6) Install the vent filter and resume normal operation. 6.9 Accumulator 6.9.1 Overview The accumulator is composed of housing, capsule, oil valve, gas valve, etc. (see Fig. 6- 63). Common sense about the use of accumulator: Fig.6-62 1 2 3 4 Fig.6-63 Structure of accumulator [1] Gas valve [2] Capsule [3] Housing of accumulator [4] Oil valve f SYG5360THB 47 6-76 Maintenance (1) The rubber capsule storing nitrogen in the accumulator has slight gas permeability. After using for a certain time, the gas pressure will decrease; therefore the working pressure of accumulator should be checked at least once every year. When the oil temperature is 50°С, its pressure is 7MPa (68.6bar). The permissible pressure range of accumulator (see Fig. 6-64). (2) If the actual value is 75% or less than specified value, the accumulator must be filled with gas.(3) The accumulator can only be filled with nitrogen. Never use other gases.(4) The working pressure, gas filling pressure and capacity (See Table. 6-12). NOTICE The checking and oil filling work of accumulator must be performed by professional person to avoid nonstandard operation. DANGER The accumulator should be filled with nitrogen. Never use other gases. If it is filled with air, nitrogen, etc., explosion may occur. Table 6-12 Charging Pressure and Capacity Working Pressure Charging Pressure Capacity 16MPa 7-8 MPa 10L Air pressure bar (MPa) Upper limit Allowable pressure range Lower limit oil temperature (°C) 0 10 30 50 70 44.1 (4.5) 49 (5) 53.9 (5.5) 58.8 (6) 63.7 (6.5) 68.6 (7) 78.4 (8) Fig.6-64 Allowable Pressure of Accumulator SYG5360THB 47 6-77 Maintenance 6.9.2 Checking the nitrogen pressure of accumulator How to test the nitrogen pressure of the accumulator when no gas filling equipment is available: (1) Start the machine to build the pressure in accumulator until it reaches 10MPa. (2) Press E-STOP button. (3) Slightly open the unloading ball valve of accumulator to slowly relieve pressure in the accumulator. With the gradually relieving pressure in accumulator, the pointer on the pressure gauge will move slowly. As soon as the pre-filled pressure of accumulator is reached, the reading on pressure gauge will suddenly decrease, that is, the indication at this time is the nitrogen pressure in the accumulator. (4) If the nitrogen pressure in the accumulator is not between 7-8MPa, adjust it to 7-8MPa. 6.9.3 Nitrogen filling and pressure adjustment of accumulator (1) Preparation work before nitrogen filling: ● remove the gas filling gap and protective hood from the accumulator; ● turn the handle of gas filling tool anti- clockwise to the end position and then connect it to the gas filling valve on the accumulator; ● Connect the joint at another end of hose to the nitrogen bottle. (2) Gas filling or gas supplement: screw in the handle of gas filling equipment clockwise until the pressure gauge on the gas filling SYG5360THB 47 6-78 Maintenance equipment displays pressure; then slowly open the cut-off valve on nitrogen bottle to gradually fill nitrogen in the capsule, and then close the cut-off valve on the nitrogen bottle. Observe the pressure gauge on the gas filling equipment and repeat above procedure until the reading reaches the upper limit in figure; unlock the vent valve on the gas filling equipment to discharge the remained nitrogen; disassemble the gas filling equipment; check the gas filling valve for leakage; if not, install gas filling cap and protective hood. (3) Gas discharging or adjustment: open the vent valve; turn the handle clockwise to allow the crown bar to open the vent valve core downwards for discharging gas; when the gas discharging is completed, turn the handle back to the original position; remove the gas filling equipment; check the gas filling valve for leakage; if not, install the gas filling cap and protective hood. The method of pressure adjustment is similar to that of gas filling. If the pressure is high, operate as per gas discharging procedure; if the pressure is low, operate as per gas supplement procedure. (4) Temperature compensation of nitrogen: the gas pressure changes with the temperature. The gas pressure of accumulator at 50 ℃ is set as 7MPa (68.6bar). For gas filling at normal temperature, adjust in accordance with figure; for general inspection, observe the hydraulic fluid temperature, e.g. if pressure is lower than the lower limit, refill gas. SYG5360THB 47 6-79 Maintenance 6.10 Oil Filter 6.10.1 Replacing hydraulic oil filters Cleanliness is a key factor in maintenance of hydraulic system.If the hydraulic oil is polluted, the hydraulic system will not work normally For new vehicle, oil return filter element GP must be replaced when running 500h.After that, oil intake filter and oil return filter element GP must be replaced every 1000h. When replacing hydraulic oil, oil intake filter and oil return filter element GP should be changed, either. You should obey local effective regulation when dealing with old filter core Replacing oil return filter element (1) Release pressure, stop the machine and cut off the power. (2) Remove the bolt on the oil-return cover of hydraulic oil tank. (3) Remove the oil-return cover. (4) Get out the oil return filter element GP from the oil tank. (5) Reinstall the new oil return filter element GP into the oil tank. (6) Put the oil-return cover back and tighten all bolts. Replacing and cleaning oil intake filter) (1) Release pressure, stop the machine and cut off the power. (2) Remove the bolt on the oil-intake cover of hydraulic oil tank. (3) Remove the oil-intake cover. Fig.6-65 Oil intake Filter [1] Compressing spring [2] Nut [3] Plan cushion [4] Spring cushion [5] Nut [6] Tie rod [7] Filter core [8] O-ring SYG5360THB 47 6-80 Maintenance (4) Get out the oil intake filter from the oil tank and remove the filter core. (5) Reinstall the new oil intake filter on tie rod. Please notice the fitted position requirements when assembling, You should obey the rule that the pin on oil-intake cover can be pressed tightly to the tie rod. (6) Put the assembled oil intake filter into the oil tank. (7) Put the oil-intake cover back and tighten all bolts. NOTICE You should make sure the fitted position unchanged when assembling the oil intake filter element. If the fitted position is greater than the specified, the oil-intake cover will cannot be covered. If the the fitted position is less than the specified, the oil-intake filter will might be dumped in the oil tank. The cleaning method of oil intake filter: Immerge the filter core into the coal oil for 10 minutes, Get out. the core and blow it from inside to outside by compressed air which is <=0.6MPa until the exterior surface of the filter core is cleaned. NOTICE It is prohibited that contacting with the filter core by such things as hand and brush that might lead screen to deform and break down. If deformation and breakage happed, replace the filter core immediately. SYG5360THB 47 6-81 Maintenance Replacing high pressure filter element) If high pressure filter is installed, you should often check whether blocked. When the indicator shows red, the filter core must be replaced (The core of high pressure filter cannot be cleaned, replace only). Steps as follows: (1) Release pressure, stop the machine and cut off the power. (2) remove canister (a) and get out the hydraulic filter element (3) Clean the canister inside. (4) Reinstall new filter element and canister (a) NOTE: When installing the filter cartridge, if the threads are not aligned, the screwing of filter cartridge will immediately be subjected to large resistance. Do not apply excessive force and the installation threads of filter cartridge should not be damaged. Draw back the filter cartridge, realign the tread and screw it to install it. When the filter cartridge is tightened to the end position, it should be unscrewed by 1/4-1/2 turn. 6.11 Air Filter The air filter is located on the hydraulic fluid tank of revolving tower (see Fig. 6-67). Since the construction site has plenty of dust, the air filter should be replaced every year. The air filter is integrated with its filter element. For replacement, remove the old filter and just install a new one. NOTICE Treat the old filter in accordance with the local regulation to avoid the pollution to the environment. a Fig.6-66 Fig.6-67 Air Filter SYG5360THB 47 6-82 Maintenance 6.12 Hoses WARNING Check all hoses (including hose fittings) with the machine running. The hoses at the slightest sign of damage or even mere indications of threatened damage must be replaced. Know the maximum pressure that your machine can exert on the concrete, and be sure that the hoses, pipes and clamps are capable of handling the pressure. Failure to do so may result in a sudden rupture in the hose or piping system or hose end-swing and personal injury. 6.12.1Checking the hoses (1) Hydraulic hose (see Fig. 6-68) Check the hydraulic hose: Dark and moist patches on the fitting are external signs of incipient damage, and carefully check: a. The hose for any defect, break or porous surface. b. The coupling of hose for tightness. c. The middle part of hose is nonmetal. The hose should be prevented from aging due to strong sunlight, thermal effect and chemical action. NOTE: Hoses should not be more than six years old, including a storage time of two years. Take note of the date of manufacture on the hoses. (2) hose joints a. Check the house joint for tightness. b. The hose joints with leakage only can be tightened with the permissible torque. If Fig.6-68 SYG5360THB 47 6-83 Maintenance no torque wrench is available, tighten the joint until hand feels obvious increment of force. If the leakage can not be stopped, replace these hose joints. 6.12.2Replacing the hoses The procedure for replacing hoses is as follows: (1) Close the engine. (2) Completely relieve the residual pressure in the hydraulic system. (3) When disassembling the hose joints, slightly open it to allow the hydraulic fluid to flow out. After relieving the residual pressure of hydraulic fluid in hose, continuously disassemble the hose. (4) Take care when undoing the joints. (5) Close the connection points with a plug immediately you have removed the old hoses. No dirt may enter the hydraulic circuit and the hydraulic circuit must not run empty. Collect the overflowed oil with a vessel and treat it in accordance with the environment protection requirements. (6) Keep the hoses free from dirt. (7) Fit the hoses to be free from bends or points of abrasion. (8) Bleed the hydraulic system. (9) Carry out a test run and inspect all hoses again after fitting new hoses. CAUTION The hydraulic line can not work without oil. The inner of new house should be clean and free of dust. The crooked hydraulic hose is subjected to mechanical pre-stressing force; therefore, the hose SYG5360THB 47 6-84 Maintenance will rebound when disassembling and lead to injury. 6.12.3Identifying the hoses The hose is composed of the hydraulic hose in the middle and joints at both ends (1) Type of hose 1SB —- hydraulic rubber hose wrapped with a layer of steel wire. 2SN—- hydraulic rubber hose wrapped with two layers of steel wire. 4SP —- hydraulic rubber hose wrapped with four layers of steel wire (medium pressure). 4SH —- hydraulic rubber hose wrapped with four layers of steel wire (high pressure) (2) Identification of hose The related specifications of hose produced by Sany Heavy Industry Co., LTD can be obtained from the name of material. Take hose 4SP20-DKOS-DKOS90-1000- V90-XXX for example: 6.13 Electrical System The electrical system is composed of the control cabinet, remote control, control box, harness, etc. Periodically check the cables on the plug of electromagnetic valve, joint of Rubber hose 4SP20-DKOS-DKOS90-1000-V90-XXX Rubber hose type Type of accessory Type of connector at one side Mounting angle Type of connector at the other side Assembly length SYG5360THB 47 6-85 Maintenance sensor, terminal row, toggle switch, instrument, etc. for tightness. WARNING The electrical cables can not connect other unauthorized electrical elements. Failure to do so may result serious damage to the elements or even personal injury. 6.13.1Electric control cabinet The electric control cabinet is the key part of pump truck control system and composed of the electrical control cabinet body, SANY motion controller assembly (SYMC), Central Power Distribution Box, SANYcomunication display (SYCD), etc. (see Fig.6-69).Check and maintenance interval (see table 6-1 on page 6-4). SYG5360THB 47 6-86 Maintenance CAUTION Do not put other items in the electric control cabinet, e.g. tool, gloves to avoid disrepair to the items inherent in the electric control cabinet. The door of electric control cabinet is generally closed. Do not open it casually. In addition, the inner of cabinet should also be dry and protected from rain water and washing. Failure to do so may result in the circuitry or connection in the electric control cabinet to be affected with damp. Fig.6-69 Structural Drawing of Electric Control Cabinet [1]Electric control cabinet body [5]Emergency stop [6]SYCD display [3]Central distribution box [4]SYMC special controller [2]Circuit board assembly SYEB 1 2 3 4 6 5 7/8 [7]SANY Truck pump electric plate SYMCEB [8]SANY Truck pump electric plate SYEB SYG5360THB 47 6-87 Maintenance CAUTION When repairing other components, if welding work is required, the general switch of power supply for chassis should be closed, and the ground wire of welder should be directly connected to the part to be welded so as to avoid damage to the electrical elements in the electric control cabinet. (1) Periodically check the connection of relay and box for tightness. If the relay is damaged, replace it with new one of the same specification. (2) If trip occurs in the circuit breaker, timely check the circuit to find the reason. When short-circuit or other faults of circuit are eliminated, replace it with new circuit breaker of the same specification. If you have any question about the specification of circuit breaker and in the event of circuit fault, connect the after-sale service engineer in time. (3) Periodically check the connections between plug board and central power distribution box, electric circuit board, SANY motion controller (SYMC), SANY comunication display (SYCD) and aviation plug for tightness. If any, tighten it timely. WARNING When replacing the circuit breaker, only the circuit breaker of the same specification can be adopted. Never use product with current larger than specified value. Failure to do so may result in serious damage to the circuitry or even injury to persons. SYG5360THB 47 6-88 Maintenance 6.13.2Maintenance operation box The maintenance operation box is located on the main support of boom and mainly used to operate the pump truck when checking and maintaining it (see Fig. 6-70). Check and maintenance interval (see table 6-2 on page 6-5). (1) Periodically check the E-STOP button of maintenance operation box, push-button switch and aviation plug for tightness. If any, tighten it in time. (2) Periodically check the waterproof seal between the panel and box. If necessary, replace it. NOTICE The maintenance operation box is generally closed. Do not open it casually. The inner of operation box should be dry and protected from rain water and washing. Failure to do so may result in the circuitry or connection in the maintenance operation box to be affected with damp. CAUTION After every construction, the concrete on maintenance operation box panel should be timely cleaned; otherwise it will cure at the acting position of switch and result in malfunction of switch which may cause injury to persons or machines. Do not damage switch and its wire during construction or handling items. Fig.6-70 Control Box for Maintenance SYG5360THB 47 6-89 Maintenance 6.13.3Small operation box The small operation box is located near the main support of the platform and convenient for operating this pump truck when pumping (see Fig. 6-71). Check and maintenance intervals (see table 6-2 on page 6-5). (1) Periodically check the E-STOP button of small operation box, toggle switch and aviation plug for tightness. If any, tighten it in time. (2) Periodically check the waterproof seal between the panel and box. If necessary, replace it. NOTICE The maintenance operation box is generally closed. Do not open it casually. The inner of operation box should be dry and protected from rain water and washing. Failure to do so may result in the circuitry or connection in the maintenance operation box to be affected with damp. CAUTION After every construction, the concrete on maintenance operation box panel should be timely cleaned; otherwise it will cure at the acting position of switch and result in malfunction of switch which may cause injury to persons or machines. 6.13.4Outrigger operation box The outrigger operation box is mainly used to conduct related operation on outrigger through cooperating with the multi-way valve of outrigger (see Fig. 6-72). In the event of emergency, the E-STOP button on panel can be used to ensure the safety of equipment. Fig.6-71 SYG5360THB 47 6-90 Maintenance Check and maintenance intervals (see Table 6-2 on page 6-5) (1) Periodically check the installation screw of support operation leg for tightness. If any, immediately tighten the screw to ensure it is reliably secured. (2) Waterproof seal is used between the operation box panel and box. If the fixing screw of panel is loosened, check the seal. If necessary, replace it and then tighten the installation screw of panel. (3) Periodically check the E-STOP button of operation box, toggle switch, and aviation plug for tightness. If any, tighten it in time. CAUTION After every construction, the operation box panel should be timely cleaned; otherwise the concrete will cure at the acting position of E-STOP button or push- button switch and result in malfunction of switch. 6.13.5Mechanical encoder The mechanical encoder is used to measure and limit the rotation control angle of boom (see Fig. 6-73). Check and maintenance intervals (see Table 6-2 on page 6-5) (1) Apply grease on the slewing part of mechanical encoder every 50 hours of operation or every week. (2) Periodically check the working condition of two sensors on the mechanical encoder and the sensing distance of sensor (less than 5mm); if the installation nut of sensor is loosened, re-adjust the measuring distance of sensor and tighten it. 3 2 1 Fig.6-72 Control Box for Outriggers [1] E-STOP button [2] Toggle switch [3] Control box 1 2 3 Fig.6-73 Mechanical Encoder [1] Sensor [2] Mechanical encoder [3] Rotary reducer SYG5360THB 47 [2] [3] [1] [2] Seal ring 6-91 Maintenance (3) Periodically check the tightening condition of plug board of mechanical encoder and harness for tightness. If not, tighten it timely; the plug board should be fixed with the harness to prevent the wire from disconnecting. (4) After every maintenance operation of mechanical encoder, re-fix the wire to avoid damage caused by gear. 6.13.6Temperature sensor The temperature sensor is used to measure the hydraulic fluid temperature. Its measuring range is -30°C~90°C(see Fig. 6-74. In the event of fault in temperature sensor, timely check the connection between sensor and plug board of harness for tightness. In the event of fault in sensor itself, replace it timely. NOTE: The pump truck is furnished with 2 temperature sensor. When the display shows the temperature sensor 1 has fault, switch the default setting of control system to the temperature sensor 2 through the operation of display to ensure the normal operation of construction. 6.13.7Liquid level sensor The liquid sensor is used to measure the water level in the water tank. If the water level is too low, the water pump will stop (see Fig. 6-75). (1) Periodically check the connection between the liquid level sensor and plug board for tightness. If not, secure it timely. (2) If the water tank is fully filled with water but the liquid level sensor is not active, it may be stuck in the water tank or has been damaged. Adjust or replace it in time. Fig.6-74Temperature Sensor [3] H ydraulic oil tank Fig.6-75 Liquid Level Sensor [1] Rear outrigger Temperature sensor Water drain ball valve Liquid level gauge SYG5360THB 47 6-92 Maintenance 6.13.8Limit switch of boom The limit switch of boom is used to control the downward stroke of boom and provide limit protection (see Fig. 6-76). Periodically check the limit switch arm of boom to ensure the flexible rotation. In the event of failure to reset or coupling stagnation of rotation, replace it timely. NOTICE Do not put items on the limit switch of boom; otherwise the controller will receive the wrong information and influence the motion of boom. CAUTION After every construction, the concrete on limit switch of boom should be timely cleaned; otherwise it will cure at the acting position of switch and result in malfunction of switch. Do not damage switch and its wire during construction or handling items. 6.13.9Limit switch of outrigger The limit switch of front outrigger and limit sensor of rear outrigger are used to control the withdraw stroke of outrigger and provide limit protection (see Fig. 6-77 and Fig. 6-78). (1) Periodically check the connection between the limit switch of outrigger, sensor and plug board of harness for tightness. If not, secure it timely. (2) Periodically check the installation nut of limit sensor of outrigger and sensing distance of sensor (less than 5mm) for tightness. If not, adjust and tighten it timely. Fig.6-76 Boom Limit Switch Fig.6-77 Limit Switch of Front Outrigger Fig.6-78 Limit Sensor of Rear outrigger SYG5360THB 47 6-93 Maintenance (3) Periodically check the limit switch arm of front outrigger to ensure the flexible rotation. In the event of failure to reset or coupling stagnation of rotation, replace it timely. 6.13.10 Limit switch of transfer case The limit switch of transfer case is used to switch the pumping and traveling status. If this limit switch has fault, the pumping may not be conducted (see Fig. 6-79). (1) Periodically check the transfer case switch for tightness. If not, secure it timely. (2) If the transfer case switch can not be turned to desired position or has damage, adjust or replace timely. 6.13.11Rocker switch The rocker switch is located in cab (see Fig. 6-80). Periodically check the performances of rocker switches for general power supply, pumping, traveling, etc. If some plug board for switch is loosened, secure it timely. NOTE: When switching the pumping and traveling status, the chassis gearbox must be in neutral position. Never conduct forced switching under when putting into gear. Fig.6-79 Limt Switch of Transfer Case 1 2 3 Fig.6-80 Rocker Switches in Cab [2] Switch for pumping [3] Switch for travelling Switch power supply of electric control cabinet [1] SYG5360THB 47 Fig.6-82 Wire electrical elements (see Fig. 6-82). 6.13.13Wire 6-94 Maintenance 6.13.12Electromagnetic valve and its plug Periodically repair the electromagnetic valve to ensure the normal operation of equipment (see Fig. 6-81). (1) The plug of electromagnetic valve has its own working indicator. When the power supply is switched on, the indicator will be on, by which the following reasons for malfunction of electromagnetic valve can be confirmed: circuit fault or electromagnetic valve fault. (2) In order to prevent the installation screw for plug of electromagnetic valve, the installation hole is filled with silica gel. When the plug of electromagnetic valve is removed for maintenance, re-fill the silica gel and re- tighten the screw. Fig.6-81 Boom Multi-way Valve [1] Electromagnetic valve for switch-over between outrigger and air cooler [2] Rotary electromagnetic valve [3] Electromagnetic valve for arm 1 [4] Electromagnetic valve for arm 2 [5] Electromagnetic valve for arm 3 [6] Electromagnetic valve for arm 4 [7] Electromagnetic valve for arm 5 The wire is used to connect different (1) Periodically check the plug board of wire and the seal of three-way and corrugated tube outside the wire. If one of them is loosened, secure it timely. (2) Remove concrete and foreign matters on wire timely to avoid prevent circuit from damage. (3) During construction and maintenance, carefully protect the circuit from the damage of circuit or failure in seal structure caused by external force. SYG5360THB 47 6.13.14Wireless remote control system 6-95 Maintenance The maintenance, care and service of wireless remote control system are conducted as per the maintenance manual supplied by the manufacturer of this remote control system. In addition, the safety operation is conducted as required by the manufacturer of remote control system. Plug to completely drain off water in the cleaning room and draw out the piston head to conduct cleaning and checking. The cleaning room should be clean and no deposit is allowed on the piston rod of oil cylinder. During forward pumping or reverse pumping, if water in the cleaning room is muddy, immediately stop the machine and check the concrete seal. During pumping, if the water temperature in the cleaning room is too high, timely replace with fresh water. SYG5360THB 47 6-96 Maintenance CAUTION For construction in cold weather, e.g. winter, completely drain off water in the cleaning room to avoid icing to damage to machine. CAUTION Do not add lithium-based grease in the cleaning room; otherwise the hydraulic system is easily be polluted and faults will frequently occurs. SYG5360THB 47 6-97 Maintenance BLANK PAGE SYG5360THB 47 6-98 Maintenance BLANK PAGE SYG5360THB 47 7-1 Specifications 7 Specifications 7.1 Technical Data ..................................................................................................7-3 7.2 Dimension .........................................................................................................7-5 7.3 Boom Operating Range ....................................................................................7-6 Specifications SYG5360THB 47 7-2 Specifications WARNING Always read the Safety section of this manual before attempting to operate this equipment. Failure to do this could result in machine damage, personnel injury or death. SYG5360THB 47 Total weight 36450 0kg Reach depth 29.3 m Length 8545mm Length 9670 mm Horizontal reach 42.0 0 . 7 4 h c a e r l a c i t r e V 7-3 Specifications 7 SPECIFICATIONS 7.1 Technical Data Overall Parameters m m 0 0 5 2 1 h t g n e L m m 0 0 5 2 h t d i W m m 0 0 0 4 t h g i e H Boom and Outrigger Specifications m 9 . 3 1 h c a e r g n i d l o f n u m u m i n i M 1 st section m m 0 6 7 9 h t g n e L ° 9 8 n o i t a l u c i t r A 2 nd section m m 0 7 6 7 h t g n e L ° 0 8 1 n o i t a l u c i t r A 3 m m 0 1 4 7 h t g n e L ° 0 8 1 n o i t a l u c i t r A 4 th section ° 5 3 2 n o i t a l u c i t r A 5 th section ° 5 1 2 n o i t a l u c i t r A ° 0 6 3 ± n o i t a t o R m m 0 0 3 9 t n o r f - R - L d a e r p s r e g g i r t u O m m 0 2 6 9 r a e r - R - L d a e r p s r e g g i r t u O m m 0 4 2 9 H L n o r a e r - t n o r f - h t d i w d a e r p s r e g g i r t u O m m 0 4 2 9 H R n o r a e r - t n o r f - h t d i w d a e r p s r e g g i r t u O SYG5360THB 47 Low pressure 29 times/min 7-4 Specifications Chassis specifications brand s i s s a h C l e d o m e n i g n E Engine maximum net power I I I o r u E d r a d n a t s n o i s s i m E L 0 0 4 y t i c a p a c k n a t l e u F t u p t u O h / m k 0 8 d e e p s m u m i x a M Pump Specifications Output Low pressure 170 m 3 /h High pressure 120 m 3 /h Delivery pressure a P M 3 . 8 e r u s s e r p w o L a P M 2 1 e r u s s e r p h g i H Strokes/min High pressure 19 times/min m m 0 6 2 r e t e m a i d r e d n i l y c y r e v i l e D m m 0 0 9 1 h t g n e l e k o r t S p o o l n e p O m e t s y s c i l u a r d y H a P M 2 3 e r u s s e r p l i o m e t s y S L 0 8 6 y t i c a p a c k n a t l e u F L 0 2 6 y t i c a p a c k n a t r e t a W m m 5 2 1 e z i s e n i l e p i P m 3 h t g n e l e s o h d n E m m 5 2 1 r e t e m a i d e s o h d n E BENZ 300kW/1800rpm 11.946 L OM501LA. III/17 Chassis model Actros 4141 SYG5360THB 47 7-5 Specifications 7.2 Dimension 5.9m 9.3m 6.06m 9.24m Fig.7-1 12500mm 4000mm 1440mm 2020mm 4280mm 1350mm SYG5360THB 47 7-6 Specifications 7.3 Boom Operating Range Fig.7-2 SYG5360THB 47 7-7 Specifications BLANK PAGE SYG5360THB 47 7-8 Specifications BLANK PAGE SYG5360THB 47 8-1 Appendix 8 Appendix 8.1 Hydraulic Basic Diagram ..................................................................................8-3 8.2 Electrical Basic Diagram ...................................................................................8-5 Appendix .........8-14 8.3 Specifications of twin pipes ........................................... .............. ............. SYG5360THB 47 8-2 Appendix WARNING Always read the Safety section of this manual before attempting to operate this equipment. Failure to do this could result in machine damage, personnel injury or death. SYG5360THB 47 8-3 Appendix 8 APPENDIX 8.1 Hydraulic Basic Diagram Fig.8-1 Basic Diagram of Pumping Hydraulic System SYG5360THB 47 8-4 Appendix Fig.8-2 Basic Diagram of Boom Hydraulic System SYG5360THB 47 8-5 Appendix 8.2 Electrical Basic Diagram General electrical schematic diagram，which are subject to actual configuration. Fig.8-3 Basic Diagram 1 of Power Supply Distribution CAN Communication interface SYG5360THB 47 8-6 Appendix Fig.8-4 CAN Communication interface Basic Diagram 2 of Power Supply Distribution 2 SYG5360THB 47 8-7 Appendix Fig.8-5 Basic Diagram 3 of Power Supply Distribution Key Switch of Chassis NOTE(4F): 15 corresponds to Benz\MAN\ISUZU chassis; 37F corresponds to VOLVO chassis. Storage Battery reverberator Side Marker Lamp Upper- structure horn chassis horn Controlling power supply start Remote Control power supply Remote Control E-stop Main spillover valve E-stop Bypass Valve E-stop Controlling power supply Work Lamp in hand engine flameout Chassis Odometer Signal switchover GPS Trigger Local Control E-stop Chassis or SYG5360THB 47 8-8 Appendix Fig.8-6 Basic Diagram of SYMC 1 position switch running position pump position position indicator running position pump position engine gearbox Speed meterage Speed Governing Speed cruise cruise speed, increase speed, decrease Left Right Left Right Main oil pump (front pump) Main oil pump (rear pump) High pressure Left Right accumulator oil inlet, right oil inlet, Left Main cylinder , reversing, high-pressure agitate Forward Backward Flushing valve Oil fill valve Low-pressure High-pressure Blower remote power Main spillover valve low pressure Swing cylinder reversing Main cylinder , reversing, low-pressure oil inlet, right oil inlet, Left return piston return piston 1 return piston 2 Inductive Switch, pumping Inductive Switch, Running Switch, water level small operation box pump farward pump backard pressure high/low remote control water pump agitate horn Discharge increase Discharge reduce maintenance operation box swing cylinder move rightward move leftward main cylinder move leftward main cylinder move rightward preheat switch manual speedup manual speeddown piston exit piston reset agitate reverse Sensor, pressure main system accumulator agitate system Emergency stop Remote manual swing cylinder temperature sensor tempera ture 1 tempera- ture 2 Hydraulic oil level detection Forcible drainage Oil Pressure Gauge to chassis control interface circuit SYG5360THB 47 8-9 Appendix Fig.8-7 Basic Diagram of SYMC 2 to Coil KA6 to Coil KA18-2 to Coil KA18-1 Arm(1) extension Arm(1) retraction Arm(2) extension Arm(2) retraction Arm(3) extension Arm(3) retraction Arm(4) extension Arm(4) retraction Arm(5) extension Arm(5) retraction Arm(6) extension Arm(6) retraction rotate leftward rotate rightward outrigger valve bypass valve left limit right limit Antiswing valve Boom pump up part horn chassis horn Multiple valve of boom arm rotary protect,valve group engine flameout outrigger position detection left front left rear r a e r t h g i r t n o r f t h g i r outrigger operation Arm limit switch rod side chamber piston side chamber Boom pump Pressure Arm 5 Emergency stop remote manual Arm 4 rod side chamber piston side chamber Arm 3 rod side chamber piston side chamber Arm 2 rod side chamber piston side chamber Mechanic encoder left proximity switch right proximity switch SYG5360THB 47 8-10 Appendix Fig.8-8 Chassis circuit of BENZ (optional) SYG5360THB 47 8-11 Appendix Fig.8-9 Chassis circuit of U Z U S I (optional) engine throttle control circuit SYG5360THB 47 8-12 Appendix Fig.8-10 Chassis circuit of O V L O V (optional) SYG5360THB 47 8-13 Appendix Fig.8-11 Chassis circuit of N A M (optional) SYG5360THB 47 designed the specification. n o i t c u d e r e h t d n a t l u a f 2 1 8 2 1 8 the scope of the warranty of Hunan SANY to install, the consequences will be not within If it is not in accordance with the instructions manufacturers of concrete pump. Cannot rdance with the requirements of equipment pipe which is installed or increased is in acco- Must ensure that the weight of the conveying the cost for customers and avoid misoperation Zhongyang Machinery Co., Ltd. To regulate the use of twin pipes, bring down Fig. - ) (1) Fig. - angle offset which lead to premature failure,warranty period 8.3 Specifications of twin pipes exceed the weight limit. 8.3.1Installation Instructions Appendix 8-14 the pipes are not axially offset or at angle with each other.If this is not the case, the joints and flanges will be unequally stressed. of service life, specially During the installation and operation of the individual pipeline components,make sure that the axes of the joint collars. Thereby (see SYG5360THB 47 Fig.8-14 on the conveying pipe. (see Fig. 8-14) Fig.8-13 8-15 gradually tapping in order to reduce the impact during assembly, must use soft tools, and to positioned by knocking the conveying pipe the surface of the delivery pipe. If it is needed as stone,hammer,levering tools,etc.) knock on (3) It is forbidden to use the hard objects (such ) 2 ( WARNING Do not use hard objects (such as stone, hammer, , etc.) konck the delivery pipe, otherwise it will lead to dam- nification of the inner tube. Appendix WARNING The centre lines of the respective compone- nts must be aligned and centred with each other.If this is not the case, the joints and flanges will be unequally stressed and single-sidedly overloaded in the event of high internal pressure. During transportation or for assembly and disassembly work,the conveying pipe should be properly handled with care. It is prohibited to throw the pipe to the ground or other hard objects. The direct impact on conveying pipe by the forks of the forklift truck should be av- oided. During transportation, wood or other soft package should be used between pipes. levering tools (see Fig. 8-13) SYG5360THB 47 6 8-16 5 1 8 age protection ring.(see Fig. 8-15) 8-16 ded to dismantle the front pipe to remove If there is a blockage, it is not recommen- (5) (see Fig. ) the inner tube and sleeve wearing of the bloc kage pipe may be in the risk of being rus Fig. - (4) the blockage with quite some force.If must adopt this method,please install the block- WARNING If blockage protection ring is not installed, hed out when the front pipe NOTICE When installed conveying pipe, if there is a direction tab on the conveying pipe, should be strictly in accordance with the direction for installation. Ensure the cleann- turn turn around 1 8 Fig. - The pipe may be wearied unequally in pumping process. It is suggested to rotate the pipe by 180° or change its direction in order to increase the lifetime of the pipe. you ess of the connection head and the mounted surface of the flange. There should not be any sundries caused wear. dismantle to remove the blockage with quite some force. Appendix SYG5360THB 47 8-17 BLANK PAGE Appendix SYG5360THB 47 8 8-1 BLANK PAGE Appendix SYG5360THB 47
