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Operation and Maintenance Manual PDF
Operation and Maintenance Manual PDF
Operation and Maintenance Manual PDF
Trailer-mounted
Concrete Pump
HBT6013C-5S
WARNING
Read and follow the safety precautions and instructions in this manual and on the machine
decals. Failure to do can cause serious injury, death or property damage. Keep this manual
with the machine for reading and future reference.
SANY GROUP
SANY AUTOMOBILE MANUFACTURING CO., LTD.
SANY Industry Town,
Economic and Technological Development Zone,
Changsha, Hunan China 410100
http://www.sanygroup.com.cn
China
Email: sanyservice@sany.com.cn
Tel: 0731- 84031888
Fax: 0731- 84031999
Service Hotline: 4008 87 8318
Complaint Hotline: 4008 87 9318
Overseas
Email: crd@sany.com.cn
Service Hotline (Complaint/Enquiry): 0086 4006098318
© 2015 by SANY Group. All rights reserved. No part of this publication may be reproduced,
used, distributed or disclosed except during normal operation of the machine as described
herein. All information included within this publication was accurate at the time of publica-
tion. Product improvements, revisions, etc., may result in differences between your
machine and what is presented here. SANY Group assumes no liability. For more informa-
tion, contact SANY Group.
SPECIFIC DECLARATION
Information on this manual is used to guide qualified operators to operate and maintain trailer-
mounted concrete pump correctly. Sany expressly bears no liability for any consequence due to
any use not observing the information on this manual.
Use genuine spare parts from Sany. Sany expressly bears no liability for any machine damage
or accident due to the use of untested or unauthorized spare parts or tools.Operate and
maintain parts (such as engine, a/c) on the trailer-mounted concrete pump, and observe related
regulations on Users' guide supplied from their manufacturer.
Sany expressly bears no liability for any machine failure or damage due to force majeure of
natural disasters (earthquake, typhoon) and wars.
Sany cannot predict every circumstance that might involve a potential hazard in operation or
maintenance. Operators and owners should highly attach importance to safety. Local specific
safety rules of the countries may be stricter. If they differ from the regulations on this manual,
observe the stricter one.
Duty of Sany
• Fulfill their promises on after-sales service, and document all maintenance and repair working
done by after-sales service personnel.
• Only after each person involved in the product’s operation, maintenance and repair is trained
and fully understands the Parts Book and Operation and Maintenance Manual, can they
operate and maintain the trailer-mounted concrete pump.
• Ensure the operation and maintenance personnel are qualified and know their related
responsibilities.
• If necessary Sany service personnel have the right to check the trailer-mounted concrete
pump for safety.
• Besides check items regulated by Sany, observe local laws and regulations to check the
trailer-mounted concrete pump.
• 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.
• If there is any abnormal symptom which may cause abnormal working of the trailer-mounted
concrete pump or potential hazard, report to your leader. If possible, correct fault in time.
• All personnel working around the trailer-mounted concrete pump must observe all warning
signals and take care of their own and others' safety.
• Watch something like high voltage wire, unrelated personnel and poor ground for potential
danger, and report to the operators and signalmen.
Duty of managers
• Ensure the operators are trained and fully understand the Operation and Maintenance Manual
supplied by Sany. Ensure they are in physical fitness and have the certification of operation.
Otherwise, it is forbidden to operate the trailer-mounted concrete pump.
• Ensure the operators have good judgment ability, teamwork consciousness and psychological
quality. Otherwise, it is forbidden to operate or repair the trailer-mounted concrete pump.
• Ensure the signalmen have good vision and acoustic judgment, master standard command
signals. At the same time, they should have enough experience in recognizing danger factors
correctly, and inform the operators of danger factors to avoid them in time.
• Ensure assistant workers can identify the model and working condition to choose a proper
trailer-mounted concrete pump.
• Publicize safety consciousness to working personnel, and make them aware of safety
precautions and their related responsibilities.
Table of Contents
HBT6013C-5S
Table of Contents
I
Table of Contents
HBT6013C-5S
II
Table of Contents
HBT6013C-5S
III
Table of Contents
HBT6013C-5S
IV
Table of Contents
HBT6013C-5S
V
Table of Contents
HBT6013C-5S
VI
Table of Contents
HBT6013C-5S
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Table of Contents
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INTRODUCTION
HBT6013C-5S
1 INTRODUCTION
● SANY-built equipment offers high-quality
performance and excellent after-sales
service support.
● SANY-built equipment is widely used
throughout the industry for various types
of applications.
● SANY is a leading manufacturer of heavy
construction equipment worldwide.
1-1
1
INTRODUCTION
HBT6013C-5S
Introduction
This section provides an overview of what is
covered in the rest of this manual, including
machine label information and SANY contact
information.
Safety
This section covers basic safety information
relating to this equipment. Make sure you
fully understand all the precautions described
in this manual.
1-2
INTRODUCTION
HBT6013C-5S
System functions
This section provides an overview of all the
controls and operating systems on your
equipment. It is important to study and
become familiar with all controls and systems
before proceeding with any operations.
Operation
This section provides the basic operating
procedures for the job. It is important to study
and become familiar with all procedures
before performing any operations with the
equipment.
Maintenance
This section provides all general maintenance
and repair procedures. It is important to study
and become familiar with all repair and
maintenance procedures before performing
any repair or maintenance operations on the
equipment.
Troubleshooting
This section outlines common malfunctions
and fault diagnostic procedures for the
equipment operating system. Basic
mechanical, hydraulic and electrical system
troubleshooting is included.
Specifications
This information provides overall required
operating parameters for the equipment you
are using.
1-3
INTRODUCTION
HBT6013C-5S
Data Plate
See Fig. 1-2 for the Data Plate.
Fig.1-2
Fig.1-3
1-4
INTRODUCTION
HBT6013C-5S
Our address:
Sany Industry Town, Economic and
Technological Development Zone, Changsha,
Hunan, China
DANGER
High level of rick, it indicates a hazard with a
high level of risk which, if not avoided, will
result in death or serious injury.
WARNING
Medium level of risk, it indicates a hazard
with a medium level of risk which, if not
avoided, could result in death or serious
injury.
1-5
INTRODUCTION
HBT6013C-5S
CAUTION
Low level of risk, it indicates a hazard with
a low level of risk which, if not avoid,
could result in minor or major injury.
NOTICE
Indicates a situation which can cause
damage to the machine, personal property
and/or the environment, or cause the
equipment to operate improperly.
1-6
INTRODUCTION
HBT6013C-5S
WARNING
● All operators or maintenance personnel
involved with the use of this equipment
must read this manual thoroughly before
operating or maintaining this equipment.
● This manual must be kept on or near
t h e e q u ip m e n t f o r r ef e r e n c e a n d
periodically reviewed by all personnel
involved with operation or maintenance
of this equipment.
● Some actions involved in the operation or
maintenance of this equipment could cause
a serious accident if they are not performed
in the manner described in this manual.
● All procedures and precautions outlined
in this manual apply only to intended
uses of this equipment. If you use your
equipment for any unintended uses that
are not specifically prohibited, you must
be sure that it is safe for you and others
to do so. In no event should you or
others engage in prohibited uses or
actions as described in this manual.
● SANY delivers equipment that complies
with all applicable regulations and
standards of the country to which the
equipment has been shipped. If this
equipment was purchased in another
country or purchased from someone in
another country, it may lack certain safety
features and specifications that are
necessary for use in your country. If there
is any question about whether your
product complies with the applicable
standards and regulations of your country,
contact your local SANY distributor before
operating this equipment.
● Improper operation or maintenance of this
equipment can be hazardous and could
result in serious injury or even death.
1-7
HBT6013C-5S
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1-8
SAFETY
HBT6013C-5S
2 SAFETY
WARNING
Make sure you fully understand the
precautions described in this manual and
the safety labels on the machine before
operating or maintaining this machine.
Read and follow all safety precautions.
Failure to do so may result in equipment
damage, serious injury or possibly death.
2-1
SAFETY
HBT6013C-5S
2-2
SAFETY
HBT6013C-5S
2.1.8 Machine
In this safety manual, concrete delivery and
placing machines refer to:
2.1.9 Operator
Authorized representative of the owner of the
concrete pumps and/or placing booms. The
operator is responsible for the use of these
machines.
2-3
SAFETY
HBT6013C-5S
2.1.11 Hoseman
Person instructed by the site management in
how an end hose is guided. Hosemen must
be able independently to evaluate dangerous
situations which may occur in the area of the
end hose and react according to the situation.
2-4
SAFETY
HBT6013C-5S
2.1.18 Maintenance
Maintenance embraces all measures required
for inspection, servicing and repair of a
machine.
2-5
SAFETY
HBT6013C-5S
Fig.2-1 Example
Stationary machines
Fig.2-2 Example
2-6
SAFETY
HBT6013C-5S
2-7
SAFETY
HBT6013C-5S
Place of work
The place of work is the area in which people
must remain in order to carry out the work.
● Place of work-hoseman
The hoseman’s place of work is within the
danger zone of the end hose, but not
beneath the placing boom. This requires a
greater level of caution. The hoseman and
machine operator must have visual contact.
Working area
The working area is the area in which work is
carried out with or on the machine. Parts of
the working area can become danger zones
depending on the operation being carried out
and the position of the placing boom.
2-8
SAFETY
HBT6013C-5S
Danger zone
The danger zone is the area surrounding the
machine, in which people may be at risk of
injury from movements required by the work.
2-9
SAFETY
HBT6013C-5S
● 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.
2-10
SAFETY
HBT6013C-5S
2-11
SAFETY
HBT6013C-5S
2-12
SAFETY
HBT6013C-5S
2-13
SAFETY
HBT6013C-5S
2.3.5 Extensions
Extension of the placing boom and end hose
beyond the length specified on the rating
plate is forbidden.
Fig.2-5
2-14
SAFETY
HBT6013C-5S
2-15
SAFETY
HBT6013C-5S
2.5 Personnel
2.5.1 Requirements
Persons operating or carrying out
maintenance work on the machine must meet
the following requirements:
– They must be aged 18 years or over.
– They must be physically and mentally
capable.
– They must be physiologically capable
(rested and not under the influence of
alcohol, drugs or medication).
– They must have been instructed in the
operation and maintenance of the
machine.
– They must have demonstrated their
competence to the operator.
– They can be expected to reliably execute
the tasks with which they are charged.
The operating personnel must not wear loose
garments or jewellery, including rings. Long
hair which is not tied back must be covered
by a hair net. Injury may result from hair
being caught up in the machinery or from
rings catching on moving parts.
2-16
SAFETY
HBT6013C-5S
2.5.2 Qualifications
Do not allow persons who have not yet
completed training or instruction, or persons
taking a general training course, to operate
the machine unless under the constant
supervision of an experienced person.
2-17
SAFETY
HBT6013C-5S
2-18
SAFETY
HBT6013C-5S
Safety helmet
A safety helmet protects your head against,
for instance, falling concrete or parts of the
delivery line in the event of a hose bursting.
(DIN EN 397; Industrial safety helmets)
Fig.2-7 Safety helmet
2-21
SAFETY
HBT6013C-5S
Safety footwear
Safety footwear protects your feet against
falling objects and against penetration by
projecting nails.
(EN ISO 20345; Safety footwear for
professional use; Class S3)
Fig.2-8 Safety footwear
Hearing protectors
Hearing protectors protect you against the
noise generated by the machine when you
are standing close to it.
(DIN EN 352-1; Hearing protectors – General
requirements – Part 1: Earmuffs or DIN EN
352-3; Hearing protectors – General
requirements – Part 3: Earmuffs on safety Fig.2-9 Hearing protectors
helmet)
Protective gloves
Protective gloves protect your hands against
aggressive or chemical substances, as well
as against mechanical effects (e.g. impact)
and cutting injuries.
(DIN EN 388; Protective gloves against
Fig.2-10 Protective gloves
mechanical risks; Class 1111)
Protective goggles
Protective goggles protect your eyes against
injuries from concrete spatters or other
particles.
(DIN EN 166; Personal eye-protection –
Specifications) Fig.2-11 Protective goggles
Safety harness
When working at height, use the climbing
aids and working platforms provided for
reasons of safety or wear a safety harness.
The relevant national regulations must be
complied with.
(DIN EN 361; Personal Protective Equipment Fig.2-12 Safety harness
Against Falls from a Height –Full Body
Harnesses; Category III)
2-22
SAFETY
HBT6013C-5S
2-21
SAFETY
HBT6013C-5S
2-22
SAFETY
HBT6013C-5S
2.9.3 Clearances
Maintain a minimum clearance from high-voltage
lines in accordance with the following table. The
minimum clearance is measured in the horizontal
when the placing boom is fully extended.
up to 1kV 1.0
1kV to 110kV 3.0
110kV to 220 kV 4.0
220kV to 380kV 5.0
unknown rated voltage 5.0
2-23
SAFETY
HBT6013C-5S
2-24
SAFETY
HBT6013C-5S
2-25
SAFETY
HBT6013C-5S
2-26
SAFETY
HBT6013C-5S
2-27
SAFETY
HBT6013C-5S
2-28
SAFETY
HBT6013C-5S
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.
2-29
SAFETY
HBT6013C-5S
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.
2-30
SAFETY
HBT6013C-5S
2.11.6 Towing
The machine must only be towed, loaded and
transported in accordance with the Operating
Instructions. Only use existing towing hitches
for towing and observe the truck
manufacturer’s regulations.
2.11.7 Loading
The lifting points fitted to the machine as
standard are provided for assembly purposes
only. They are not suitable for lifting the
complete machine. The lifting points for lifting
the entire machine are specially marked. Fig.2-21
2-31
SAFETY
HBT6013C-5S
2-32
SAFETY
HBT6013C-5S
2-33
SAFETY
HBT6013C-5S
2-34
SAFETY
HBT6013C-5S
Fig.2-24
2-35
SAFETY
HBT6013C-5S
Fig.2-26
2-36
SAFETY
HBT6013C-5S
2-37
SAFETY
HBT6013C-5S
2.14.2 Safety
Before switching on the machine, you must
make sure that nobody can be injured by the
running machine.
2-38
SAFETY
HBT6013C-5S
2-39
SAFETY
HBT6013C-5S
2.15 Cleaning
2.15.1 General
You must drain the delivery line, pump and
hopper completely. Concrete leavings in the
hopper, in particular, may be thrown out
whilst the truck is moving.
2-40
SAFETY
HBT6013C-5S
2.15.3 Hazards
There is a risk of injury at all points on the
machine from slipping, tripping, bumping into
things, etc. Use the handles and steps to climb
into and out of the machine. It is forbidden to
stand on the grille. Do not jump from the machine.
2-41
SAFETY
HBT6013C-5S
2-42
SAFETY
HBT6013C-5S
2-43
SAFETY
HBT6013C-5S
2-44
SAFETY
HBT6013C-5S
2-45
SAFETY
HBT6013C-5S
2.17 Welding
2-46
SAFETY
HBT6013C-5S
2-47
SAFETY
HBT6013C-5S
2.20 Software
2-48
SAFETY
HBT6013C-5S
2-49
SAFETY
HBT6013C-5S
2-50
SAFETY
HBT6013C-5S
2.23.1 General
Work on hydraulic systems must only be
carried out by qualified personnel.
2-51
SAFETY
HBT6013C-5S
2-52
SAFETY
HBT6013C-5S
We a r pers on al pr o tect i ve cl ot hi n g a n d
equipment for all work in which exhaust
gases or particles of building material can
enter the body through the respiratory
passages. Comply with the information issued
by the manufacturer of the building material.
2-53
SAFETY
HBT6013C-5S
2-54
HBT6013C-5S
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2-55
HBT6013C-5S
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2-56
SYSTEM FUNCTIONS
HBT6013C-5S
3 SYSTEM FUNCTIONS
1 2 3
4 5
Table 3-1
3-1
SYSTEM FUNCTIONS
HBT6013C-5S
3-2
SYSTEM FUNCTIONS
HBT6013C-5S
3-3
SYSTEM FUNCTIONS
HBT6013C-5S
Table 3-2
3-5
SYSTEM FUNCTIONS
HBT6013C-5S
Pumping control
Pumping operation can be controlled by the
switch on the electrical cabinet and the
remote control box.
Fig.3-4
Fig.3-5
3-6
SYSTEM FUNCTIONS
HBT6013C-5S
4
(3) The attached accessories of diesel 1
3-7
SYSTEM FUNCTIONS
HBT6013C-5S
17 RPM+ RPM-
I O I O
Fig.3-8
3-8
SYSTEM FUNCTIONS
HBT6013C-5S
NOTICE
To keep the hydraulic oil free of foreign
substances, it is forbidden to uncover the
hydraulic oil tank at random.
3-9
SYSTEM FUNCTIONS
HBT6013C-5S
Machine body
The machine body (covering parts) is
installed on the base structure and mainly
used to protect the internal parts (see Fig. 3- 4
11).
1 2
3-10
SYSTEM FUNCTIONS
HBT6013C-5S
Axle assembly
The axle of trailer-mounted concrete pump
mainly works as the traveling mechanism
1 2
when the trailer-mounted concrete pump is
being towed with guiding wheel and outrigger
retracted (see Fig. 3-12).
NOTICE
When the trailer-mounted concrete pump
is towed, its guiding wheel should be
completely retracted and should not
contact the ground or the machine may be
damaged.
1
3-11
SYSTEM FUNCTIONS
HBT6013C-5S
3-12
SYSTEM FUNCTIONS
HBT6013C-5S
3-13
SYSTEM FUNCTIONS
HBT6013C-5S
5 3
4
2
Water cooling system operation 1
Water cooling system is installed under the
base structure generally, featuring convenient
use, simple structure, fast cooling and low Fig.3-15 Water Cooling System
cost. It is applicable when the cooling water
is available easily. 1. Water inlet/outlet
2. Valve
When the oil temperature ≥ 50°C, open the 3. Oil-return tube
water cooler valve, and the water will flow in 4. Radiator
the water inlet and flow out the water outlet 5. Oil-in tube
after passing through the cooler. At this time,
heat exchange is conducted between the
hydraulic oil and the water in the cooler, so
that the hydraulic oil is cooled.
Table 3-3
3-14
SYSTEM FUNCTIONS
HBT6013C-5S
1
Pressrue oil
3 4 5 6 7 8 9
3-15
SYSTEM FUNCTIONS
HBT6013C-5S
(2) If the oil pressure is too low, please clean Air-bleed valve
(3) If the double power lubrication Fig.3-18 Double power lubrication pump
pump is used for the first time, or the
lubricant is exhausted, the pump may
suck air and can’t pumping lubricant for
along time. Loosen two air-bleed valves
by screwing them half circle until the air
exhausting and the lubricant comes out
continuously with no air pocket. Then
lock the two valves.
NOTICE
Double power lubrication pump
should keep clean. Prevent dust and other
impurity entering. It is forbidden to
contact with the acid and alkali materials.
3-16
SYSTEM FUNCTIONS
HBT6013C-5S
Table 3-4
Outriggers operation
Pull the handle leftwards or rightwards the
outriggers will extend or retract. The manual
change valve can automatically return to zero
position after released, at this moment the
outriggers stop action. Cross pin
of outrigger
Fig.3-21
3-17
SYSTEM FUNCTIONS
HBT6013C-5S
2 3
Make the agitator switch between the two
rotation directions by controlling the reverse
agitating solenoid valve. During forward
agitating (when the electromagnet is Fig.3-21
deenergized), the agitator “feeds” the delivery 1. Hopper
cylinder with concrete; during reverse 2. Agitating motor
agitating (the electromagnet is energized), the 3. Agitating ball valve
agitator pushes the concrete out from the
delivery cylinder.
Fig.3-22
3-18
SYSTEM FUNCTIONS
HBT6013C-5S
3.5.3 Accumulator
Accumulator installed on the right side of oil
tank of trailer-mounted concrete pump (taking
the hopper as front), is used to supply the
reversing circuit with auxiliary energy and
reduce system impact.
Fig.3-23
3-19
SYSTEM FUNCTIONS
HBT6013C-5S
Fig.3-24
1. Oil tank
NOTE:To prevent the pump from sucking air, 2. Self-sealing device of oil suction
the self-sealing device must be often 3. Oil-suction tube of main oil pump
opened to ensure smooth oil suction.
The oil suction is adjusted by the
adjusting threaded rod. Screw it down
to open the oil circuit, while screw off it
to seal the oil circuit (the thread of
threaded rod must be screwed off
completely).
Do remember to mount and screw
down the adjusting threaded rod after
system inspection.
3-20
SYSTEM FUNCTIONS
HBT6013C-5S
3-21
SYSTEM FUNCTIONS
HBT6013C-5S
18 5
4
2
Electrical Control
Box
6 7 8 9 10 11
I O
+ -
RPM+ RPM-
I O I O
17 16 15 14 13 12
3-22
SYSTEM FUNCTIONS
HBT6013C-5S
Table 3-5
No. Designation
1 Power supply button
2 Malfunction indicator light
3 Operation indicator light
4 Power supply indicator light
5 E-STOP (emergency stop) button
6 Diesel engine start toggle switch
7 Diesel engine stop toggle switch
8 Pumping direction toggle switch
9 High/low pressure toggle switch
10 Output adjust toggle switch
11 Control mode toggle switch
12 Outrigger movement toggle switch
13 Pre-heating control toggle switch
14 Piston adjust toggle switch
15 Swing cylinder movement toggle switch
16 Main cylinder movement toggle switch
17 Rotating speed control toggle switch
18 SYCD display
3-23
SYSTEM FUNCTIONS
HBT6013C-5S
5 4 3 2
Fig.3-26
Table 3-6
3 monopole Breaker
3-24
SYSTEM FUNCTIONS
HBT6013C-5S
NOTICE
It is prohibited to flush the electrical
control cabinet and electric appliance
elements with water or expose them to
water, or short cut will damage the
electrical elements.
3-25
SYSTEM FUNCTIONS
HBT6013C-5S
Fig.3-31
(6) High/low pressure toggle switch (see Fig.
3-32)
Low position and the High position can’t
be used at the same time. This switch is high low
pressure pressure
used to switch the pumping pressure.
In the left position, the device will pump
in high pressure.
In the right position which is the default,
Fig.3-32
the device will pump in low pressure.
3-26
SYSTEM FUNCTIONS
HBT6013C-5S
3-27
SYSTEM FUNCTIONS
HBT6013C-5S
Fig.3-40
3-28
SYSTEM FUNCTIONS
HBT6013C-5S
Table 3-7
No. Designation
1 E-STOP button
2 Pumping direction switch
3 Output adjustment switch
4 Agitate reverse
5 Indicator light
3-29
SYSTEM FUNCTIONS
HBT6013C-5S
10 5 1 2 11 12
9 HBT60C-1816DIII V2.6 F1
Remote Fan mode Low-P
F2
8 0 125 0 10
Lang
Oil Pre 0.0 bar
uage
F3
0 Speed:0 rpm
30 3
Force F4
fan
0 15 -30 90
Ene-
Oil Posi:57 L Oil Temp:18 F5
7 sel
Flux 74%
Emergerncy Stop! Batter 24.0V Menu F6
6 4
Fig.3-43
1. Type of the machine 7. Oil position
2. Version number of SYCD 8. Water temperature
3. Function buttons 9. Control mode of the machine
4. Oil temperature 10.Cooling mode
5. Diesel engine rotating speed 11.High/Low pressure
6. Error information 12.Oil pressure
3-30
SYSTEM FUNCTIONS
HBT6013C-5S
3-31
SYSTEM FUNCTIONS
HBT6013C-5S
F3
Function of the buttons are as follow:
● F1: turn to home page F4
● F3 to F6: no function. F6
Fig.3-46
3-32
SYSTEM FUNCTIONS
HBT6013C-5S
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.
RPM+ RPM-
I O I O
Fig.3-49
3-33
SYSTEM FUNCTIONS
HBT6013C-5S
Table 3-8
Engine Outrigger
start/stop I O extend/retract I O
Pumping
Washing
forward/reverse
Output
Pre-heating
increase/decrease + - I O
Local/remote Running
control indicator
Malfunction
Reverse agitate
indicator
Main cylinder
extend/retract
3-34
HBT6013C-5S
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3-35
HBT6013C-5S
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E
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3-36
OPERATION
HBT6013C-5S
4 OPERATION
This section provides the basic operating
procedures for the job. It is important to study
and become familiar with all procedures
before performing any operations with the
equipment.
Admixture
Admixture is material added during the mixing
process of concrete in small quantities related
to the mass of cement to modify the
properties of fresh or hardened concrete.
Aggregate
Aggregate is a kind of granular mineral material
suitable for use in concrete. Aggregates may be
natural, artificial or recycled from material
previously used in construction.
4-1
OPERATION
HBT6013C-5S
Addition
Addition is finely divided material used in
concrete in order to improve certain properties
or to achieve special properties.
Coarse aggregate
(1) Variety and quality of coarse aggregate
Gravel, macadam and combined aggregate
of gravel and macadam can be adopted for
pumping concrete. The pumpable capacity
of gravel aggregate concrete is the best, that
of combined aggregate ranks the second,
and that of macadam aggregate is a little bit
poor. Acicular aggregate in macadam, and
macadam with relatively great porosity (such
as vesuvianite and porous aggregate)
should be under strict control for the frequent
occurrence of pipe blockage due to their
relatively poor pumpable capacity.
100 30 25
125 40 30
150 50 40
4-2
OPERATION
HBT6013C-5S
Fine aggregate
Fine aggregate influences concrete pumpable
capacity more than coarse aggregate. It is
required to get a good gradation of fine
aggregate. Refer to Table. 4-3 for the weight
percentage of fine aggregate passing through
the sieve:
4-3
OPERATION
HBT6013C-5S
Cement proportion
The minimum cement proportion is required to be
300 kg / m3.
4-4
OPERATION
HBT6013C-5S
4-5
OPERATION
HBT6013C-5S
Table 4-6
Aggregate size
40 mm / 30 mm 50 mm / 40 mm 80 mm / 70 mm
(gravel/ macadam)
4.2.2 Disposal
Preparation of Pipe
Prepare pipes and pipe connectors according
1 2 3 4 5
to the 2-gradation pipes list (see Fig. 4-1).
4-6
OPERATION
HBT6013C-5S
4-7
OPERATION
HBT6013C-5S
1 2 3 4 5 6 7 9
10
Fig.4-2
1. trailer-mounted concrete pump 5. 45° elbow 9. 90° elbow with R=1000
2. Hopper 6. Spigot 10. Vertical pipe support
3. Discharge outlet 7. Straight tube 11.90° elbow with R=1000
4. Tapered tube 8. Base 12.Horizontal support
4-8
OPERATION
HBT6013C-5S
Precaution of Blockage
(1) Improve the quality of the concrete to
prevent blockage.
(2) Prevent leakage of the connectors. Never
use elbows with too small bent radius.
Use uniform pipes connected well.
(3) Adjust the parameters of the hydraulic
system properly. Prevent unauthorized
persons operate the adjustment.
(4) If the pumping has to be stopped for a
long time, start the pump once every
15~30 min to carry out reverse pumping
for 1-2 strokes and then forward pumping
for 1-2 strokes.
4-9
OPERATION
HBT6013C-5S
WARNING
Before remove the connectors, screw off
the bolts of the connectors and shake the
pipe to reduce the inner pressure to 0. It
is to prevent injury of the concrete splash.
4-10
OPERATION
HBT6013C-5S
WARNING
Air will enter the pipeline at the time of
blockage elimination. When restarting
pumping, prevent the concrete jetting out
from the pipe end to injure people.
4-11
OPERATION
HBT6013C-5S
WARNING
Never operate a machine that is unsafe,
damaged or in need of repair. Using
inappropriate equipment can cause
accidents or possibly death. Always check
the maintenance record for this equipment
before operating.
4-12
OPERATION
HBT6013C-5S
4-13
OPERATION
HBT6013C-5S
4-14
OPERATION
HBT6013C-5S
4.5 Starting Up
The operator can start the trailer-mounted
concrete pump after having conducted all the
inspection work.
CAUTION
Make sure all the switches and buttons
are at the position of stopping forward
pumping and reverse pumping. Or
damage of the machine and injury of
personnel may occur.
RPM+ RPM-
I O I O
4-15
OPERATION
HBT6013C-5S
4-16
OPERATION
HBT6013C-5S
1000 5000
psi
5800
MPa
0 40
Fig.4-8
psi
5800
MPa
0 40
Change-over pressure
Fig.4-9
pumping.
Fig.4-10
4-17
OPERATION
HBT6013C-5S
Fig.4-11
4-18
OPERATION
HBT6013C-5S
Fig.4-13
Fig.4-14
4-19
OPERATION
HBT6013C-5S
Fig.4-15
4-20
OPERATION
HBT6013C-5S
CAUTION
Take care to prevent your feet from being
injured by outriggers during operation
(see Fig. 4-17).
Fig.4-18
position 2
position 1
Fig.4-19
4-21
OPERATION
HBT6013C-5S
Switch over
Check for an unimpeded switch over function
of the delivery pistons and the S-valve at
various engine speeds.
Stroke time
Measure the machine stroke time under no
load, i.e. without concrete.
● Set the engine to maximum speed.
● Set the maximum pumping rate.
● Start the measurement at the first switch
over of the S-valve.
● The first single stroke is complete with
the next S-valve switch over.
4-22
OPERATION
HBT6013C-5S
Environmental protection
Comply with the waste disposal regulations in
force for your area when changing the fluid
filter.
4-23
OPERATION
HBT6013C-5S
Fig.4-25
4-24
OPERATION
HBT6013C-5S
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.
4-25
OPERATION
HBT6013C-5S
DANGER
You must stop work if you open the grille,
but
● the agitator continues to run
● the S-valve continues to switch
● the concrete pump does not run to its
end position.
Failure to do this could result in serious
injury to persons.
CAUTION
Failure to observe and follow this directive
may result in loss of control, a possible
rollover and personal injury.
4-26
OPERATION
HBT6013C-5S
Fig.4-26
4-27
OPERATION
HBT6013C-5S
Fig.4-27
CAUTION
Stop pumping in the forward mode and
place the system in the reverse mode
immediately if the signal person uses this
signal during operations. Failure to do so
may result in a sudden rupture in the
piping system or hose end-swing and
personal injury.
Fig.4-28
4-28
OPERATION
HBT6013C-5S
Fig.4-29
CAUTION
This signal may be used by other
personnel in an emergency. The operator
shall obey a STOP signal at any time from
anybody.
Fig.4-30
4-29
OPERATION
HBT6013C-5S
WARNING
The pumping system can be started, only
after making sure that the change valve of
the auxiliary valve group is set at the
mixing position, the mixing shaft runs
properly, the engine and oil pump run switch (a)
normally, the outriggers are supported
well and all the examinations are carried
RPM+ RPM-
I O I O
4-30
OPERATION
HBT6013C-5S
NOTICE
When the trailer-mounted concrete pump
is running, the level of the mixed concrete
must be higher than the mixing shaft to
avoid air pumping (Fig. 4-35).
Fig.4-35
L1
L2
Fig.4-36
Fig.4-37
4-31
OPERATION
HBT6013C-5S
Fig.4-38
Fig.4-40
4-32
OPERATION
HBT6013C-5S
Fig.4-41
Fig.4-42
Fig.4-43
4-33
OPERATION
HBT6013C-5S
Fig.4-44
Fig.4-45
4-34
OPERATION
HBT6013C-5S
NOTICE
Failure to monitor this system may result
in component damage or lock-up.
4-35
OPERATION
HBT6013C-5S
4.9.4 Pumping
Control mode selection
RPM+ RPM-
I O I O
Fig.4-47
1
7
2
8
3
9
4
10
ten-pin socket
4-47). At this time, the power indicator light
on the remote control box goes on, which ten-pin plug
4-36
OPERATION
HBT6013C-5S
Fig.4-49
Output adjustment
There are two ways of adjusting output.
position).
● Output will be decreased when held the
switch in “Decreased” position (right I O
+ -
RPM+ RPM-
position).
I O I O
Fig.4-50
Fig.4-51
4-37
OPERATION
HBT6013C-5S
RPM+ RPM-
I O I O
Fig.4-53
DANGER
Never reach into the hopper while the
paddles are rotating. Be sure all hydraulic
functions are shut down completely and
all movement has stopped before reaching
into the hopper. Failure to do so may
result in serious injury.
4-38
OPERATION
HBT6013C-5S
CAUTION
Failure to observe and follow this caution
could result in equipment damage and
minor or major injury if a blockage is
ejected from the end hose under extreme
pressure or if an end hose whipping
situation occurs.
WARNING
Failure to observe and follow this warning
could result in injury or possibly death if
the resulting concrete structure fails.
(1) Set the “Control mode” switch (a) on the RPM+ RPM-
I O I O
4-39
OPERATION
HBT6013C-5S
4-40
OPERATION
HBT6013C-5S
4.10Equipment Clean-up
Remove and clean all concrete material
residue from the machine after all pumping
operations are completed.
NOTICE
Failure to thoroughly clean the pumping
system at the completion of pumping
operations will result in equipment
damage.
4-41
OPERATION
HBT6013C-5S
Above 500m
100~500m 3
Below 100m 1 1
1 2 2
2 3 3
Pu
Pu
Pu
mp
mp
mp
in
ing
ing
gD
Dir
Di
ire
rec
ec
cti
tio
tio
on
n
n
Fig.4-53
4-42
OPERATION
HBT6013C-5S
4-43
OPERATION
HBT6013C-5S
WARNING
Clear the work area of all personnel and
equipment before proceeding. Never
retract the outriggers before all operation
completed. Loss of control may occur,
resulting in equipment damage, personal
injury or death.
Fig.4-55
4-44
OPERATION
HBT6013C-5S
CAUTION
When the equipment is moving, prevent
the guiding wheel or the wheels from
pressing on your feet (see Fig. 4-8).
Fig.4-56
4-45
OPERATION
HBT6013C-5S
Fig.4-57
Fig.4-58
4-46
OPERATION
HBT6013C-5S
Fig.4-59
4-47
OPERATION
HBT6013C-5S
4.13Machine Decals
It is important that all safety, alert and
warning decals are in place, not damaged,
covered or removed. It is also important for
the operator and all personnel involved to be
aware of the decal content and locations on
the equipment.
4-48
OPERATION
HBT6013C-5S
1 8 9 13 12 11 10 14 15 16 17 18 25
24 20 19 7 6 5 4
26 23 22 21
2
A
27 A B
water box electrical box
28
30 35 31 32 29 33 34
Fig.4-59
4-49
OPERATION
HBT6013C-5S
4.13.2Decal Descriptions
Table 4-8 Decal Descriptions
4-50
OPERATION
HBT6013C-5S
29 Smoking Prohibition
30 Sign of Rating Voltage of Plug
31 Mark for Self-sealing Device of Oil Tank
32 Warning Mark for Accumulator
33 Identification Mark on Hydraulic Oil Tank
34 Mark for Towing Bracket
35 Mark of main switch
4-51
OPERATION
HBT6013C-5S
4.13.3Detailed explanations
Fig.4-61
11558272
Fig.4-62
4-52
OPERATION
HBT6013C-5S
Fig.4-63
Fig.4-64
Fig.4-65
4-53
OPERATION
HBT6013C-5S
Fig.4-66
Fig.4-67
ergen
(see Fig. 4-68)
cy
emergency stop.
Fig.4-68
Fig.4-69
4-54
OPERATION
HBT6013C-5S
Fig.4-70
Fig.4-71
Fig.4-72
4-55
OPERATION
HBT6013C-5S
Fig.4-73
Fig.4-74
Fig.4-75
4-56
OPERATION
HBT6013C-5S
Fig.4-76
Fig.4-77
4-57
OPERATION
HBT6013C-5S
12379614
Fig.4-79
4-58
OPERATION
HBT6013C-5S
Fig.4-80
Fig.4-81
Fig.4-82
4-59
OPERATION
HBT6013C-5S
Fig.4-83
Fig.4-84
Fig.4-85
4-60
OPERATION
HBT6013C-5S
Fig.4-86
Fig.4-87
Fig.4-88
4-61
OPERATION
HBT6013C-5S
Fig.4-90
Fig.4-91
4-62
OPERATION
HBT6013C-5S
Fig.4-92
Fig.4-93
Fig.4-94
4-63
OPERATION
HBT6013C-5S
E
G
PA
K
AN
BL
4-64
MAINTENANCE
HBT6013C-5S
5 MAINTENANCE
In order to guarantee normal operation of the
machine and avoid malfunctions affecting
construction, all inspection and maintenance
work should be earnestly carried out. Only in
this way, can the failure rate of product be
decreased, the service life of the machine be
prolonged, and the repair cost be reduced,
thus greater profits be achieved.
5-1
MAINTENANCE
HBT6013C-5S
5-2
MAINTENANCE
HBT6013C-5S
WARNING
You must follow the Safety Inspection
Intervals (Table. 5-1), Maintenance
Interv als (T able. 5-2) and M anda to ry
Overhaul (Table. 5-3) during the
maintenance process. The Manufacturer
accepts no liability for any safety accident
arising from the failure to perform due
mandatory overhaul.
5-3
MAINTENANCE
HBT6013C-5S
Every...Hours of Operation
Assembly Action
Daily 100 500
5-4
MAINTENANCE
HBT6013C-5S
Every...Hours of Operation
Assembly Action
Daily 50 100 250 500 1000
5-5
MAINTENANCE
HBT6013C-5S
Every...Hours of Operation
Assembly Action
Daily 50 100 250 500 1000
Q
or when
the
Hydraulic Replace hydraulic oil filter element indicator
system
turns
red
Clean oil suction filter element(new
Q
oil tank)
Replace oil suction filter
Q
element(new oil tank)
Q
Replace oil return filter element(new First Q
oil tank) time
Full hydraulic oil change Q
5-6
MAINTENANCE
HBT6013C-5S
Every...of Operation
Action
daily 50 125 250 500 1000 1500 2000
Q
Replace primary filter of diesel oil First Q
time
Q
Replace filter of diesel oil First Q
time
Q
Replace engine oil First Q
time
Q
Replace filter of engine oil First Q
time
Q
Check injector oil-return First
pipe(change it if necessary) time
Q
Check air valve clearance(adjust it First Q
if necessary) time
Q
Check engine suspension First Q
time
Q
Check V-belt First Q
time
Q
Check alarm equipment First
time
Q
Check fixed component First Q
time
Check Battery and wire Q
5-7
MAINTENANCE
HBT6013C-5S
Every...of Operation
Action
daily 50 125 250 500 1000 1500 2000
necessary)
Check hose connector,tube
Q
collar,air intake and inter-cooler
Check preheater plug Q
Q
Replace injector oil-return pipe or two
years
Q
Replace coolant or two
years
CAUTION
The running time during maintenance of
engine refers to the running time of
engine.
For the new or overhauled machine, the
o i l l e ve l o f e n gi n e m u st b e c h e ck e d
everyday and twice everyday during
wearing period.
5-8
MAINTENANCE
HBT6013C-5S
CAUTION
When used in China, it suggests to
replace the engine oil, reduce the filtrating
time by half and use the cleaning diesel
oil when the working condition is bad, the
oil is dirty or the quality of oil doesn’t
meet the standard of SANY.
Every...of Operation
Assembly Action
1 Year 2 Years 5 Years
Pumping
Replace seal of main oil cylinder
mechanism
5-9
MAINTENANCE
HBT6013C-5S
WARNING
For any safety accident caused by not
performing obliged overhaul in
time,manufacturer doesn’t take for any
responsibility.
5-10
MAINTENANCE
HBT6013C-5S
5-11
MAINTENANCE
HBT6013C-5S
NOTICE
Looseness or breakage could occur if
fasteners, hose or line couplings are not
torqued to the specified value. If you will
be doing any repairs or service
procedures on this machine, always refer
to this table if the tightening torque value
is not listed or specified in the procedure.
Failure to do so could damage the
machine, shorten machine life or cause
premature system failure.
5-12
MAINTENANCE
HBT6013C-5S
5-13
MAINTENANCE
HBT6013C-5S
5-14
MAINTENANCE
HBT6013C-5S
5.3 Lubrication
The lubrication sustem comprises automatic and
manual lubrication.
handle
Autom atic lubricati o n
(1 ) Check and add lubricant to oil storage of Synchronizing lubricating Pressure regulating
grease port
overflow valve
double power lubrication pump (se e Fig. 5-1)
every time before start the machi ne.
5-15
MAINTENANCE
HBT6013C-5S
NOTICE
Double power lubrication pump
should keep clean. Prevent dust and other
impurity entering. It is forbidden to
contact with the acid and alkali materials.
Manual lubrication
Fi g. 5-2
5-16
MAINTENANCE
HBT6013C-5S
5-17
MAINTENANCE
HBT6013C-5S
NOTICE
Do not use grease mixed with foreign
matters; otherwise the valve core of
distribution valve will be easily stuck and
lead to faults in the lubrication system.
Thus the abrasion of parts of pumping
system will be aggravated. Failure to do
so may result in instability in operating
positions or serious damage to the
machine.
5-18
MAINTENANCE
HBT6013C-5S
(2) Precautions
Do not set the lubricating oil in air to
avoid deterioration resulting from
moisture absorption.
Do not mix the lubricating oil with other
oil for application.
SANY SPECIAL
Prevent the foreign substances and dust GREASE NO.00
getting into lubricating grease, and GENUINE PARTS
5-19
MAINTENANCE
HBT6013C-5S
Applicable
temperature °C
-40 -30 -20 -10 0 10 20 30 40 50
Grade
Equivis ZS 46S
(2) Precautions
The hydraulic oil can not be mixed for
application.
It is forbidden to use the hydraulic oil with
additives such as molybdenum to prevent
damage of bearing.
Thoroughly replace the hydraulic oil with
the residual hydraulic oil in hydraulic
system less than 2%.
Preheat the hydraulic oil when the
temperature is lower than 20°C.
5-20
MAINTENANCE
HBT6013C-5S
5-21
MAINTENANCE
HBT6013C-5S
DANGER
You should particularly closely and
carefully check the electrical cables. There
is a danger of overvoltage from defective
cables, especially in high air or ambient
humidity. There is a danger of fire and
explosion through the formation of sparks
in a potentially explosive atmosphere.
5-22
MAINTENANCE
HBT6013C-5S
5-23
MAINTENANCE
HBT6013C-5S
5-24
MAINTENANCE
HBT6013C-5S
Over view
The concrete piston mainly consists of
concrete seal body, piston body, pressure
plate, connecting rod, connecting disc and
several sealing elements. Fig. 3-3 gives the
specific structure.
3
7
3
12
11
2
3
1
7
5 3
8
9
10
Pre-inspection procedures
(1) Unscrew the water-drain ball valve to
drain the water in the washing room.
5-25
MAINTENANCE
HBT6013C-5S
Exit Reset
NOTE:This function will position the concrete
piston in the wash box for inspection
or removal.
Fig.5-4
5-26
MAINTENANCE
HBT6013C-5S
2 4
1 3
Fig.5-6
1. Main valve block
2. Unloading ball valve of accumulator
3. Accumulator
4. Oil tank
WARNING
Failure to set the unloading ball valve in Fig.5-7
the OPEN position could result in
unexpected movement of the concrete
piston during service procedures.
Unexpected movement of a component
could result in serious injury.
5-27
MAINTENANCE
HBT6013C-5S
5-28
MAINTENANCE
HBT6013C-5S
5-29
MAINTENANCE
HBT6013C-5S
Over view
Fig. 5-9 and Fig. 5-10 show the outline of the
cutting ring and the glasses plate. Fig.5-9 Outline of Cutting Ring
5-30
MAINTENANCE
HBT6013C-5S
5-31
MAINTENANCE
HBT6013C-5S
5-32
MAINTENANCE
HBT6013C-5S
5-33
MAINTENANCE
HBT6013C-5S
Over view
1
2
3
4
5
8
6
Fig.5-16
1. Transitional bushing 5. Glasses plate
2. O-ring 6. Cutting ring
3. Bolt 7. Rubber spring
4. Washer 8. S-tube assembly
Disassembly of S-tube
(1) Disassemble the mixing system:
a) Shut down the engine, cut off the power
and release the pressure.
Open the unloading ball valve of
accumulator to release the pressure of
the accumulator pressure oil.
Shut down the engine and cut off the
power to avoid unauthorized startup.
b) Take off the screen, loosen the mounting
screw of mixing blade and dismount the
mixing blade.
c) Dismount the lubricating tube as well as
the three oil tube connectors connecting
to the mixing motor (see Fig. 5-17).
Fig.5-17
5-34
MAINTENANCE
HBT6013C-5S
5-35
MAINTENANCE
HBT6013C-5S
18
14
13 11
15
17
16
29
23
30
20
21
19
7
28 24
3
8
26
27
5 6
25
22
9
10 1 2
3
4
12
Fig.5-18
5-36
MAINTENANCE
HBT6013C-5S
18
17
16
14
15
4 28
13
1
3 22
2
12
11 21
8
10
9
5
7
6
27
24
26
25
23
19
20
Fig.5-19
5-37
MAINTENANCE
HBT6013C-5S
16
15
18
17
14 23
10
24
13
7 9
12
6
8 22
21
6
6
5
11
4
3
2
1
19
20
Fig.5-20
5-38
MAINTENANCE
HBT6013C-5S
4 1
1
9 11
5
12
7 9
5
3 4
15
13
2 8
6
10 3 4
5 1
14
7
6
2
15
Fig.5-21
5-39
MAINTENANCE
HBT6013C-5S
8 9 10
7
6
3
11
12
2
1 13
14
5
4
16 15
17
Fig.5-22
5-40
MAINTENANCE
HBT6013C-5S
1
2
3
4
5
8
6
Fig.5-23
1. Transitional bushing 5. Glasses plate
2. O-ring 6. Cutting ring
3. Bolt 7. Rubber spring
4. Washer 8. S-tube assembly
5-41
MAINTENANCE
HBT6013C-5S
5-42
MAINTENANCE
HBT6013C-5S
Assembly of S-tube
(1) Assembly of S-tube and Swing Mechanism
a) Mount the wearing sleeve onto the
straight tube of S-tube.
b) Lift the S-tube with a crane and flexible
cable. Fit the rubber pads onto both
ends. Adjust the S-tube to the slanting
side and lower it into the hopper. First,
set the outlet hole of S-tube into the
mounting hole on the discharge outlet of
hopper; push it to the end, and then set
the small shaft of S-tube into the
mounting hole of hopper. Mount the
rubber spring and cutting ring applied
with some lubricating grease onto the S-
tube.
c) Replace the YX-type seal ring, J-type
dust-proof ring, dust-proof ring and seal
ring; apply lubricating grease on the
sealing elements, bearing as well as the
inside and outside of the bearing seat;
mount the nylon bearing, YX-type seal
ring and J-type dust-proof ring on the big
bearing seat at the outlet (see Fig. 5-20).
Mount the bearing, dust-proof ring and
seal ring onto the small bearing seat (see
see Fig. 5-22).
NOTICE
During installation, pay attention to the
correct installation direction of seal ring
and dust ring. Failure to do so may result
in oil leaking and the dust crushing into
the containers or pipes.
5-43
MAINTENANCE
HBT6013C-5S
NOTICE
When installing the rocker arm, allow the
S-tube to hang down freely. The center
lines of gravity of S-tube and rocker arm
must be overlapped when viewed from the
right behind the hopper (see Fig. 5-25).
Or fit the key way, which is located on
rocker arm and symmetrically coincides
with the center line, on the spline teeth
located on the shaft end of S-tube and has
a center line symmetrically coincides with
that of S-tube.
If the installation positions of S-tube and
rocker arm is not correct, S-tube can not
swing to the desired position.
2 1
$
Fig.5-25
5-44
MAINTENANCE
HBT6013C-5S
5-45
MAINTENANCE
HBT6013C-5S
5-46
MAINTENANCE
HBT6013C-5S
5.6.5 Hopper
The regular check and maintenance of
hopper and its relative spare parts may
effectively prevent abnormal wear of hopper.
5-47
MAINTENANCE
HBT6013C-5S
5-48
MAINTENANCE
HBT6013C-5S
2
9
10
11
1
7
2 4
6
3
5
Fig.5-29
5-49
MAINTENANCE
HBT6013C-5S
(2) Elbow
After pumping every 5000m3 of concrete,
turn over the elbow for 180° to make the
wear evenly distributed. The exterior wear
of an elbow is severer than the internal
wear or the wear of a straight tube. Thus,
when measuring the wall thickness of an
elbow, special attention should be paid to
the wall thickness at the positive camber.
10
180
14 125
65
DN
DN
DN
DN
0
DN5
160
or injury of life caused by pipe burst. 0
N
150
15
D
140 N
Concrete Pressure (bar)
130 D 0
120 18
Fig. 5-30 shows the minimum wall thickness 110 DN 0
20
DN
of delivery pipe. 100
90
80
(1) Carry out measurement according to the 70
60
measuring regulation of the equipment. 50
40
Don't measure the wall thickness at one 30
20
point only. Instead, measure at several 10
points around the outer diameter of 0 1 2 3 4 5 6 7 8
X
delivery pipe, in particular at the lateral Min.wall thickness (mm)
5-50
MAINTENANCE
HBT6013C-5S
CAUTION
Never increase the wall thickness, outer
diameter and length of delivery line;
otherwise the service life of boom will be
reduced, influencing the stability of this
pump truck and potentially leading to
breaking of boom and tilting of pump.
NOTICE
The shock influence to the delivery pipe
during working is depended on many
affects and hard to measure. Therefore,
even the working pressure is under the
normal range, the delivery pipe may burst
also.
When blockage happen, the working
pressure fluctuate. If the wall thickness is
not under the required level, the pipe may
burst.
5-51
MAINTENANCE
HBT6013C-5S
5-52
MAINTENANCE
HBT6013C-5S
5-53
MAINTENANCE
HBT6013C-5S
8
7
6
5 2
5
3
2
5-54
MAINTENANCE
HBT6013C-5S
5-55
MAINTENANCE
HBT6013C-5S
NOTICE
Take care when re-assembling the oil
cylinder. Do not damage the seal and
chromium coating. Use the new bolt for
fastening. Slowly extend and retract the
hydraulic cylinder twice at a speed not
more than 0.5m/min to drain the air in the
cylinder. If the air is compressed, the
hydraulic oil may be burnt so that the
sealing parts of the piston and O-ring will
be damaged.
5-56
MAINTENANCE
HBT6013C-5S
5-57
MAINTENANCE
HBT6013C-5S
5-58
MAINTENANCE
HBT6013C-5S
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.
5-59
MAINTENANCE
HBT6013C-5S
5-60
MAINTENANCE
HBT6013C-5S
5-61
MAINTENANCE
HBT6013C-5S
5.8 Accumulator
1
NOTICE
T h e ch e c k i n g a n d oi l f i l l i n g w or k o f 2
4
DANGER
The accumulator should be filled with
nitrogen. Never use other gases. If it is
filled with air, nitrogen, etc., explosion
may occur. Fig.5-39
5-62
MAINTENANCE
HBT6013C-5S
Working Charging
Capacity
Pressure Pressure
5-63
MAINTENANCE
HBT6013C-5S
5-64
MAINTENANCE
HBT6013C-5S
5-65
MAINTENANCE
HBT6013C-5S
The air filter and its filter core are integral. Thus,
please replace the air filter with a new one.
WARNING
The electrical cables can not connect
other unauthorized electrical elements.
Failure to do so may result serious
damage to the elements or even personal
injury.
5-66
MAINTENANCE
HBT6013C-5S
of same specification.
+
RPM+ RPM-
I O I O
5-67
MAINTENANCE
HBT6013C-5S
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.
5-68
HBT6013C-5S
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5-69
HBT6013C-5S
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5-70
TROUBLESHOOTING
HBT6013C-5S
6 TROUBLESHOOTING
The SANY trailer-mounted concrete pump is
designed for pumping concrete and
implementing a continuous pour during
operation. If the trailer-mounted concrete
pump malfunctions, it will delay the
construction schedule and bring negative
influence on the economic and social benefits
of both sides. Timely diagnosis and
troubleshooting are needed in order to reduce
economic losses and maintain a good
corporate image.
This section will elaborate on common
malfunctions and troubleshooting the
machinery, hydraulic system, electrical
systems and diesel engine.
6-1
TROUBLESHOOTING
HBT6013C-5S
Table 6-2
6-2
TROUBLESHOOTING
HBT6013C-5S
Table 6-2
6-3
TROUBLESHOOTING
HBT6013C-5S
Table 6-2
Blockage of the damping hole in the oil- Check the damping hole in
drain valve the oil-drain valve.
Random reversing of
6 Check or replace the small oil
the pumping system The valve core of small oil controlled
controlled valve of the swing
valve of the swing cylinder blocked
cylinder.
The main overflow valve with overflow Replace the main overflow
during pumping. valve.
The hydraulic oil No rotation of the air-cooled motor or
7 temperature rising with low rotation speed due to decline Replace the air-cooled motor.
abnormally of volume efficiency.
The air cooler radiator grill blocked by Clear the dust on the radiator
dust, making the cooling not smooth. grill.
Table 6-3
Refer to the corresponding electrical basic diagram for the common malfunction diagnosis and
troubleshooting of electrical control system. Carry out analysis, diagnosis and troubleshooting
according to the following methods:
6-4
TROUBLESHOOTING
HBT6013C-5S
Table 6-4
6-5
TROUBLESHOOTING
HBT6013C-5S
Table 6-5
No oil in the fuel tank Fill oil and carry out bleeding.
Fuel filter screen blocked by foreign Clean the primary filter screen or
substances replace the filter
Replace it with winter-grade fuel; use
Fuel filter screen or pipeline blocked pump oil or hot water to submerge the
Failure in engine by wax deposits in winter lower part of the filter to melt the wax,
1
startup discharge the air and clean the pipeline.
Check all fuel pipe connectors for
Poor seal of fuel pipe tightness; if necessary, tighten the
connectors.
Indicator lamp off (but bulb in good Check and fasten all connections of
condition) terminals and conductors.
Check if the solenoid valve is
Solenoid overflow valve in the
electrified and if the overflow valve
hydraulic system not returned.
works normally.
Main pump damaged or jammed. Repair or replace the main pump.
Check the battery voltage; clean
Insufficient voltage of battery, loose or
and fasten the terminal; coat the
oxidized terminal.
terminal with carbon-free grease.
Application of engine oil with great Use engine oil suitable for the
viscosity in winter. specific environment.
Difficult engine Replace it with winter-grade fuel;
2
startup use pump oil or hot water to
Small fuel flow (fuel system blocked submerge the lower part of the filter
by wax deposits in winter). to melt the wax, discharge the air
and clean the prefiltration screen
and oil circuit.
Blockage of diesel oil filter. Clean or replace the diesel prefiltration.
Diesel oil of poor quality (for example, Drain the diesel oil of poor quality
containing water) and use qualified diesel oil.
Air in the oil-in circuit. Bleed the diesel oil circuit.
Loose diesel oil filter. Fasten it.
Replace the filter, discharge the air,
Small fuel flow. clean the primary filter screen and
tighten the tube connector.
Engine power
decreases or Valve clearance not in accordance
3 Adjust the valve clearance and
engine works with the requirements; breakage of
replace the spring.
abnormally valve spring.
Fuel injector damaged. Replace the fuel injector.
Dirty air filter. Clean or replace the filter core.
6-6
TROUBLESHOOTING
HBT6013C-5S
Table 6-5
Blue or black Black smoke: coking at valve or poor Check and adjust the valve clearance
4 smokes from the seal due to improper valve clearance. by professional personnel.
exhaust pipe Black smoke: oil injector damaged. Replace the oil injector.
Black smoke: blockage of air intake Clean the intake system and
system or poor seal. fasten the clamp.
Coolant pump damaged. Replace the coolant pump.
Incorrect adjustment of injection Adjust it by professional
Engine quantity for oil injection pump. personnel.
overheated and
Insufficient cooling air from the cooling fan. Unblock the air duct.
the indicator of the
thermometer Check and adjust the exhaust regulator;
5 Slow blowing speed of cooling fan.
pointing to the red check the belt for looseness and crack.
area; engine
Adjust the oil level to the “MAX”
stopped Too less or too much engine oil.
mark on the oil level gauge.
immediately
Too less coolant. Fill coolant to the specified level.
Poor seal of air intake tube. Check the air intake tube.
Fill or drain the engine oil; dismount the
Incorrect engine oil level or engine oil oil delivery pump and check the
diluted by diesel oil (with the diesel sealing condition of its plunger; replace
engine working normally). the oil delivery pump with leakage and
replace the engine oil.
Engine oil diluted by diesel oil with the Check the coupling parts of nozzle for
diesel engine working unstably or with seizure; if not, exchange the fuel
insufficient power. injector and replace the engine oil.
Check if the filler cover or oil level gauge
Engine oil diluted by water.
falls off; replace the engine oil.
Check the engine oil cooler, water
Engine oil diluted by coolant jacket and water seals for leakage;
Low engine oil (antifreeze coolant). replace the spare parts with leakage;
6
pressure replace the engine oil.
Engine oil with incorrect grade. Check the specifications of engine oil.
Check the engine oil pressure gauge
Failure of engine oil pressure gauge. and engine oil pressure sensor;
replace the damaged parts.
Check and clean the pressure
Seizure of pressure regulating valve or
regulating valve and replace the
breakage of pressure regulating spring.
damaged spring.
Replace the engine oil and engine
Blockage of engine oil filter.
oil filter.
Replace the sealing elements and
Loose oil-suction tube or failed seals.
fasten the oil-suction tube.
6-7
TROUBLESHOOTING
HBT6013C-5S
Table 6-5
Blockage of air filter. Check, clean and replace the air filter.
Check or adjust the oil injection
Incorrect timing of oil injection pump.
timing.
Air leakage of connecting tube
between the turbocharger and air Get rid of the air leakage trouble.
Heavy smoke intake tube.
7 when the diesel
engine is loaded More than 1 packing washers under
Remove the redundant washers.
the oil injector.
Dismount the oil injector for
Oil injector works abnormally. calibration or replace it if
necessary.
Turbocharger works abnormally. Replace the turbocharger.
Low water temperature when the Check the thermostat and cooling
diesel engine is under operation. system.
Dismount and check the oil
Large diesel oil supply quantity.
injection pump.
Failure to reach
the rated rotation Improper adjustment of throttle control Check the position of throttle
8 speed when the lever. control lever.
diesel engine is
Conduct calibration with manual or
loaded Failure of tachometer.
digital tachometer.
Replace the fuel filter, check the
Blockage of fuel supply. fuel pipeline, primary filter and
filter screen for blockage.
6-8
HBT6013C-5S
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6-9
HBT6013C-5S
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6-10
SPECIFICATIONS
HBT6013C-5S
7 SPECIFICATIONS
Dimensions
Lengt h 6785 mm
Width 2100 mm
Height 2630 mm
Feeding height 1320 mm
Gross weight 6300 kg
1320 mm
6785 mm
2100 mm
2630 mm
Fig.7-1
7-1
SPECIFICATIONS
HBT6013C-5S
Pump Specifications
7-2
SPECIFICATIONS
HBT6013C-5S
High-pressure Low-pressure
pumping pumping
Fig.7-2
7-3
HBT6013C-5S
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7-4
APPENDIX
HBT6013C-5S
8 APPENDIX
8.1 Hydraulic Basic Diagram
Fig.8-1 TPHDCA_EN_01
8-1
APPENDIX
HBT6013C-5S
8-2
APPENDIX
HBT6013C-5S
Grille switch E-stop Remote Forward Reverse Outpur Output Reverse Swing
control pumping pumping increase decrease mixing cylinder
indicator inching
8-3
APPENDIX
HBT6013C-5S
Display GPS
Power
confirm
8-4
APPENDIX
HBT6013C-5S
8-5
APPENDIX
HBT6013C-5S
Diesel engine
speed
Pulse counter adjusting
Direction Enable
Green
Blue
Red
Step motor
8-6
APPENDIX
HBT6013C-5S
piston-return
double
Pump solenoid valve
Proportional valve
control
8-7
APPENDIX
HBT6013C-5S
Speed increase
place
Speed increase
PWM
Water temperature
A signal
Oil pressure A
signal
Diesel engine
start
Speed
decrease
Speed
increase
Fault
indicator
Operation
indicator
Diesel engine A
thickened
Diesel engine A
start
E-stop
output
Electrical
change
8-8
APPENDIX
HBT6013C-5S
Function control 1
Reverse mixing
Swing cylinder
backward
Forward mixing
Reset
Piston
Keep
adjusting
Exit
Water pump
control
Diesel engine
stop
Reverse
pumping
Forward
pumping
Local control
Remote control
Main cylinder
backward
Main cylinder
forward
Pressure detect
of oil pump
Output decrease
Output increase
8-9
APPENDIX
HBT6013C-5S
Function control 2
Oil level
Agitating pressure
Hydraulic oil
temperature 1
Hydraulic oil
temperature 2
change-over
switch 2
change-over
switch 1
Change-over pressure
detect 2
Change-over pressure
detect 1
S-valve
high/low pressure
Slide valve
flush control
Speed adjusting
select
Pre-heat
Outrigger adjusting
Hopper switch
E-stop
8-10
APPENDIX
HBT6013C-5S
8-11
APPENDIX
HBT6013C-5S
Diesel engine
Pulse counter speed
B adjusting B Direction Enable
Green
Blue
Red
Step motor
8-12
APPENDIX
HBT6013C-5S
Diesel engine
startl
Diesel engine
B start
Diesel engine B
thickened
Oil pressure B
signal
Water temp B
signal
Note:Added I/O for trailer-mounted concrete pump with dual diesel engine
8-13
APPENDIX
HBT6013C-5S
To preheat
system
Oil-water
seperate swith
Detect plug
Note: Apply to trailer-mounted concrete pump with CAN bus diesel engine
8-14
APPENDIX
HBT6013C-5S
Local control
Remote control
To preheat
system Oil-water
seperate swith
Detect plug
Note: Apply to diesel engine B of trailer-mounted concrete pump with CAN bus diesel engine
8-15
APPENDIX
HBT6013C-5S
Solenoid valve action list for S-tube pump with large output I
Working state
Fo rwar d
pu m pin g Ele ct ric
High r ev er si n g
pressure
Rev ers e
pu mp in g No e lec t ri c Elec tric
r eve r si ng r eve r si ng
Forwar d
Elec tric
Low pu mp in g
r eve r si ng
pressure
Re ve rs e
p um p ing No e lect ri c Elec tric
r ev er si ng r eve r si ng
Swing cylinder
Elec tric
forward r eve r si ng
Forward mixing
Reverse mixing
Air cooling
Water pump
Outrigger
Piston
Keep
Reset
Mode
Fig.8-16 Solenoid valve action list for S-tube pump with large output I TPEDCA_EN_01
8-16
APPENDIX
HBT6013C-5S
Solenoid valve action list for S-tube pump with large output II
Working state
F orwa r d
pumpin g
High
pressure Re verse
pu mp in g
Fo rwa rd
pu mp in g
Low
pressure Re ve rse
pumping
Forward inching
Backward inching
Swing cylinder
forward
Swing cylinder
backward
Forward mixing
Reverse mixing
Air cooling
Water pump
Outrigger
Exit
Piston
Keep
Reset
Mode
Fig.8-17 Solenoid valve action list for S-tube pump with largel output II TPEDCA_EN_01
8-17
APPENDIX
HBT6013C-5S
Solenoid valve action list for S-tube pump with small output I
Working state
F o rwa r d
p u m p in g
High
pressure Re ve rse
p u m p in g
F o rw a r d
p u m p in g
Low
pressure Re ve rse
p u m p in g
Forward inching
Backward inching
Swing cylinder
forward
Swing cylinder
backward
Forward mixing
Reverse mixing
Water pump
Outrigger
Exit
Piston
Keep No dual
power
Reset
Mode
Fig.8-18 Solenoid valve action list for S-tube pump with small output I TPEDCA_EN_01
8-18
APPENDIX
HBT6013C-5S
Solenoid valve action list for S-tube pump with small output II
Working state
Forward pumping
Reverse pumping
Forward inching
Backward inching
Reverse mixing
Air cooling
Mode
Fig.8-19 Solenoid valve action list for S-tube pump with small output II TPEDCA_EN_01
8-19
APPENDIX
HBT6013C-5S
Solenoid valve action list for slide valve pump with small output I
Forward pumping
Reverse pumping
Forward inching
Backward inching
Swing cylinder
forward
Swing cylinder
backward
Reverse mixing
Air cooling
Water pump
Outrigger
Exit
Keep
Reset
Mode
Fig.8-20 Solenoid valve action list for slide valve pump with small output I TPEDCA_EN_01
8-20
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Materials and specifications are subject to change without notice in accordance with our continuous technical innovations.
Featured machines in photos may include additional equipment.