XCMG

XZJ5413THB
TRUCK-MOUNTED CONCRETE BOOM PUMP

MAINTENANCE MANUAL
XUZHOU CONSTRUCTION MACHINERY GROUP CO., LTD.

XUZHOU XCMG SCHWING MACHINERY CO., LTD.
The First Edition in August, 2010
TRUCK- MOUNTED CONCRETE BOOM PUMP
XZJ5413THB
MAINTENANCE MANUAL
Total pages: 56
VIN
Delivery Date
The operation manual is a part of the product!

Always keep it at hand for reference!
The design and manufacture of the machine comply with the standard of
QC/T 718-2004 Truck-mounted Concrete Pump
Preface
Thank you for selecting the products made by Xuzhou XCMG SCHWING
Machinery Co., Ltd.
This manual describes the maintenance and troubleshooting for truck-mounted
concrete boom pump of XZJ5413THB (HB48AIII).
In order to give full rein to the machine high performance, please read,
understand and use the instructions in this manual to ensure safety and high
efficiency work for a long time.
Only the trained and qualified personnel can operate this machine!
The untrained personnel can never operate the machine!
The operation of the machine should strictly obey the instruction manual!
We decline any liability in case of machine faults and accidents caused by
incorrect operation.
This manual is an indispensable part of the equipment, so it should be kept with
the equipment.
We reserve the right to modify the design without notice for improvement. If
there are parts of these instructions or individual chapters that you do not
understand, please contact our company.
Suggestions and advice about the equipment are welcomed.
August, 2010
Contents
I. Safety------------------------------------------------------------------------------------------------------1-1
1. Symbol & icon-------------------------------------------------------------------------------------------1-1
2. Safety protection equipment--------------------------------------------------------------------------1-2
3. Safety regulations on maintenance--------------------------------------------------------------------1-2
II. Maintenance--------------------------------------------------------------------------------------------2-1
1. Maintenance intervals-----------------------------------------------------------------------------------2-1
2. Delivery pipelines---------------------------------------------------------------------------------------2-3
2.1 Minimum wall thickness and operating pressure of delivery pipelines-------------------------2-3
2.2 Measuring wall thickness-----------------------------------------------------------------------------2-5
3. Lubrication------------------------------------------------------------------------------------------------2-5
3.1 Lubricant------------------------------------------------------------------------------------------------2-6
3.2 Lubricating modes-------------------------------------------------------------------------------------2-6
4. Replacing hydraulic oil---------------------------------------------------------------------------------2-7
4.1 Preparation----------------------------------------------------------------------------------------------2-8
4.2 Replacing oil--------------------------------------------------------------------------------------------2-8
5. Accumulator----------------------------------------------------------------------------------------------2-9
6. Replacement and adjustment of wear parts-----------------------------------------------------2-9
6.1 Disassembly and assembly of delivery piston------------------------------------------------------2-9
6.2 Adjustment of proximity switch---------------------------------------------------------------------2-11
6.3 Disassembly/assembly and adjustment of S-transfer tube and spectacle wear plate--------2-12
6.4 Disassembly and assembly of filter element------------------------------------------------------2-13
6.5 Replacement of other parts---------------------------------------------------------------------------2-14
7. Swivel parts----------------------------------------------------------------------------------------------2-14
7.1 Swivel device------------------------------------------------------------------------------------------2-14
7.2 Slewing ring--------------------------------------------------------------------------------------------2-14
8. Transfer case---------------------------------------------------------------------------------------------2-15
9. Related technical data in maintenance---------------------------------------------------------------2-16
9.1 Capacity------------------------------------------------------------------------------------------------2-16
9.2 Oil brand and capacity--------------------------------------------------------------------------------2-16
9.3 Tightening torque of bolts----------------------------------------------------------------------------2-17
III. Malfunction and troubleshooting----------------------------------------------------------------3-1
1. Delivery piston doesn’t work--------------------------------------------------------------------------3-1
2. Oil pump doesn’t work----------------------------------------------------------------------------------3-1
3. Core pump doesn’t switch over----------------------------------------------------------------------3-2
4. Agitator does not work----------------------------------------------------------------------------------3-2
5. S-Transfer tube does not switch over or pause during switching---------------------------------3-3
6. Oil is overheated-----------------------------------------------------------------------------------------3-3
7. Reverse pumping is faulty------------------------------------------------------------------------------3-4
8. A section of boom drops automatically --------------------------------------------------------------3-4
9. Placing boom can’t rise up-----------------------------------------------------------------------------3-4
10. Remote controller doesn’t work or partial function is faulty-------------------------------------3-4
11. Stabilizers fail to maintain positions under loading ----------------------------------------------3-5
12. Screen----------------------------------------------------------------------------------------------------3-5
13. Operation button----------------------------------------------------------------------------------------3-5
14. No power------------------------------------------------------------------------------------------------3-5
15. Remote controller--------------------------------------------------------------------------------------3-6
IV. Appendix-----------------------------------------------------------------------------------------------4-1
Chassis hydraulic system diagram------------------------------------------------------------------------4-1
Superstructure hydraulic system diagram---------------------------------------------------------------4-2
Electrical system principle diagram----------------------------------------------------------------------4-3
HB48AIII Easy-wear parts list-------------------------------------------------------------------------4-27
HB48AIII Main parts list--------------------------------------------------------------------------------4-28
XUZHOU CONSTRUCTION MACHINERY GROUP CO., LTD. CHINA
XUZHOU XCMG SCHWING MACHINERY CO., LTD.
Add：No. 29 Taoshan Road, Xuzhou Economic Development Zone, Jiangsu Province, China
Post code: 221004
Network address: www.xcmgjsjx.com
E-mail: xgjjbckf@163.com
Tel: +86-516-87892066
Fax: +86-516-87892529
Service telephone: +86-400-110-9999
Service fax: +86-516-87892055
Spare parts telephone: +86-516-87892511
Spare parts fax: +86-516-87892510
Service and quality complaint telephone: 0086-516-87892555
August, 2010
HB48AIII Truck-mounted Concrete Boom Pump Maintenance Manual Safety
I. Safety
1. Symbol & icon
Warning
Danger of tightening material to people
Risk of explosion
Abrupt stress relaxation may also lead to explosion.
Suspended load
Danger of falling objects.
Crushing danger
Danger of crushing
High voltage power lines
Death hazard
Burned danger
Danger of being burned by battery liquid
Poison
Danger of being poisoned by smelling or touching poisonous substance
Falling object
Danger of being injured by falling objects.
1-1
Daily checks
Check every 60 hours
2. Safety protection equipment
Helmet:
Helmet is used to protect head against the falling concrete or components of
delivery pipes if the hose explodes.
Glasses:
Glasses can keep eyes from the concrete splash or other granule attack.
Ear shields:
For protecting ears against noises when you are close to the machine.
Gloves:
Keep your hands from corrosive chemicals and machine’s corrosion and avoid
cut.
Safety shoes:
Protect your feet from being injured by falling objects and pierced by a
scrapped nail.
3. Safety regulations on maintenance

Periodic check and maintenance of the machine is necessary. The maintenance should be
implemented by the qualified repairman.
If it’s necessary to readjust the safety valve and throttle valve that have been adjusted by our
engineers, it must be done by the persons trained by our company. It is forbidden to remove lead
sealing from the safety valves.
1-2
1) The work of welding and repairing the placing boom and

its components, backstop, fixing devices, outriggers,
sub-frame and every wearable part must be implemented by
qualified persons. Refer to the right figure. Particular
attention must be paid to the boom support abutment or the
stabilizers serving as the hydraulic oil tanks. There is the
DANGER OF EXPLOSION.
i NOTE
Before carrying out welding, disconnect the battery, turn off all the switches on the control
box and disconnect the receiver of the remote controller.
2) The drive engine must always be shut down and pressure let off from the hydraulic units and
pipelines before carrying out repair work. Release the pressure in hydraulic accumulator.
Remove the engine key.
Repair works on machine with accumulator may be carried out only after the pressure in
hydraulic system has been released. No alterations are allowed to the hydraulic accumulator
circuit. Repair work on the accumulator should be performed by a qualified man.
3) Carry out maintenance and repair work on the placing boom when it is drawn in or supported,
the engine switched off and the support legs secured.
Support the boom sections whenever performing maintenance and repair work on the pressure
valves, cylinders or hydraulic pipelines.
i NOTE
Rigid delivery pipelines can be easily replaced with the placing boom folded in travelling
configuration. If rigid delivery pipelines are replaced with the placing boom unfolded,
stress could ensue when reassembling.
4) Before cleaning the machine with high-pressure water, remove the end hose and install a
collector for air flow cleaning.
5) If components in the electric, pneumatic and hydraulic circuits (valves, pumps etc.) need to be
changed, they are to be checked and adjusted in accordance with the data (pressure, voltage, etc.)
1-3
of the machine record sheet and circuit diagram.

6) To increase the service life of the delivery pipeline, all delivery pipes must be clockwise
turned 120°and elbows 180°after delivering approx. 6000m3. Observe the minimum wall
thickness and operating pressure.
7) If pumping does not work and fault can’t be removed within an hour, contact our serviceman
in time, meanwhile, clear the concrete in delivery pipeline, otherwise the concrete will solidify.
8) When dismount parts, take note of their fitting positions and refer to parts catalogue. Make use
of the spare parts list and service information to ensure correct assembly.
9) Before cleaning the machine with water or steam jet (high-pressure) or other cleaning material,
close off or glue up all openings into which no water/steam/cleaning material is allowed to enter
due to safety and functional reasons. Especially dangerous are electric motors and switch boxes.
After cleaning, water and glue should be completely removed.
DANGER
Never aim a water or steam jet at electric components of the machine!
Danger to life due to the conductivity of the machine! Moreover, the electrical
devices can be damaged!
1-4
HB48AIII Truck-mounted Concrete Boom Pump Maintenance Manual Maintenance
II. Maintenance
1. Maintenance intervals
1) Routine maintenance: before and after every day’s work.
2) 50 hours maintenance: after every 50 hours of operation.
3) 100 hours maintenance: after every 100 hours of operation
General information:
Concrete pump and placing boom have to be inspected after 1000 hours of operation, at least
once a year by a qualified person trained by our company. Inspected items are control pressure
of pump, pressure of accumulator and mixing pressure as well as slewing speed, welding
conditions and all articulated joints of the placing boom, leakage of pump and elevating
cylinders.
1.1 Routine maintenance
Before and after every day’s work, the following maintenance work should be done:
1) Check the hydraulic oil, fuel, gear oil and cooling water levels, top up if necessary.
2) Drain off any condensation formed at the bottom of hydraulic oil tank. Close draining cock
when oil emerges.
3) Inspect all parts which have come into contact with the concrete. Replace parts which are
worn.
4) Inspect the wear condition of the concrete pipes by knocking gently with a wooden hammer
or using a wall thickness measuring instrument and replace the worn parts. Refer to section 2.1
in this chapter for the permissible minimum wall thickness.
5) Grease the seals of pressure pipe and agitating axle.
6) Visually inspect hydraulic pipelines and screwed fittings for leakage.
7) Clean dirt and dust off the surface of hydraulic oil radiator carefully.
8) Lubricate all lubrication points on the S-transfer tube cylinder and fill up the grease
distributor with grease (fill it up every 2 operating hours).
9) Check the sensibility of electric switches.
10) Check the clearance between the S-transfer tube change valve and the wear plate. Adjust it if
it is more than 5mm.
11) After every day’s work, clean all the parts which contact concrete and the whole machine
carefully to prevent the delivery pipelines from being blocked by the leftover concrete.
2-1
1.2 50 hours maintenance

After the first 50 hours of operation, the machine should be maintained as follows.
1) Lubricate all the lubrication points, and fill the lubrication center according to specification.
2) Clean all filter elements, pipeline screens and dirt trap in the hydraulic system, replace
damaged filter element or paper filter element.
3) Check all bolts for looseness and tighten them by torque wrench according to the given
torque.
After every 100 hours of operation, the machine should be maintained as follows:
1) Routine maintenance and the 50 hours maintenance should be implemented.
2) Inspect the bolts and nuts on the spacer flanges between delivery piston and rod flange. If
necessary, re-tighten or replace the hexagon bolts 2.
3) Check the stroke time with concrete at maximum pump speed. Check the stroke time at the
maximum delivery amount.
4) Change the filter element and clean the magnetic bar and filter cartridge. Only use the filter
element supplied by our company.
5) Clean the magnetic bar with cloth (wipe several times along the rod).
6) When clean the filter screen, soak it into liquid in which lubricating oil can be dissolved (such
as acetone, petroleum ether and crude oil, etc.) for 10~15 minutes, and then blow it with
high-pressure air from outside to inside. During blowing, insert a bar wrapped by paper stripe
into filter screen, so that the dust blown from the filter screen by high-pressure air will stick to
the paper.
1) All the 100 hours maintenance work should be implemented.
2-2
2) Clean the suction filter of the water pump.

2) Inspect S-transfer tube for wear with a wall thickness measuring instrument. The permissible
minimum wall thickness of S-transfer tube is 4mm. The tube should be replaced if its wall
thickness is less than 4mm.
3) Clean the suction filter of the water pump.
4) Clean the hydraulic oil tank，change the oil in the engine and transfer case, as well as the
hydraulic oil in the hydraulic oil tank.
a. Shut off the engine when oil temperature is between 40°and 50°, and then drain off the oils
when the engine is still warm.
b. Change only with the oil recommended in this manual.
2) Have all the mechanical and hydraulic devices inspected by the specialist of our company and
the user.
3) Check that all safety devices are in proper working order. And inspect the condition of wear in
slewing bearing and pinions.
2. Delivery pipelines
2.1 Minimum wall thickness and operating pressure of delivery pipelines
Example for the min. wall thickness:
Given: operating pressure =120bar, pipe diameter = 150mm
Solution: trace a horizontal line from axis Y at height 120 towards the right until intersecting
diagonal line DN150. Then trace a vertical line until reaching axis X at the position of 5.8mm.
The minimum wall thickness is 5.8mm.
ND= low pressure HD= high pressure
BD= operating pressure DN=nominal diameter
2-3
Chart of the relation between min. wall thickness and pressure
2-4
2.2 Measuring wall thickness

The delivery pipes are subject to wear, so it’s very important to measure the wall thickness of
the delivery pipe before starting heavy work. Otherwise, the unexpected burst of the pipe will
affect the work and even endanger human life.
DANGER
When the delivery pressure reaches the given value, and the wall thickness is less
than the permissible min. wall thickness, the pipe may burst especially if it is
blocked.
WARNING
Hammer the delivery pipeline with wood hammer shaft slightly. Otherwise the
delivery pipeline may be damaged.
Measure the wall thickness according to instructions on the measuring equipments. Measure
the wall thickness by knocking at many points along the outside of the pipe, not only at one
point. The wear outside the elbow is larger than that inside the elbow or straight pipe, so pay
more attention to the outside of the elbow while measuring.
To ensure uniform wear of the concrete delivery pipeline, all delivery pipes should be turned
120° clockwise and elbows 180° after delivering approx 6000m3 concrete so that the service life
of delivery pipeline can be extended.
3. Lubrication
Lubricate all lubrication points on reciprocal moving parts periodically to ensure the
machine’s service life.
2-5
3.1 Lubricant
Such lubricant as L-XBCHB 0, L-XBCHB 00 and L-XBCHB 000 EP lithium-base grease are
recommended.
WARNING
Molybdenum bisulfide grease is forbidden. In order to ensure the effective
lubricating and guarantee the service life of truck-mounted concrete pump, please
use EP lithium-base grease below No.2.
3.2 Lubricating modes
1) Automatic centralized lubrication
The automatic centralized lubrication system is equipped on the lower structure. Connection
between each lubrication point and the lubricating pump is achieved by lubrication line.
a. Filling method
Fill with grease through grease nipple by manual or pneumatic grease gun.
b. Startup
Before the first startup or startup after an overhaul, enough grease should be filled into the
lubricant vessel. Keep the pump working until grease emerges from the end of each lubrication
line. The following should be done:
Before connecting the line, especially the longer line connected with the small displacement
pump, the line should be filled with grease in advance.
Keep the main line end open at first and do not perform connection until all air bubbles escape
from the line.
Press the compulsory lubrication button, the lubricant pump will rotate along the direction
indicated by the arrow on the lubricant tank and meanwhile supply lubricant by means of a cam
plate driving pump unit. There should be grease emerging from the main line. (The pumping of
hydraulic lubricant pump needs to be activated so that the centralized lubrication system can
automatically and continuously run.)
2-6
After connecting the main line, there is grease emerging from the outlets of all distributors.
Inspect the union of each lubrication point for leakage. If there is leakage found, re-tighten.
Inspect the union of all lines to ensure no leakage. If there is leakage, re-tighten.
c. Maintenance
It is recommended to fill the lubricant tank with L-XBCHB 0, L-XBCHB 00, L-XBCHB 000
EP lithium base grease
NOTE
Make sure that the grease filled in oil tank is clean.
After certain operating hours, inspect all the lines and joints for leakage or damage. Any
problems found should be repaired at once and all parts damaged should be replaced. If a section
of line needs to be replaced, the new one should be filled with grease before installation.
NOTE
Generally, the customers shouldn’t disassemble the electric pump.
If there is unclear malfunction or something in need of repair, please contact our company
in time.
2) Manual lubrication
a. Grease the rotating joints of concrete delivery pipe.
b. Lubricate all the articulation joints of booms and swing stabilizers every 60 hours.
c. After 100 operating hours (there is a clock on control box), the bearings and seals must
be checked and replaced if necessary.
d. If there is concrete or slurry containing oil emerging from the hopper bearing, replace the
bearing at once.
e. During repairing, the bearing bush of S-transfer tube must be tightened to prevent its axial
displacement under high pressure.
4. Replacing hydraulic oil
This part explains how to replace hydraulic oil completely. The maintenance interval can be
found in “maintenance”.
Cleaning is the most important operation for hydraulic system maintenance. You have to do
everything possible to keep dust, dirt and other impurities out of the system. Even little particle
can cause spots on the valves, seizures on the pumps and blockages inside the throats. New oil
2-7
must be settled for a while and without ever extracting the bottom before being taken from the
barrel. A special filter should be used for filling.
4.1 Preparation
Before replacing oil, carefully perform the following operations:
Switch off the remote controller
Stop engine
Depressurize the accumulator
WARNING:
The pressure in the accumulator must be released.
Ensure to prevent any unauthorized start-up by moving the ignition key from the
control panel. Remove the key from switch and turn off power.
4.2 Replacing oil
a. Remove all hoses from oil tank.

i NOTE
Make marks on all hoses and joints so as to reassemble them correctly.
Wipe all openings with clean cloth as deep as possible. Don’t forget the concealed holes.
b. Drain off the hydraulic oil by opening the draw-off valve under the oil tank.
c. Remove all liners of filters.
d. Remove all filters and re-install the filter elements.
e. Replace all defective hoses.
f. Fill up the oil tank with new oil.
i NOTE
Effectively dispose of used filter liners in conformity with regulations as regards waster
products.
You must fill the tank through filters. After trial run, refill the tank to the maximum
permissible capacity.
g. Clean the dust off the oil cooler.
h. Check all joints including screwed joints.
i. Check connection of electric devices.
j. Carry out functional check.
k. Drain the hydraulic system.
l. Implement trial run for several times.
m. Re-install all safety devices, signs and indication plates removed.
2-8
Air filter
Top of tank
Bottom of tank
Oil outlet
5. Accumulator
Explosion Danger
Inflate the accumulator only with nitrogen. There may be a danger of explosion
if it is inflated with compressed air, oxygen or something alike.
i NOTE
Once hydraulic oil temperature reaches its operating value, check the pre-inflation pressure of
the accumulator. The fixed value of accumulator’s pre-inflation pressure is given in hydraulic
principle diagram. The pressure value measured may be not more than 15% of the given value.
The pointer on the pressure gauge goes down to the lower value along with the release of
pressure in the accumulator. Once the pre-inflation pressure of the accumulator is reached, the
reading on the gauge will lower suddenly. That is to say, the reading of abrupt reduction
indicates the accumulator’s pre-inflation pressure.
1) Let the hydraulic oil enter into the accumulator until the pressure gauge pointer indicates
the maximum value.
2) Switch on the relief valve slightly to release the accumulator pressure slowly.
3) Check the reading on pressure gauge to get the pre-inflation pressure. If the value is less
than 75% of the given value (10MPa), inflate the accumulator.
i NOTE
The expert who checks and inflates the accumulator must be an authorized inspector. Tools
and equipment for checking and inflating the accumulator must be taken with.
6. Replacement and adjustment of wear parts
6.1 Disassembly and assembly of delivery piston
1) Dismounting delivery piston
2-9
a. Loosen the bolts fixing the cover board of proximity switch assembly and remove the cover
board. Switch off the ball valve at the bottom of the oil cylinder completely to ensure that the
cylinder can run to end without change of direction.
b. Meantime, make the pumping cylinder move by pressing the button of piston automatic return
and the pressure holding switch.
c. Stop the engine when the delivery piston 1 is completely visible. Remove the cover of water
box, and drain off the water in it.
WARNING:
All work in the water box can be carried out only after the drive engine is
switched off.
d. Delivery piston can be dismounted after spacer flanges 2 and 3 are removed as well as bolt 1.
Remove the water draining mechanism (if attached).
e. Remove the remaining slurry from all parts and the front ends of the delivery cylinder. Take
care not to damage the hard chrome lining.
2-10
2) Mounting delivery piston

a. Coat the delivery piston and the cylinder inner wall with a thick layer of grease.
b. Connect the new delivery piston by means of the bolt 1 with the half flanges 2 and 3. Start the
pump to drive the delivery piston into the delivery cylinder.
c. Tighten the bolt
d. Mount the other delivery piston with the same method.

e. Install the proximity switch and pay attention to the distance between the switch bottom and
the highest point of the piston connection. This distance should be in the range of 4mm~5mm.
Tighten the nuts of the proximity switch and cover the water box with cover grid.
NOTE:
While perform the work mentioned above, all work in the water box must be carried out with
the drive engine switched off!
6.2 Adjustment of proximity switch
1) The distance between the switch bottom and the highest point of the piston connection should
be 4～5mm.
Note: Our Company is not responsible for the damaged proximity switch caused by
improper adjustment or operation in violation of specified regulations and requirements.
2-11
2) Check the position of proximity switch and if proximity switch is too close to the front, the
bottom of the cylinder is liable to be impacted or the proximity switch fails to change direction.
If the proximity switch is too close to the rear, it is easy for the short stroke to be caused. The
principle of adjustment: the position of proximity switch can make the cylinder realize its
maximum stroke and the bottom of cylinder not impacted at the same time.
6.3 Disassembly/assembly and adjustment of S-transfer tube and spectacle wear plate
Prior to the operation, the engine must be switched off and the pressure in accumulator
released. The structure diagram is shown below:
1) Disassembly
a. Remove the cover grid of the hopper.
b. Loosen bolt 3 after loosening bolt 2 and make several anticlockwise turns.
c. Shift the S-transfer tube 10 towards the pressure connection 13.
d. Unscrew the bolt 5 of spectacle wear plate 6, dismount and take out the wear plate by
executing a slight slewing movement.
e. Remove the wear ring 8, rubber ring 9 and O-ring 7.
f. Clean wear ring 8, rings 7 and 9, spectacle wear plate 6 and the end of S-transfer tube 10.
2) Assembly and adjustment
a. Mount the O-ring 7 and grease the contact surface for the spectacle wear plate 6.
b. Apply grease onto the wear ring 8 and locate it and the rubber ring 9 together with S-transfer
tube.
c. Mount wear plate 6 in the hopper and tighten the bolt 5.
d. Tighten the adjusting bolt 3 until the wear ring 8 aligns with the spectacle wear plate 6.
e. Measure the distance A between wear ring 8 and S-transfer tube 10. Make the distance A in
the range of 1mm ~3mm by adjusting the bolt 3. If this can’t be realized and the distance A is
more than 5mm, replace the spectacle wear plate.
2-12
f. Tighten the clamp bolt 14 on switch-over lever 1 (Tightening torque: 210 NM).
g. Tighten bolt 2 after tightening the adjusting bolt 3, and then cover the hopper with cover grid.
6.4 Disassembly and assembly of filter element
i NOTE
The filter elements must not be cleaned and then used again. They must be replaced.
Before replacing them, inspect O-rings and other seals of filtering components, which should be
replaced if damage is found.
1) Clean the filter casing with diesel oil or other cleaning agent.
2) Place a receptacle beneath filter head to collect oil from the filter.
3) Screw out the bolt in the middle of filter by approx.20mm, and then the check valve of casing
5 will seal the oil inlet.
4) Remove the suction pipe connector in the middle of the filter and drain off the oil inside the
filter.
5) Screw out the 6 bolts at the end of the filter, and then the filtering element can be taken out
6) Pull out filtering element and clean the magnetic bar.

7) The filtering element is made of paper. It can’t be cleaned
or repaired but replaced if it is damaged or blocked (in this
case, the reading in vacuum meter is higher than –0.02Mpa
during working). Only use the element supplied by our
company.
8) Clean the parts disassembled carefully, replace the new filtering element, and then re-mount
them following the reverse procedure.
2-13
9) Finally tighten all the fixing bolts; otherwise the oil suction resistance may increase.
6.5 Replacement of other parts
1) Inspect the guide device and seals of S-transfer tube after 100 operating hours. If there is
slurry or grease overflowing from support shaft, the guide device and seals should be replaced.
During maintenance, the support sleeve of S valve must be fixed with bond to avoid axial
movement under high pressure.
2) Inspect the seals on both ends of mixing shaft. If wear on seals or mixing shaft is so serious
that slurry enters into mixing shaft bearings, replace the seals or mixing shaft.
3) The hose which is exposed to sunlight or under high pressure should be put through
mechanical test. If a hose line becomes brittle or cracked, replace it at once.
7. Swivel parts
7.1 Swivel device
1) Maintenance
After the first 100 operating hours of reducer (including the intermittent operating time),
clean the inside of the reducer and the brake with cleansing agent and replace oil.
Check the inside of the reducer and brake for metal particles.
It’s better to exchange oil before the oil becomes cool. That’s helpful to drain the oil in the
tank completely.
Replace oil every 2000-2500 operating hours, or at least once a year.
Don’t use mixed oil.
2) Replacing oil
Make sure that all oil ports of reducer and brake are in proper positions.
Remove the plugs and drain the oil in the reducer and brake completely.
i NOTE
Clean the inside of the reducer and the brake with cleansing agent before filling new oil.
Fill cleansing agent into the reducer and brake and install the plugs. Let them run at high
speed for several minutes and then drain off cleansing agent.
WARNING
The application of erosive cleansing agent and improper lube will change oil
character, and consequently damage the slewing track and relevant parts.
7.2 Slewing ring
(1) Lubrication
Proper lubrication is necessary for durability of the slewing track and the teeth.
The frequency of lubrication depends on the working conditions and circumstance. Normally
it has to be done every 150 operating hours.
2-14
WARNING:
When the machine has been at a standstill for a long period, the bearing should
be lubricated. Lubrication should be carried out more frequently in tropical
climates, dusty or damp environments or areas that are subject to notable changes in
temperature.
(a) Lubricate the slewing bearing of the placing boom. Grease it to reduce wear. Maintain the
seals to avoid corrosion. Grease it until the grease seeps from grease nipple.
(b) Lubricate the pinions. Whether greasing by spraying or brushing, the lube should cover the
pinions and the toothed surfaces fully.
(c) Check the tightness of the bolts on the boom slewing bearing. During this operation, the
tensile stress caused by the boom must be released from the bolted connection. The placing
boom should be placed in the transport position. Tightening should be carried out on the
diametrically facing bolts, two by two.
(d) Inspect the bearing ring teeth and pinions in order to reduce wear. The requirements below
should be followed:
1) Position the placing boom with sections closed in vertical position;
2) Measure the working condition between the bearing ring tooth and pinion tooth;
3) Disconnect the bolts from the unit;
4) Disassemble the slewing unit;
5) Adjust the tooth side gap between the main gear and the pinion to approximately 0.3mm.
6) Re-assemble all parts and re-tighten them with bolts. Inspect the tightness of all bolts and
consistence of every bolt and nut periodically.
7) Overall inspection: inspect the tightness of bolts. Inspect the consistence of every bolt and
nut periodically.
8. Transfer case
i NOTE
 Ensure no oil leak to the ground to cause environmental pollution during replacing, filling
and draining oil.
2-15
 Only after switching off the engine, it is permitted to disassemble the oil dip stick and
screws of overflow port, or it will hurt people.
 Shift of transfer case can’t be carried out under the load. It only can be shifted on condition
that the pressure in the pipeline for pneumatic shift maintains not less than 0.6MPa after
stopping the machine.
 Contacting lube for a long time will hurt your skin, so please use ointment.
 After a long running, the temperature of the lube and the transfer box will become very
high. So maintenance should be done when the transfer box is cool to avoid scald. Wear
protective garment, gloves and so on during working.
 Comply with relevant environment and safety laws and regulations made by national, local
government or enterprises.
 Maintain the transfer case periodically. If anything abnormal happens (such as too high
input power, too high temperature, excessive vibration, unusual noise and smell and so on),
it indicates there is something wrong with the machine. Repairman should keep an eye on
the abnormal phenomenon all the time to avoid accidents. The malfunction should be
inspected at once with engine stopped, and make sure the machine won’t be started up
unintentionally.
 To ensure radiation, clean the dust and dirt off the gear box case periodically.
Replacing lubricating oil
The first time of changing oil should be carried out after the first 200 operating hours of the
transfer case, and subsequently after every 2000 operating hours or 12 months.
In order to drain the old oil completely, the oil temperature shouldn’t be too low while
draining oil.
Suggestion: if the old oil is very dirty, the gear should be cleaned with new oil or special oil.
Different oils such as mineral oil, compound oil and grease should not be mixed in any case.
Before replacing the old oil with another brand of oil, clean the gear box.
9. Related technical data in maintenance
9.1 Capacity
1) Hydraulic oil tank capacity: about 860L;
2) Hydraulic system capacity: about 350L (excluding oil tank);
3) Concrete delivery pipeline: about 12L/m for ф125mm pipe;
9.2 Oil brand and capacity
1) Lubricant of transfer case: L-CKD220-320 heavy duty gear oil, 4L.
2) Hydraulic oil: L-HM46 wear-resistant hydraulic oil, 860L.
2-16
NOTE:
Different brands of hydraulic oil should not be mixed. Before filling another
brand of oil, drain the old oil in the oil tank completely.
9.3 Tightening torque of bolts
The given friction coefficient is 0.14, tightening torque in N·m
1) Tightening torque of the screw with special threads
a. The bearing flange for the mixer shaft and the thermo-probe should be tightened to 30N·m.
b. Contact our company for the tightening torque of the seven long bolts which connect the
hopper, water box and delivery cylinder together.
2-17
2) Refer to the following table for tightening torques of bolts

Thread pitch Spanner size Quality grade
Size
h sw1 sw2 6.8 8.8 10.9 12.9
M4 0.7 7 3 2.4 2.9 4.1 4.9
M5 0.8 8 4 5 6 8.5 10
M6 1 10 5 8 10 14 17
M8 1.25 13 6 21 25 35 41
M10 1.5 17 8 41 49 69 83
M12 1.75 19 10 72 86 120 145
M14 2 24 14 180 210 295 355
M16 2 24 14 180 210 295 355
M18 2.5 27 14 245 290 405 485
M20 2.5 30 17 345 410 580 690
M24 3 36 19 600 710 1000 1200
M27 3 41 19 890 1050 1500 1800
M30 3.5 46 22 1200 1450 2000 2400
M8﹡1 1 13 6 23 27 38 45
M10﹡1 1 17 8 44 52 73 88
M12﹡1 1 19 10 76 90 125 150
M14﹡1.5 1.5 22 12 125 150 210 250
M16﹡1.5 1.5 24 14 190 225 315 380
M24﹡2 2 36 19 650 780 1100 1300
M30﹡2 2 46 22 1350 1600 2250 2700
Tightening torque N·m
2-18
HB48AIII Truck-mounted Concrete Boom Pump Maintenance Manual Malfunction and Troubleshooting
III. Malfunction and Troubleshooting

NOTE:
Only experts can perform the repair on the electric control box and the hydraulic system. If
it runs into special trouble and no remedy found in this manual, please contact the after service
department of our company for repair.
1. Delivery piston doesn’t work
1) Pump doesn’t switch on
Solution: Press the pumping button on the control box and inspect it. If the pumping system is
running, the indicator on the screen should be light.
2) Insufficient oil in hydraulic oil tank
Solution: Fill up with oil.
3) Pump output is not suitable for pumping
Solution: regulate (125) throttle valve.
4) Piston seizes up.
Solution: Press the stop pumping button or reverse pumping button
5) Rotation speed of the engine is less than the minimum working speed of oil pump (500rpm).
Solution: Speed up engine.
7) Too low oil temperature
Solution: Run the machine until oil warms up.
2. Oil pump doesn’t work
1) High-pressure relief valve (138) is contaminated
Solution: Loosen the valve cap 2~3 turns with a spanner so that the dust can be removed, and
then re-tighten it.
2) Low-pressure relief valve (139) is contaminated
Solution: Refer to item 1).
3) Swash plate of the main oil pump (127) doesn’t work normally
Solution: Measure the pressure at the point of m8. If it is less than 1.2Mpa, inspect whether the
throttle hole of ф1.2 is blocked. Clean it if it is blocked.
4) The relief valve of make-up oil pump (116) can’t be closed, and the pressure of make-up oil
pump is too low
Solution: Remove the pilot valve core of the relief valve (116)，and re-install it after cleaning.
Adjust the relief pressure to 3.4Mpa (measure the pressure at the point of Ps)
5) Solenoid change valve (103a) faulty (to cut off the valve when it is in neutral)
Solution: Check and clean the valve. Check the on/off function of the valve. Replace it if
necessary.
3-1
6) There is dust in the intake check valve of one-way relief valve (138a) or it seizes up.
Solution: Turn anti-clockwise to remove the valve cover. Inspect its operation performance and
surface sealing.
3. Core pump doesn’t switch over
1) Insufficient hydraulic oil
Solution: Fill up with oil.
2) Fuse FU3 blown
Solution: Replace the fuse.
3) Loose terminal of proximity switch
Solution: Tighten it.
4) Too much oil in intercommunication cavity of pumping oil cylinder
Solution: Internal leakage of pumping oil cylinder, replace the piston sealing.
5) Solenoid change valve (103a) doesn’t work
Solution: Inspect and repair or replace the valve (103a).
6) Reverse control valve（108）seizes up
Solution: Inspect and clean the valve.
7) Too long detecting distance of proximity switch
Solution: adjust the switch’s position
8) Seal of“SN”damping valve is faulty
Solution: Clean“SN”valve
9) If the machine still can not switch over except for the above causes, then the cable from power
supply to control box or from control box to the machine may be damaged.
Solution: Check the cable with ohmmeter.
4. Agitator does not work
1) Relief valve setting pressure is too low or it is contaminated
Solution: adjust the pressure to 15~16Mpa by blocking the agitator with a wood stick, and clean
the valve if necessary.
3-2
2) Hydraulic motor is damaged

Solution: Check the motor for leakage, and replace it if necessary.
5. S-Transfer tube does not switch over or pause during switching
1) Hydraulic-controlled change valve (103) seizes up.
Solution: Thoroughly check and clean the valve to ensure free and smooth motion of sliding
parts.
2) S-Transfer tube is set too tightly
Solution: Adjust the clearance between the transfer tube and spectacle wear plate.
3) Aggregate sticks to swing area and deposit exists in the hopper
Solution: repeat pumping and reverse pumping to remove these aggregate, and open the hopper
for cleaning if necessary.
4) Accumulator pressure is too low
Solution: Pressure relief valve of accumulator (121) is not well closed, close it well.
5) Accumulator inflation pressure is too low
Solution: Inflate the accumulator until the inflation pressure is 10Mpa±0.5MPa.
6) Throttle valve in cut-off valve (181) is blocked
Solution: clear this valve.
7) Swing oil cylinder fails
Solution: Inspect the piston sealing, and replace it if necessary.
8) Pump in S-transfer tube control circuit (128) is damaged
Solution: Replace it.
6. Oil is overheated
1) Insufficient water in water box
Solution: Fill up with water.
2) Too high flushing water temperature
Solution: Change water.
3) Poor concrete
Solution: improve concrete quality.
4) Pump runs at large displacement for a long time
Solution: Reduce pump output.
5) Pressure is too high due to blockage
Solution: Clear away the block.
6) Oil cooler is contaminated and the fan in it doesn’t work
Solution: Clean the cooler
7) Setting pressure of high-pressure relief valve is too low
Solution: regulate the pressure of this valve (138) to 34~35MPa.
3-3
8) Leakage in shuttle valve (197)

Solution: Check and repair or replace.
7. Reverse pumping is faulty
1) Reverse pumping switch (SA5) is damaged
Solution: Repair or replace the switch.
2) Pump-controlled solenoid change valve (108) is jammed by dirt
Solution: Press the manual button on the valve repeatedly, and clean or replace the valve if
necessary.
3) Loose terminals
Solution: Tighten terminals on control box or reverse pumping control valve.
4) Reverse pumping can’t be performed by means of remote controller, reverse pumping switch
is damaged
Solution: Replace the switch.
8. A section of boom drops automatically
1) Balance valve becomes dirty
Solution: telescope the hydraulic cylinder of the descended
boom repeatedly to get rid of the dirt; disassemble and clean
the balance valve.
2) There is dust in relief valve
Solution: telescope the hydraulic cylinder of the boom
repeatedly to get rid of the dust; inspect and clean the relief
valve
3) Internal or external leakage. The seals of hydraulic cylinder
piston or piston rod are damaged.
Solution: Replace the seals
9. Placing boom can’t rise up
1) Insufficient pressure in hydraulic system
Solution: Inspect the system pressure and adjust it to the value specified.
2) Relief valve dirty or damaged
Solution: Inspect and clean the valve.
3) Hydraulic pump faulty
Solution: Inspect the pump.
4) PTO of transfer case faulty
Solution: Inspect transfer case and replace it if necessary.
10. Remote controller doesn’t work or partial function is faulty
1) The plug of remote controller is not in socket or not in place
3-4
Solution: Inspect the plug for correct connection.

2) Plug short circuited or no electricity
Solution: Check the connection of plug, socket and cable, and replace components damaged.
3) Turn button or press button damaged
Solution: Check and replace them if damaged.
11. Stabilizers fail to maintain positions under loading
Danger！
Unload the stabilizers’ hydraulic cylinders by rotating the placing boom towards the
reverse direction of the retracted stabilizers at once. Inspect and repair the machine in travel
configuration.
1) Leakage in check valve
Solution: Inspect and clean it, replace it if necessary.
2) Leakage in hydraulic oil cylinder
Solution: Replace oil cylinder gaskets.
3) Relief valve is jammed
Solution: Inspect the relief valve, clean or replace it if necessary.
12. Screen
1) No indication displayed on the screen after it is turned on
Solution: turn it off and turn it on again or contact serviceman.
2) No reading on speedometer or incorrect reading
Solution: re-start the machine and engage PTO (mainly for ISUZU chassis), and check the pulse
signal of rotation speed when there is no reading displayed on the speedometer; contact service
man if reading displayed is not correct.
3) No reading on oil temperature gauge
Solution: Contact service man, check sensor circuit for trouble, replace sensor.
NOTE: confirm that the case of temperature measurement adapter grounds reliably while
carrying out replacement. It should be sealed by copper gasket rather than PTFE raw material
tape and adhesive.
4) Operating time and pumping times are not accurate
Solution: Contact service man.
13. Operation button
1) The machine had no action after the button is activated
Solution: check fuse and contact service man.
14. No power
Solution: check PTO switch, DC circuit breaker, the PTO switch on transfer case and fuse.
Contact service man.
3-5
15. Remote controller

1) No power
Solution: Inspect fuse, contact service man.
2) No action
Solution: re-start the remote controller (start emergency stop button first, and then key switch),
contact service man.
3) Partial function faulty
Solution: Check the circuit of movement parts. Contact service man.
NOTE: all service men for electric devices should possess electric knowledge. Alteration of
electric components and circuits and addition of electric function are not permitted.
3-6
HB48AIII Truck-mounted Concrete Boom Pump Maintenance Manual Appendix
IV. Appendix
Chassis Hydraulic System Diagram
4-1
Superstructure Hydraulic System Diagram (5-Section Boom)
4-2
Electrical System Principle Diagram－A (5-Section Boom)
4-3
Electrical System Principle Diagram－B (5-Section Boom)
4-4
Electrical System Principle Diagram－C (5-Section Boom)
4-5
Electrical System Principle Diagram－D (5-Section Boom)
4-6
Electrical System Principle Diagram－E (5-Section Boom)
4-7
Electrical System Principle Diagram－F (5-Section Boom)
4-8
Electrical System Principle Diagram－G (5-Section Boom)
4-9
Electrical System Principle Diagram－H (5-Section Boom)
4-10
Electrical System Principle Diagram－I (5-Section Boom)
4-11
Electrical System Principle Diagram－J (5-Section Boom)
4-12
Superstructure Hydraulic System Diagram (6-Section Boom)
4-13
Electrical System Principle Diagram－A (6-Section Boom)
4-14
Electrical System Principle Diagram－B (6-Section Boom)
4-15
Electrical System Principle Diagram－C (6-Section Boom)
4-16
Electrical System Principle Diagram－D (6-Section Boom)
Electrical System Principle Diagram－E (6-Section Boom)

4-17
Electrical System Principle Diagram－F (6-Section Boom)
4-18
Electrical System Principle Diagram－G (6-Section Boom)
4-19
Electrical System Principle Diagram－H (6-Section Boom)

4-20
Electrical System Principle Diagram－I (6-Section Boom)
4-21
Electrical System Principle Diagram－J (6-Section Boom)

4-22
Electrical System Principle Diagram－K (6-Section Boom)

4-23
Electrical System Principle Diagram－L (6-Section Boom)

4-24
Electrical System Principle Diagram－M (6-Section Boom)
4-25
HB48AIII Easy-wear Parts List

4-26
No. Drawing code Name Material Qty. Position

1 152601233 S-transfer tube assembly -- 1 Hopper
2 150102095 Bearing ring assembly -- 1 Hopper, transfer tube
3 152601234 Cutting ring Q345 1 Hopper, transfer tube

4 152601235 Spectacle wear plate Q235 1 Hopper, transfer tube
5 151500767 Delivery cylinder -- 2 Core pump
6 150102099 Support ring Polyurethane 2 Core pump
7 152601245 Rubber ring (piston) Polyurethane 2 Core pump
8 152601240 Intermediate ring 45 2 Core pump
9 150102018 Flange bearing -- 1 Hopper, transfer tube
10 150102114 Spheric base ZCuAlFe3Mn2 4 Swing cylinder
11 150102113 Wear sleeve 45 1 Hopper, transfer tube
12 152600675 Blade Q345 4 Hopper, transfer tube
Φ125 Delivery pipe Delivery pipeline of
13 —— -- 1set
(including elbow) Lower structure
Φ125 Delivery pipe Delivery pipeline of
14 —— -- 1set
(including elbow) Lower structure
Delivery pipeline of
15 152601330 Flange ZG40Mn 1
Lower structure
16 152601331 Hinge elbow pipe ZG40Mn 1
Lower structure
17 150102122 Three-way elbow -- 1
Lower structure
Φ180-Φ150 Tapered Delivery pipeline of
18 150601335 ZG40Mn 1
pipe Lower structure
19 150501697 30° elbow ZG40Mn 1
chassis
Φ150-Φ125 Tapered Delivery pipeline of
20 150102268 ZG40Mn 1
pipe chassis
21 152601232 End hose -- 1 Placing boom
HB48AIII Main Parts List

4-27
No. Model Name Qty. Position Remarks

1 803001668 Quadruple pump 1 Modified chassis Rexroth, Germany
Slewing reducer
2 800306884 assembly (including 2 Slewing mechanism Ningbo Zhongyi
motor)
STIEBEL,
3 819904261 Transfer case 1 Modified chassis
Germany
Turret-base
4 800303518 Slewing bearing 1 Xuzhou Rothe Erde
structure
5 802100197 Chassis 1 Lower structure Isuzu, Japan
6 803000505 Gerotor motor 1 Mixing device Ningbo Zhongyi
Superstructure Superstructure
7 803002075 1 Hawe, Germany
multi-way valve hydraulic system
803112895 Stabilizer combination Superstructure
8 1 Walvoil
803112894 valve hydraulic system
803500936
9 803501011 Pressure gauge 3 Hydraulic system American Parker
803501013
10 803501136 Remote controller 1set Electrical system HBC, Germany
11 803001758 Boom pump 1 Modified chassis Rexroth, Germany
NOTE: The products of our company are always in improvement, so take this table only as
reference and take the configuration of delivered vehicles as standard.
4-28

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XZJ5413THB

TRUCK-MOUNTED CONCRETE BOOM PUMP

XUZHOU CONSTRUCTION MACHINERY GROUP CO., LTD.

The operation manual is a part of the product!

Danger of tightening material to people

Abrupt stress relaxation may also lead to explosion.

Danger of falling objects.

High voltage power lines

Danger of being burned by battery liquid

Check every 60 hours

2. Safety protection equipment

Helmet is used to protect head against the falling concrete or components of

delivery pipes if the hose explodes.

3. Safety regulations on maintenance

1) The work of welding and repairing the placing boom and

of the machine record sheet and circuit diagram.

1.2 50 hours maintenance

2) Clean the suction filter of the water pump.

Chart of the relation between min. wall thickness and pressure

2.2 Measuring wall thickness

4.2 Replacing oil

a. Remove all hoses from oil tank.

2) Mounting delivery piston

d. Mount the other delivery piston with the same method.

6) Pull out filtering element and clean the magnetic bar.

2) Refer to the following table for tightening torques of bolts

III. Malfunction and Troubleshooting

2) Hydraulic motor is damaged

8) Leakage in shuttle valve (197)

Solution: Inspect the plug for correct connection.

15. Remote controller

Superstructure Hydraulic System Diagram (5-Section Boom)

Electrical System Principle Diagram－A (5-Section Boom)

Electrical System Principle Diagram－B (5-Section Boom)

Electrical System Principle Diagram－C (5-Section Boom)

Electrical System Principle Diagram－D (5-Section Boom)

Electrical System Principle Diagram－E (5-Section Boom)

Electrical System Principle Diagram－F (5-Section Boom)

Electrical System Principle Diagram－G (5-Section Boom)

Electrical System Principle Diagram－H (5-Section Boom)

Electrical System Principle Diagram－I (5-Section Boom)

Electrical System Principle Diagram－J (5-Section Boom)

Superstructure Hydraulic System Diagram (6-Section Boom)

Electrical System Principle Diagram－A (6-Section Boom)

Electrical System Principle Diagram－B (6-Section Boom)

Electrical System Principle Diagram－C (6-Section Boom)

Electrical System Principle Diagram－D (6-Section Boom)

Electrical System Principle Diagram－E (6-Section Boom)

Electrical System Principle Diagram－F (6-Section Boom)

Electrical System Principle Diagram－G (6-Section Boom)

Electrical System Principle Diagram－H (6-Section Boom)

Electrical System Principle Diagram－I (6-Section Boom)

Electrical System Principle Diagram－J (6-Section Boom)

Electrical System Principle Diagram－K (6-Section Boom)

Electrical System Principle Diagram－L (6-Section Boom)

Electrical System Principle Diagram－M (6-Section Boom)

HB48AIII Easy-wear Parts List

No. Drawing code Name Material Qty. Position