Jiuhe Heavy Machinery Operating Manual of Concrete Pump Truck

Preface
Sincerely thank you for choosing the concrete pump truck of Qingdao Jiuhe Heavy
Machinery Co., Ltd, quality products and star-level services are what we will provide for you.
The pump truck developed by Qingdao Jiuhe Heavy Machinery, through absorbing the
technical essence of the international concrete pump trucks, is integrated with high reliability,
economy, safety and durability, with flexible and fast telescopic boom, small covering space of
the landing legs, and whole truck being easy and flexible to move. They are widely used in
new rural construction, urbanization, road, airport, port, high-speed rail, beam fabrication yard
and bridge construction, etc. Qingdao Jiuhe Heavy Machinery has become a leader in the
small- boom concrete pump truck industry. This Operating Manual will detail the safety
regulations, technical characteristics, performance parameters, working principle, structural
composition, operation and maintenance and other contents of JH series of concrete pump
trucks. For better use of the pump truck, please read this manual carefully before operation,
which will:
•Help you understand the structure and performance characteristics of the pump truck;

•Avoid danger and machine fault due to improper operation;

•Increase the reliability in pump truck use;

•Extend its service life.

•Reduce repair cost and abnormal downtime.

The manual shall be made as readily available as tools in a toolbox for reading at any time.
You can operate the pump truck expertly and safely only by fully understanding the content of
this Manual.
Thanks very much for your trust and support for Jiuhe products, and sincerely wish you
plenty of prosperity and achievements in your cause.

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Jiuhe Heavy Machinery Operating Manual of Concrete Pump Truck

Special Suggestion
Users shall carefully maintain and properly use the pump truck, and Qingdao Jiuhe Heavy
Machinery is not obliged to assume responsibilities for the consequences caused due to
violation of the following provisions:
Do read this Manual carefully and operate according to the said requirements before using
the pump truck.

Use the pump truck in accordance with the scope stipulated herein, and not for other
purposes at will.

Operators must be trained and skilled workers. Operators shall be emotionally stable,
clearheaded and quick-minded during operation.

It is not allowed to hire unskilled technicians to maintain, or disassemble it without

authorization.

Each technical maintenance must be conducted as required herein.

Please conduct maintenance and care of the engine in strict accordance with the
requirements of the operating and maintenance manuals provided by the engine manufacturer.
Please use the accessories provided by our company to guarantee its normal operation, as
any substitute or imitation may cause serious damage to the product, for which our company
will not be responsible.
Any refit or device addition to the pump truck is prohibited without consent of Jiuhe
Heavy Machinery; adjustment of safety equipment and valves is prohibited; welding of the
main components is prohibited.
As the Manual is an important integral part of the product, please do transfer this manual
together when transferring this machine to the assignee.

Products of our company will be continuously improved as the science and

technology develop. The content of this Manual is for reference only and the real product
shall prevail. The product is subject to change without notice. Please call the local service
engineer if you have any questions. Thank you!

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Jiuhe Heavy Machinery Operating Manual of Concrete Pump Truck
Contents
Chapter I Safety Regulations ………………………………………………………………5

1-1. Ground Rules …………………………………………………………………………5

1-2 Operation Precautions ……………………………………………………………… 6

1-3. Protective Equipment …………………………………………………………………9

1-4. Injury Risk………………………………………………………………………………10

1-5. Hazardous Area…………………………………………………………………………11

1-6. Selection and Qualification of Operator …………………………………………… 12

1-7. Requirements for Work Place ………………………………………………………….14

1-8. Boom Operation Precautions ………………………………………………………….17

1-9. Precautions of Pumping Operation …………………………………………………….19

1-10. Cleaning of Pump Truck………………………………………………………………21

Chapter II Instruction of Complete Machine ………………………………………………21

2-1. Overview …………………………………………………………………………21

2-1.1 Main performance and configuration ………………………………………………....21

2-1.2 Nameplate of complete machine …………………………………………………….22

2-1.3 Nameplate position diagram of complete machine ……………………………….....22

2-2. Working Range Diagram and Main Technical Parameters ……………………………22

2-2.1 Working range diagram of 32m pump truck……………………………….…………22

2-2.2 Main technical parameters of 32m pump truck…………………………………….…24

2-3 System Overview …………………………………………………………….……25

2-3.1 Chassis ………………………………………………………………………….…25

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Jiuhe Heavy Machinery Operating Manual of Concrete Pump Truck

2-3.2 Boom system …………………………………………………………………………25

2-3.3 Supporting platform landing leg assembly of slewing mechanism ……….…………25

2-3.4 Pumping mechanism …………………………………………………………..…26

2-3.5 Control system ………………………………………………………………….…28

2-3.5.1 Hydraulic principle …………………………………………………………..…28

2-3.5.2 Electrical principle …………………………………………………………..…31

2-3.5.2.1 Electric appliance schematic diagram of sinotruck chassis……..……………...…31

Chapter III Operation Instruction …………………………………………………………32

3.1 Start operation of SINOTRUCK chassis pump truck ………………………….……… 32

3.2 Boom Operation …………………………………………………………………34

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Jiuhe Heavy Machinery Operating Manual of Concrete Pump Truck

Chapter I Safety Regulations

Special announcement:
Jiuhe Heavy Machinery will not be responsible for the injuries caused due to operation
not in accordance with the requirements of this Manual or due to negligence.
•Please first consult Jiuhe Heavy Machinery if you have to carry out operations
inconsistent with the safety operation regulations of this Manual.

1-1. Ground Rules

Concrete pump truck is a kind of equipment integrating the pumping mechanism used to
pump concrete and the boom system used to distribute materials on the vehicle chassis. The
pumping mechanism pressurizes the concrete in the hopper to send it in the pipeline attached to
the boom by using the power of the chassis engine (diesel engine for independently top
mounted power model). The operator only has to move the boom to directly send the concrete
output by the pumping mechanism to the pouring point. JH series of concrete pump trucks of
Jiuhe Heavy Machinery are designed and manufactured according to relevant provisions of
China's road traffic law and construction machinery administration law, and have obtained the
performance and type approval certificates issued by relevant departments.
Strictly follow the following restriction principles when operating this equipment:
1. It is strictly prohibited to use this equipment in an environment in explosion risk or
other danger
2. This equipment is dedicated for concrete and not for other purposes (such as: transport,
and lifting heavy objects, etc.), and it is not allowed to pump the concrete larger than the
density of 2.4Kg/L.

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Jiuhe Heavy Machinery Operating Manual of Concrete Pump Truck

3. Put this manual together with the equipment for the operator to read it at any time.

1-2. Operation Precautions

1. The total weight of objects loaded or placed on the pump truck shall not exceed 200Kg
to avoid overload.
2. When driving with accessories such as spare pipes, its load and height, width and
length are not allowed to exceed the indexes specified by the road traffic law. Make sure to
leave sufficient room and distance when the truck is to traverse underground passage, bridge,
tunnel or high-altitude pipelines or overhead cables.
3. The ambient temperature optimum for the pump truck operation is 0-40℃, and when
the ambient temperature is less than 0℃ or more than 40℃, contact with the manufacturer to
decide on the special maintenance matters.
4. The highest wind velocity permitted for the complete machine operation state is force 6
(50km/h). Stop operation and retract the material distributing arm to the driving state when the
wind velocity is higher than force 6.
5. The pumping height and distance of the concrete pump truck are confirmed through
rigorous calculation and numerous experiments (refer to the warning sign for the operating
range permitted for the pump boom or the diagram of the material distribution range). No
person is allowed to expand the working range by using the following methods:
(a) Lengthen the delivery pipe of the pump truck boom;
(b) Replace an end hose of more than 3m;
(c) Add a hose at the discharge port part of the end hose;
(d) Use a pump line other than the original.
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Jiuhe Heavy Machinery Operating Manual of Concrete Pump Truck

6. Properly protect all the devices on the equipment during working such as the warning
plate, tank cover plate, and hopper grating cover, which are not allowed to be damaged or even
removed or replaced.
7. Do keep the system oil sufficient and clean, and please timely conduct addition or
replacement in case of shortage or deterioration.
8. Must make sure that the boom and landing legs have been completely tucked and fixed
before driving the pump truck, otherwise it is not allowed to drive the truck on the road.
9. Immediately press the "E-stop" button to stop pumping operation in case of emergency
during operation by the remote control, and restart the pumping operation by pulling out the
"E-stop" button after troubleshooting.
10. Pull the hand brake and place wooden wedges behind the wheels (as shown in the left
below figure) after the pump truck enters the construction site and before unfolding the landing
legs, to prevent the pump truck from accidentally moving. In the meantime, the pump truck
landing legs must be supported on a level ground instead of on holes, inclined plane or soft
ground. After unfolding, the landing legs must be kept horizontal, with the inclination of the
front and back, and left and right outriggers relative to the horizontal plane of less than 3°,
otherwise it is prohibited to run the equipment. (As shown in the following right figure)

Full direction 0-3 air meter

11. Confirm whether the foundation bearing capability is sufficient before lowering down
the landing legs. If the foundation is insufficient to bear, supporting plates and auxiliary square
battens shall be added under the landing legs and then the landing legs be lowered down. (As
shown in the following figure)

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Jiuhe Heavy Machinery Operating Manual of Concrete Pump Truck

12. It is prohibited to climb to the rotary table and parts above it (such as: boom and
delivery pipe) at any time. When it is needed to maintain the rotary table and parts above it,
park the pump truck in a flat and spacious place, make sure that the pump truck will not
accidentally move, tuck the boom, shut down the engine, fix the landing legs, and send the
maintenance personnel to the faulty part via other auxiliary equipment (such as: engineering
truck). Or fold and lay flat the boom and make proper support so as to avoid damage to the
boom (see the following figure). If you open the balance valve or lower the set pressure
without fastening the boom in advance, there will be risk of falling of boom and potential
injury to people.

13. The running speed of the pump truck should not exceed the maximum speed in the
technical data sheet, or else there will be a risk of tip-over.
14. The concrete pump truck has a high gravity center, so you must slow down when
turning in case of tip-over (the running speed should be within 40km/h).
15. Before moving the boom and spreading the landing leg, check if there is any obstacle
surrounded to prevent the boom or landing leg from touching constructions or other obstacles.
When the operator's location cannot observe the whole working area or judge the distance
between the stretching parts of the pump tuck and adjacent objects, please arrange a signalman
to give commands.
16. Be careful during operation near the electric wires, and pay attention to keeping
proper distance from the electric wire, or else it will cause fatal danger to all the personnel
working on the pump truck and attachments near or of the pump truck (remote control device,
end hose etc.). A "high voltage funnel area" will be created under the equipment when a high
voltage spark appears. Along with the deviation from the center, the voltage will become
weaker (see the left below figure). The closer one get to the funnel area, the greater danger
there is. If you stride over different voltage areas (step voltage), the electric current created by
potential difference will flow past human body (see the left right figure).

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Jiuhe Heavy Machinery Operating Manual of Concrete Pump Truck

17. Every time when the concrete pumping is completed or shutdown caused by abnormal
condition, you must clean up the S pipe, concrete cylinder and hopper. Residual concrete
materials in S pipe, concrete cylinder and hopper are strictly prohibited.

1-3. Protective Equipment

In working area, the following protective equipment must be worn to get rid of the risk of
personnel injuries and deaths.

1. Safety helmet
The safety helmet can protect personnel's head and prevent the falling concrete or
components of the delivery pipe (when delivery pipe cracks) from hurting personnel's head.

2. Safety shoe

The safety shoe can protect the personnel's feet and prevent the falling or throwing sharp
objects from injuring personnel's feet.

3. Safety earmuffs
The safety earmuffs can protect the operator's ears when he is getting close to a strong-noise
machine.

4. Safety gloves
The safety gloves can protect the operator's hands from corrosion of chemical reagent or from
friction and cuts caused by mechanical operation.
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Jiuhe Heavy Machinery Operating Manual of Concrete Pump Truck

5. Safety goggle
The safety goggle can protect the operator's eyes from injury caused by splashing concrete
powder or other particles.

6. Safety rope

Using a safety rope can protect the personnel from falling down when working at heights.

7. Breathing device and mask

Wearing a breathing device and mask can prevent the dust and particle of construction material
(such as concrete mixture) from entering human body via the respiratory tract.

1-4. Injury Risk

1. Climbing up to the machine to carry out operations is forbidden when the concrete
pump truck is running. Please select remote control to protect the operator from falling down.
2. When working, you must pay attention to prevent the hose from bending or blocking;
and the end hose cannot be put into the concrete. Or else, the pressure in the pipeline will
increase and cause an explosion, thus giving rise to injury accidents.
3. When the pump truck is running, it is not allowed to open the hopper screen, water tank
cover plate, etc. safety protection facilities, and you cannot either put your hands into the
hopper, water tank or grasp other moving parts (such as the running diesel engine and swinging
S hose etc.) by hand.
4. When pumping, you must make sure that the concrete in the hopper is on the mixer
shaft and avoid concrete ejection caused by air intake.
5. During operation, you must not stand at the edge of a construction and hold the end
hose by hand, because the swinging of the hose or boom may cause personnel to fall down,
thus giving rise to human injury. You should choose to stand at a safe location and guide the
end hose with appropriate auxiliary tools.

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Jiuhe Heavy Machinery Operating Manual of Concrete Pump Truck

6. When you need to remove the pipe clamp during operation, you should reverse the
pump for 3-5 times to reduce the pressure in the pipeline. It is strictly prohibited to remove the
pipe clamp when the pipeline is under pressure.
7. Be careful to the potential instantaneous concrete ejection when dealing with concrete
blocking.

1-5. Hazardous Area

1. Hazardous area of landing legs
(1) When stretching or unfolding the landing legs, you should
prevent your body from being sandwiched between the landing leg
and other objects; and the swinging and stretching of the landing leg
should not be too fast.
(2) Pay attention that if there is any object below the landing legs when putting them
down to stop the object from being pressed by the landing legs.
(3) People are forbidden to go through under the landing legs to avoid injury.
2. Hazardous area of hopper
Personnel is forbidden to stand surrounding the hopper to stop them from being hurt by
the splashing concrete.
3. Hazardous area of boom
When operating the boom, the location below the rotation area of the boom is just the
hazardous area. So when operating, the workers must wear safety helmets and they are
forbidden to enter the hazardous area so as to keep away from fatal injuries caused by the
falling of boom or delivery hose parts. Once seeing there is anyone entering the hazardous area,
you should immediately press the emergency stop button and then restart the machine until
confirming that there is nobody under the boom.

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Jiuhe Heavy Machinery Operating Manual of Concrete Pump Truck

4. Hazardous area of end hose

Personal safety accidents may be caused by the sudden swinging of the end hose when
starting the equipment. So people are strictly prohibited to enter the hazardous area (the area
that covered by the swinging of the end hose) when starting the pumping operation. The
diameter of the hazardous area is twice of the length of the end hose. For example, if the
maximum length of the end hose ① is 3m, the hazardous ② will be 2 × the length of the
end hose, which equals to 6m.

1-6. Selection and Qualification of Operator

1. Pump truck driver
(a) Job responsibility: Responsible for driving the pump truck.
(b) Personal skills: 25-55 years old, with normal intelligence level, and in good health
condition; must hold a valid driving license.
2. Pump truck operator
(a) Job responsibility: Responsible for the operating of the pump truck, which mainly
means the concrete distribution of the pump truck.
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Jiuhe Heavy Machinery Operating Manual of Concrete Pump Truck

(b) Personal skills: 25-55 years old, with normal intelligence level, and in good health
condition. Having received the training of pump truck operation and maintenance, and
obtained the pumpman operation certificate issued by the Labor Department.
3. Pump truck signalman
(a) Job responsibility: Indicate the movements of the boom and landing leg via agreed (or
stipulated) hand signals and assist the pump truck operator to finish the concrete distribution
and avoid accidents.
(b) Personal skills: 25-55 years old, with normal intelligence level, and in good health
condition. Be familiar with the hazardous areas and operating procedures of the pump truck
running and make clear and correct hand signals.
4. Welder and electrician
Please contact the supplier when the pump truck cracks or the electric device
malfunctions. It is forbidden to make repair welding or modification without permission, and
Jiuhe Heavy Machinery shall not be liable for any consequence caused therefore.
(a) Welder: The welder must be a person who is appointed by the supplier and holds a
valid welder certificate. He will be mainly responsible for solving the problem of welding
components cracks of the pump truck (for example: boom, landing leg or other important
parts).
(b) Electrician: The electrician must be a person who is appointed by the supplier and
holds a valid electrician certificate. He will be mainly responsible for the modification and
upgrade of the electrical circuits and components of the pump truck.
5. Hydraulic engineer
(a) Job responsibility: The hydraulic engineer is mainly responsible for the parameter
adjustment, fault diagnosis and troubleshooting of the hydraulic system of the pump truck.
(b) Personal skills: Only the person who has professional knowledge and experience on
hydraulic system can engage in this job. The adjustable devices of the pump truck (for example:
reducing valve, distribution valve and balance valve) can only be adjusted by a hydraulic
engineer or after-sales engineer; other personnel's random operation is not allowed.
6. Electrical engineer
(a) Job responsibility: The electrical engineer is mainly responsible for the parameter
adjustment, program update, fault diagnosis and troubleshooting of the electrical system of the
pump truck.
(b) Personal skills: The inspection, modification and replacement of the electrical system
and components of the pump truck must be carried out by an electrical engineer or after-sales
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Jiuhe Heavy Machinery Operating Manual of Concrete Pump Truck

engineer (and can also be completed under the guidance of an electrical engineer or after-sales
engineer). Only the personnel qualified can install, connect, split and open the electrical switch
box.
7. After-sales engineer
(a) Job responsibility: The after-sales engineer is mainly responsible for the maintenance
of pump truck, which mainly includes the fault troubleshooting, daily maintenance guidance,
accessories replacement and system upgrading.
(b) Personal skills: All after-sale service engineers of Qingdao Jiuhe Heavy Machinery are
well trained and assigned to different places for handling various faults of pump truck
independently and providing one-to-one service to the users. If you have any problems about
the functions, usage and maintenance of the equipment, please call the after-sale service hotline
and contact the service dispatch center, we will try our best to help you.

1-7. Requirements for Work Place

1. Space requirement:
(a) Ensure that there is enough space to fully expand the pump truck landing legs.
The concrete pump truck shall be placed in an open place or in the middle of the
minimum placement space where the pump truck landing legs of the model can be expanded.
When the landing legs are expanded or moved, prevent it from contacting any obstacles and
start to operate the boom after the legs are expanded in place. Qingdao Jiuhe Heavy Machinery
will not be responsible for the consequences (such as tipping and injury) caused by the fact the
boom is expanded forcibly when the legs are not expanded in place.
(b) Ensure there is enough space to expand the distribution boom.
The second section of the boom can be operated after the first section of the boom is
expanded to the specified minimum expanding height to prevent the boom from striking other
parts of pump truck or rubbing the ground. Before moving the boom, check if there is any
obstacle surrounded to prevent the boom from touching constructions or other obstacles.
(c) Ensure that there is enough space to discharge waste gas.
During the construction of pump truck, the space shall be ventilated adequately, since the
gas discharged from the truck contains hazardous substance, and it shall be emitted as soon as
possible.
2. Distribution area
Four landing legs must stretch and expand to the specified position, or the danger of
tipping may exist. At this time, see 2-2.1 Working range diagram for the distribution range of

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Jiuhe Heavy Machinery Operating Manual of Concrete Pump Truck

boom.
3. Safety distance of landing legs' supporting
When the pump truck expands the landing legs, the legs must keep a safe distance with
the pit, slope, channel, excavating land and other machines.
(a) Minimum interval from slop A: (See the following figure)

When the landing leg pressure is no more than 12t, A=1m;

When the landing leg pressure is more than 12t, A=2m;
(b) Safe interval from pit B: (See the following figure)

When being on the soft backfilling ground, B ≥ 2 × T (T refers to the depth of pit);

When being on the solid ground, B ≥ 1×T (T refers to the depth of pit).

4. Selection of supporting ground

(a) No matter what the ground condition is, the supporting ground must be horizontal,
and a horizontal supporting surface must be constructed if necessary. Meanwhile, the truck
shall not support on a hole.

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Jiuhe Heavy Machinery Operating Manual of Concrete Pump Truck

(b) The maximum drift angle in the horizontal plane of the complete machine shall not
exceed 3°, and the stability of the supporting ground shall be noticed constantly during the
operation of the machine.
(c) When the ground has factors which may reduce the stability, the boom must be
tucked at once and supported again according to the requirement after the factors are removed.
The factors reducing the stability mainly include:

•Ground condition changes due to rain water, snow water and other water sources;

•The ground on one side of landing legs sinks;

•The oil cylinder of the landing leg occurs leakage.

5. Load of supporting ground

(a) All arms of landing legs of pump truck are marked with the maximum pressure of the
legs.
(b) The pump truck must be supported on the solid ground, and the load bearing
capability of the supporting ground shall be checked before construction. If the maximum
pressure of the landing leg is larger than the allowable pressure of ground, increase the surface
area of the supporting ground using support plates or auxiliary timber strips. See the following
table for the allowable pressure of ground:

Allowable pressure (KN/m²)

Soil dressing not compacted 150
Bituminous street whose minimum
200
thickness exceeds 20cm
Compacted crushed stone concrete
250
material

Hard paste or mud clay 300

Rugged ground with different qualities 350

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Jiuhe Heavy Machinery Operating Manual of Concrete Pump Truck

Ground with dense pebbles 400-500

Pebble bed (pebble ground compacted
750
suitably)

Dry rocky ground 1000

1-8. Boom Operation Precautions

The operation of boom can be started after confirming that the landing legs of pump truck
are supported properly. The boom must be operated according to the sequence described in the
operating procedure.
1. When severe weather or rainstorm occurs
(a) Under the condition of thunderstorm or severe weather, the boom shall not be
expanded;
(b) When there are warning signs about rainstorm or tornado, stop the operation and
withdraw, reset and fix the boom;
(c) The boom shall not be used when the wind force exceeds class 6 (13.8m/s).
2. Function of signalman
The signalman plays an important role in the expansion of boom. When the operator
cannot observe the whole operation area or judge the distance between the external expanding
portion of pump truck and the adjacent object correctly in his position, please arrange a
signalman to command the operation. The operator must cooperate with the action of
signalman closely to control the boom motion and prevent the boom from contacting obstacles
like buildings or hurting others. During the operation, the whole operation process of boom
shall be controlled in the view of the signalman.
3. Boom movement
(a) Prevent the hose of boom from shaking and spraying concrete to hurt people during
movement.
(b) The lower portion of the boom rotation area is a hazardous area, and once someone
enters the place, the operator shall press the emergency button at once to stop operation.
Meanwhile, the work staff must wear a safety helmet.
(c) If the motion of the boom is abnormal, stop the operation at once and ask the
professional maintenance personnel to find the reason and remove the fault before operation
again.
4. Harm of obstacles in the boom stroke
Before moving the boom, check if there is any obstacle surrounded to prevent the boom
from touching constructions or other obstacles. If the boom is collided, at best, the boom
system may be damaged which cause the fault of machine; at worst, the boom or the delivery
pipe drops off, and this may result in injury and major safety accidents. When the operator's
location cannot observe the whole working area or judge the distance between the stretching
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Jiuhe Heavy Machinery Operating Manual of Concrete Pump Truck
parts of the pump tuck and adjacent objects, please arrange a signalman to give commands.
During the operation, the whole operation process of boom shall be controlled in the view of
the signalman.

5. Working range prohibited by the distribution boom

Prohibited
distribution area

6. Placement of distribution boom during driving of pump truck

During driving of pump truck, ensure whether there are residual materials exist in the end
hose, fix the hose on the boom through the pipe clamp, and ensure that the boom has been
tucked and placed in the central position on the main support completely. Otherwise, the pump
truck shall not drive on the road.

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Jiuhe Heavy Machinery Operating Manual of Concrete Pump Truck

Driving when the boom is expanded is prohibited

1-9. Precautions of Pumping Operation

1. Working area
(a) The working area of pump truck is determined by the length and the rotating angle of
boom. It is prohibited to expand the working range by lengthening the delivery pipe and hose.
Otherwise, seriously potential safety hazard may exist.
(b) Please refer to the "Distribution range diagram of pump truck" for the distribution
range of the pump trucks with specific modes or boom lengths.
2. Operator Responsibility
(a) During operation of pump truck, the signalman must pay close attention to the
workplace and direct the operator to expand the landing legs and control the boom to reach the
material delivering position safely. The operator shall operate the landing legs and boom to
motion through a remote controller according to the guidance gestures of the signalman.
(b) During pumping, both the signalman and the operator shall pay attention to the
ground and the lower portion of the boom to prevent the ground from changes (such as land
subsidence) or someone standing under the boom. During operation, the operator must wear a
safety helmet and follow the operation safety specification of the construction site and pump
truck.
3. Inspection and maintenance of pump line
(a) Check whether the pump line is worn and whether the clamp is loose or damaged
before each operation.
(b) Check the pump line through the wall thickness instrument. Under the normal
pumping pressure (6MPa), when the thickness of the pump line is less than 2mm, please
replace the pump line. Do not exhaust the use of pump line till burst, since the sprayed concrete
caused by burst may cause hurt. In addition, an experienced operator can check the wear
situation of the pipe wall by knocking the pump line via a wooden hammer, but it is prohibited
to knock the pump line under the pressurization state.
(c) If it is found that the clamp is loose, please tighten it; if it is found that the clamp is
damaged, please replace it. The dropping of pipeline parts caused by loose or damage of clamp
may cause personal injuries.

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Jiuhe Heavy Machinery Operating Manual of Concrete Pump Truck
(d) Before pumping, please fill water to fully lubricate the pumping mechanism. When
water flows out of the end hose, fill the mortar till mortar flows out of the hose, and pump the
concrete. This pumping mode is mainly for preventing blocking of pump line and prolonging
the service life of pumping. It is unnecessary to fill water for future operation, instead, fill the
mortar before pumping the concrete.
4. Blocking of pump line and harm
(a) When the delivery pipe is blocked, clear the blocking through anti-pumping for
several times. If the blocking problem cannot be solved with this method, it indicates that the
blocking is more serious, please stop anti-pumping at once to prevent aggravation of blocking.
(b) If it is found that the concrete has been condensed when disassembling and washing
the pipe, open all pipe joints at once and clear them rapidly to prevent the concrete from
condensing and resulting in scrap of the delivery pipe. When the pipe is disassembled, conduct
the anti-pumping and release the pressure in the pipeline before disassembling the delivery
pipe.
(c) It is prohibited to adopt the compressed air to dredge the blocking, since this may
result in blasting of delivery pipe.
5. Disassembly of pump line
(a) Do not disassemble the delivery pipe and clamp during the operation of pump truck,
since there is pressure in the pump line during the operation of pump truck, and concrete may
spray out under the pressure and result in a hazard.
(b) When disassembling the delivery pipe,
remove the clamp firstly which fixes the delivery pipe.
Before disassembling the clamp, conduct
anti-pumping for a period of time so as to reduce the
pressure in the pipe.
When disassembling the clamp, stand on the side
surface of the clamp.
Do not face directly the joint of delivery pipe to disassemble the clamp.
Meanwhile, cover the joint with wood or metal to prevent spraying of concrete.
6. Hopper
(a) During the operation of pump truck, the screen of hopper shall cover the hopper.
Meanwhile, no one shall open the screen and stretch hands or other object into the hopper.
(b) During the operation of pump truck, no one shall climb to the pedal or the hopper
screen to prevent dropping into the hopper and resulting in fatal injuries.
7. Mixing operation
(a) When pumping, you must make sure that the
concrete in the hopper is on the mixer shaft and avoid
concrete ejection caused by air intake.
(b) When the pump truck conducts the mixing
operation, it is prohibited to open the hopper screen or stretch
any object into the hopper.

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Jiuhe Heavy Machinery Operating Manual of Concrete Pump Truck

1-10. Cleaning of Pump Truck

After the pump truck is repaired or filled with functional liquid, clean the mark of
hydraulic oil, fuel or other preservative left in the pump truck and handle properly the dust
cloth stained with corrosive and polluting liquid. Do not use combustible as the cleaning agent
nor sea water or other liquid containing salt as the cleaning agent. After cleaning, check
whether the fuel, lubrication and hydraulic systems are leaking, loose or damaged. Solve the
problems at once whenever found.
1. Cleaning of excess materials
(a) After pumping, concrete in the pipeline and
hopper shall be cleaned, since the residue concrete may
block the pipe after condensation.
It is prohibited to clean the rest material with
compressed air.
Jiuhe Heavy Machinery shall not be responsible for
the consequences caused by using compressed air for
washing.
(b) When cleaning the delivery pipe, both dry
cleaning method and wet cleaning method can be
adopted.
Try to expand the boom so as to enable the easy
passing of sponge balls.
Be careful when the sponge balls are not be absorbed. At this time, the residue concrete in
the pipe and the sponge balls may be sprayed instantly, which may result in personal injury.
(c) During the dry cleaning, the residue concrete in the hopper must submerge the mixing
shaft. Otherwise, the concrete flowing back to the hopper may cause impact on the mixing
shaft, which may result in damage to relevant components and parts.
2. Equipment Cleaning
a) After the delivery pipe is cleaned, open the discharge port of hopper and discharge the
residual material completely, and install a water gun to clean the hopper, S pipe and delivery
cylinder. It is prohibited to use the water torch under the condition that there is no water in the
water tank.
(b) In freezing winter, in order to prevent icing, the water in the water tank and water pump
shall be discharged and cleaned to prevent frost damage.

Chapter II Instruction of Complete Machine

2-1. Overview
2-1.1 Main performance and configuration
The complete machine of the JH series pump truck is advanced in technical performance
and reliable in quality. According to different users' requirements, the chassis can adopt the

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Jiuhe Heavy Machinery Operating Manual of Concrete Pump Truck
chassis of Foton Motor, FAW Jiefang and Dongfeng. The distribution boom and the landing
leg assembly adopt the high-intensity structural steel, and the boom is controlled in wireless
remote. The main configuration adopts the international and domestic famous brands.
2-1.2 Nameplate of complete machine

九合重工
JH concrete pump truck
最 大 输 送 量 功率
m3/h KW
Max.output Power
最 大 泵 送 压 力 主 油 路 压 力
Mpa Mpa
Max.outlet pressure Oil pressure
最 大 垂 直 高 度 外 形 尺 寸
m mm
Max.vertical height Outlet dimension
产 品 编 号 出 厂 日 期 年 月
yr. mo.
Serial NO. Factory date

青岛九合重工机械有限公司 0532-88563257 400-0532-779

Qingdao Jiuhe Heavy Industry Machinery CO.,Ltd www.Jiuhezg.com

2-1.3 Nameplate position diagram of complete machine

The nameplate of complete machine is set below the walking board on the right

Nameplate of complete machine

2-2. Working Range Diagram and Main Technical Parameters

2-2.1 Working range diagram of 32m pump truck

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Jiuhe Heavy Machinery Operating Manual of Concrete Pump Truck

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 Jiuhe Heavy Machinery Operating Manual of Concrete Pump Truck

2-2.2 Working range diagram of 32m pump truck

I. Chassis
1 Chassis Brand Sinotruck
2 Chassis engine powerd 280HP
3 Driving mode Left hand drive truck
4 Emission standard China 3
II. Boom system
1 Max. Vertical height(M) 31.9
2 Max. Horizontal Concrete Placing radius (M) 27.6
3 Concrete placing depth(M) 18.6
4 Boom Opening height(M) 7.3
5 Rotating angle of each boom 90°/180°/230°/245°
6 Control mode Electric proportion
7 Folding type of boom M type
8 Slewing Range 470°
9 Span distance of front landing leg (MM) 6445
10 Span distance of rear landing leg (MM) 4940
11 Longitudinal distance between front and rear landing leg (MM) 6568
12 Opening mode of landing leg X-R
13 Length of end hose (MM) 3000
14 Concrete delivery pipe dia. 125
III. Electric Control System
1 Working voltage（V） 24

IV. Hydraulic transmission system

1 Type of hydraulic system Open type
2 System working pressure (Mpa) 31.5
3 Hydraulic oil tank capacity (l) 420
4 Cooling mode of hydraulic oil Forced-air Cooling
5 High-low pressure changeover valve None
VI. Dimension and weight
1 Total length (MM) 10600
2 Total width (MM) 2500
3 Total height (MM) 3620
4 Total weight (T) 20.1
VII. Pumping system
1 Form of concrete distribution valve S Valve
2 Maximum concrete outlet pressure (Mpa) 8
3 Reversing times of distribution valve 25
4 Inner diameter of delivery cylinder 230
5 Maximum feeding height (MM) 1450
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 Jiuhe Heavy Machinery Operating Manual of Concrete Pump Truck
6 Hopper capacity (M3 ) 0.65
7 Slump of pumped concrete 160-220
8 Dimension of allowable maximum aggregate (MM) 40
9 Lubricating method Centralized lubrication

2-3. System Overview

The pump truck is mainly composed of chassis, boom system, slewing mechanism, supporting
platform landing leg assembly, pumping system and control system.
2-3.1 Chassis
Jiuhe concrete pump truck mainly adopts the chassis of Dongfeng, FAW and Foton. The
chassis can be selected according to the requirement of customer.
2-3.2 Boom system
(a) The boom system is used for concrete delivery and distribution.
(b) The boom system is mainly composed of the turntable, multiple sections of boom,
connecting rod, oil cylinder and connecting pieces.
(c) The concrete is directly delivered to the specified position at the tail end of the boom
(pouring point) through the delivery pipe attached to the boom after the retraction of boom oil
cylinder and the rotation of turntable. The following figure (four sections) is the boom system
picture.

Boom

Connecting
rod
Turntable

Boom system

2-3.3 Supporting platform landing leg assembly of slewing mechanism

(a) The boom system is installed on the rotating device which is used for enabling the boom
to rotate, the landing legs are directly supported on the solid ground, and the supporting
platform provides a stable base for the boom and the slewing mechanism and is connected with
the chassis through the auxiliary beam.

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Jiuhe Heavy Machinery Operating Manual of Concrete Pump Truck

Supporting platform landing leg assembly of slewing mechanism

2-3.4 Pumping mechanism

The pumping mechanism is the actuator of the concrete pump truck and delivers the concrete
to the pouring field continuously through the delivery pipe.
(a) Structure

Schematic diagram of pumping mechanism

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Jiuhe Heavy Machinery Operating Manual of Concrete Pump Truck

1. Pumping oil cylinder 2. Pumping oil cylinder 3. Water tank 4. Reversing signal device

5. Concrete cylinder 6. Concrete cylinder 7. Concrete piston 8. Concrete piston

9. Hopper 10. S pipe valve 11. Rocker arm 12. Swing cylinder

13. Swing cylinder 14. Discharge hole

(b) Pumping principle

The concrete cylinder pistons (7, 8) are respectively connected with the piston rods of the
pumping oil cylinders (1, 2), and the two oil cylinders 1 and 2 adopt the serial connection mode
and make the reciprocating motion under the action of pumping oil cylinder hydraulic oil. One
cylinder piston advances while the other cylinder piston goes backwards. The concrete cylinder
outlet is communicated with the hopper. One end of the distribution valve 10 is communicated
with the discharge port 14 of the hopper 9; the other end of the distribution valve 10 is
communicated with the concrete cylinder 5 or 6. The spline shaft on the distribution valve 10 is
connected with the rocker arm, and the distribution valve 10 can swing leftward and rightward
under the action of the swing cylinders 12 and 13 and in alternative communication with the
concrete cylinder (5, 6).

When the concrete materials are pumped, under action of the pumping oil cylinder, the
concrete piston 7 is pushed forward and pushes the concrete in the concrete cylinder 5 into the
distribution valve 10, the concrete enters the discharge port 14 (at this moment, the distribution
valve 10 is communicated with the concrete cylinder 5), and the concrete piston 8 goes
backward and absorbs the concrete in the hopper 9 into the cylinder 6. When the concrete
piston 8 goes backward to the stroke terminal, the hydraulic-control check valve 4 on the
pumping oil cylinder is opened (see the hydraulic principle diagram) so as to control the oil to
flow into the hydraulic-control two-position four-way valve from the hydraulic-control check
valve and enable the valve to change the direction. The swing cylinders (12, 13) enable the
distribution valve 10 to be communicated with the concrete cylinder 6 and the concrete
cylinder 5 to be communicated with the hopper. At this moment, the high pressure oil of the
system enables the two-position four-way valve to change the direction through the swing
cylinder (see the hydraulic principle diagram). Therefore, the piston 7 goes backward and
absorbs concrete from the hopper, and the piston 8 advances and pushes the concrete in the
concrete cylinder into the S valve and the delivery pipe. So the cycle continues, which realizes
the continuous pumping (see the schematic diagram of positive pump state).

During the anti-pumping, the concrete cylinder during the absorption stroke is communicated
with the distribution valve through the "anti-pumping" button, and the concrete cylinder during
the pushing stroke is communicated with the hopper. Therefore, the concrete in the pipeline is
pumped back to the concrete cylinder 5, and the concrete in the cylinder 6 is pressed into the
hopper 9 (see the schematic diagram of anti-pumping state).

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 Jiuhe Heavy Machinery Operating Manual of Concrete Pump Truck

Schematic diagram of positive pump state Schematic diagram of anti pump state

2-3.5 Control system

2-3.5.1 Hydraulic principle
See Figure I for the hydraulic principle diagram of air-pressure type water washing system, and see
Figure II for the hydraulic principle diagram of water pump washing system.

Figure I Component name

1. Oil cylinder: 2. Hydraulic-control one-way valve 3. Ball valve 4. Two-position
four-way valve 5. Swing cylinder 6. Electro-hydraulic directional control valve 7.
Overflow valve 8. Motor 9. Oil pump 10. Manual reversing valve 11. Stirring motor 12.
Overflow valve 13. Ball valve 14. Gear pump Ⅰ 15. Radiator 16. Oil return filter 17.
One-way valve 18. Pressure gauge 19. Oil tank 20. Boom pump 21. Changeover valve22.
Landing leg multi-way valve 23. Landing leg oil cylinder 24. Boom multi-way valve 25.
Rotary motor 26. Boom oil cylinder 27. Cooling motor

Figure II Component name

1. Oil cylinder: 2. Hydraulic-control one-way valve 3. Ball valve 4. Two-position
four-way valve 5. Swing cylinder 6. Electro-hydraulic directional control valve 7.
Overflow valve 8. Motor 9. Oil pump 10. Mixing positive-negative manual reversing valve
11. Stirring motor 12. Overflow valve 13. Fan starting valve 14. Gear pump Ⅰ 15. Radiator 16.
Oil return filter 17. One-way valve 18. Pressure gauge 19. Oil tank 20. Boom pump 21.
Changeover valve 22. Landing leg multi-way valve 23. Landing leg oil cylinder 24. Boom
multi-way valve 25. Rotary motor 26. Boom oil cylinder 27. Cooling motor 28 Washing
mixing changeover valve 29 Water pump motor

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Jiuhe Heavy Machinery Operating Manual of Concrete Pump Truck

3 4
11 22

6
18
23

10

13

17 27 21
7
12

8
2 18
Z
T
24
LS
Y

1 14
M1
15 20
19
9
16

25
P4

P3

26

Figure I

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Jiuhe Heavy Machinery Operating Manual of Concrete Pump Truck

11

3 4
22
10
6 29
18
23

28 27

13

17
7

21
8 P
R

2 18
Z

12 T
24
LS
Y
14
1

M1
15 20
19
9
16

25
P4

P3

26

Figure II

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Jiuhe Heavy Machinery Operating Manual of Concrete Pump Truck
2-3.5.2 Electrical principle
2-3.5.2.1 Electric appliance schematic diagram of SINOTRUCK chassis

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 Jiuhe Heavy Machinery Operating Manual of Concrete Pump Truck

Chapter III Operation Instruction

3.1 Start operation of SINOTRUCK chassis pump truck:
3.1.1. PTO Operation
Due to it needs to control the rotating speed with the external accelerator when the pump
PTO selector
operating, after the pump truck sends the pump to the working place, pressing the PTO switch switch
to guarantee the effectiveness of the external accelerator. After the completion of the pump
delivery work, close PTO.
After the pump truck is completely stopped, pull the parking brake, change to the neutral
position and switch PTO switch into the upload work state (press upward).

PTO switch (the indicator light will be on after being opened)

3.1.2. Drive pumping switch operations

Driving status light

Open the key of
Pumping status light Driving pumping switching

the cab to the position of ON, the gearbox is idle, switch "power" knob of the operation panel
of the electric cabinet to the position of ON, at this time, the indicator light will be on.
If the indicator light of "driving status" is on, after switching the "driving pumping" to the
position of "pumping", the "pumping status" indicator light will be on; if the "driving status"
indicator light is off, it indicates that the transfer case has been switched to the position of
pumping.
If the "pumping status" light is on, switch the knob to the position of "driving", and the
"driving status" indicator light will be on; if the "pumping status" light is off, it indicates that
the transfer case has been switched to the position of driving.
3.1.3. Gear position operation
After switching the transfer case to the pumping position, engage the gearbox gear 10 upon the
pumping work.
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Jiuhe Heavy Machinery Operating Manual of Concrete Pump Truck

3.1.4. Outrigger operation

Turn the "close control and remote control" knob on the operation panel to the status of "close
control", press the green outrigger button, meanwhile, move the corresponding handle, the
outrigger acts can be realized. After the completion of outrigger operation, switch it to the
remote control status, used for realizing the boom operation.
3.1.5. Operation of remote control

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Jiuhe Heavy Machinery Operating Manual of Concrete Pump Truck

Turn the "close control and remote control" knob on the operation panel to the status of
"remote control", at this time, the remote control is in power-up state.
"Ignition" and "extinction" buttons are used for the starting and extinction control of the
engine.
"Positive pump and anti-pump" switch: Leaving go of the switch after turning it to the
"positive pump" position, the system is under the status of positive pump working; press the
"pump stopping" button, the system will stop pumping. Turning the switch to the "anti-pump"
position, the system is under the status of anti-pump working; if loosening it, the system will
stop the anti-pump automatically.
"Fast and slow speed" switch: Used for the speed selection of the boom acts.
"Displacement knob": Used for the adjustment of the pumping speed. Right-handed rotation is
acceleration.
"Accelerator knob": Used for the infinitely variable control of the engine speed; when the knob
is turned from left to the right, the rotating speed will be increased from idle speed to
1900RPM.
"Power supply switch": Used for the starting of the ejector.

3.2 Boom Operation

The boom operation can be conducted after switching the changeover valve "landing
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Jiuhe Heavy Machinery Operating Manual of Concrete Pump Truck

leg/boom" (beside the leg multi-way valve) to the boom operation side.
Expansion of boom: The first section of the boom which is expanded firstly is about 70 degrees,
and expand the second, third and fourth section of the boom sequentially (refer to the following
figure)
Step 1: Expand the first section of boom to about 70 degrees.

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Jiuhe Heavy Machinery Operating Manual of Concrete Pump Truck

Step 2: Expand the second boom to the horizontal plane

Step 3: Rotate the turntable, and the boom stretches to the front or the side

Step 4: Expand the fourth arm, which forms a certain angle with the third arm (about 5
degrees).
Note: The 27m pump truck and 29m earlier-stage pump truck shall not move the third arm
before the fourth boom is not expanded to a certain angle! Otherwise, the fourth arm and the
connecting rod may collide.
Step 5: Meanwhile, multiple arms are expanded. Expand the fourth boom to the distribution
position.
The boom is retracted according to the above process in a reversed sequence.
Note: 1. The 28m and 29m earlier-stage pump truck shall tuck the second arm before the third
and the fourth booms are tucked, and the connecting rod 3 may reject the 1# oil cylinder.
Conduct the boom operation in the sequence of expansion/retraction!
2. The 33m boom pump truck number is five sections, and one more section of boom is
expanded / retracted on the basis of the four sections of booms.

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