Cause of concrete pump spare parts damage failure

Concrete pump spare parts failures are diverse, the main failure cause of concrete pump parts include natural or abnormal wear between parts, corrosion caused by contact between parts and harmful substances, fatigue fracture of parts under long-term alternating loads, deformation under the action of external loads and temperature residual internal stress, non-aing and accidental damage of metal parts and electrical components, etc.

In concrete pump design, it is impossible to give all spare parts the same lifespan. Some concrete pump spare parts itself are wearing parts. Spare parts with a short service life need to be replaced regularly. If not replaced and do maintenance for concrete pump parts in time, the concrete pump equipment will break down.

Common damage of pumping system spare parts

The main oil cylinder piston does not move, the main oil cylinder does not change direction, and the delivery cylinder does not discharge enough material etc. Following is possible reasons:

Pump start button wiring disconnected, and the intermediate relay is burned out. The electromagnetic reversing valve is faulty, usually the electromagnet is burned out. The main pump displacement adjustment knob is improperly adjusted, because too little hydraulic oil in the tank, and the filter element is seriously blocked. The control oil line throttle plug is blocked and the side pressure switch of the one-way valve is burned out. S valve tube was blocked, and concrete piston was worn.

Distribution valve system spare parts failure

S pipe valve does not swing, and swing arm end leaking mortar. The reason maybe as following problems:

The distribution valve inching button is faulty or the wiring is disconnected. The pilot spool of the electro-hydraulic reversing valve is stuck or the solenoid coil is burned out. The pilot relief valve failure causes insufficient reversing pressure. The constant pressure pump fails, causing the reversing pressure to fail to meet the requirements. Insufficient pressure in the accumulator or damaged bladder. Oil leakage from swing cylinder. The dust ring at the small end is deformed or the bearing is excessively worn and the gap is large.

Concrete pipes problems.

Main causes of concrete pipe blockage:

Concrete leakage in pumping pipelines, such as between the cutting ring and the wear plate, because the thrusting ring worn, and the gas became large between cut ring and wear plate. Also between the hopper port and the "S" pipe valve tube, between the piston and the delivery cylinder, and the concrete pipe connector place, etc. Insufficient pressure in the hydraulic system. Poor pumping performance of concrete. Air is absorbed into the concrete, this is also easy for concrete blocked. If the blocked pipes are not cleared in time, pipe explosions may easily occur and construction workers may be injured.

Common faults in boom parts system

Insufficient pressure in the hydraulic system, and there are other abnormal and redundant loads on the boom. So prevent excess items from loading on the boom. The solenoid valve is blocked or the solenoid valve is burned out. The fixed pin maybe loosen or worn, and it should replace and tighten in time. Replace seal kits, add grease in time. Without grease, connecting parts will wear out more quickly. The hydraulic system cannot work stably, which may seriously damage the concrete pump. Especially for high-altitude operations, the boom expansion range is large and the injured area is uncontrollable.

Common faults in electrical parts system

The main power fuse is blown, and controller failure. It may be that the remote control's displacement adjustment voltage output is too low or has no output. If the displacement is normal, the pumping signal may be wrong or the terminal relay may be broken. The proportional pressure regulating valve is broken. Too much high-frequency interference, and the antenna of the receiving box is not tightened. The temperature around the receiving box is too high, the suction cup antenna was not replaced, and the communication module is broken. The panel or remote control panel potentiometer is burned out or aged. Proximity switch failure and the solenoid reversing valve is burned out. At this time, wires, relays, electrical panels, etc. must be replaced in time.

Spare parts with heat temperature

The concrete pump engine piston temperature is too high, which can easily lead to melting and cylinder explosion. Seal kits, triangular tapes, and tires are overheated, leading to premature aging, performance degradation, and shortened service life. The coils of electrical equipment such as starters, generators, regulators, etc. are overheated and can easily burn out and be scrapped. If the vehicle bearings overheat, the lubricating oil will quickly deteriorate, eventually causing the bearings to burn out and the vehicle to be damaged.

Poor quality of concrete pump spare parts

For the twin wall boom pipe, choose to use single concrete pipe. The single pipe have thin walls and are damaged quickly, easily bursting and causing casualties. 

If the seal kits are not up to standard, the sealing effect will be poor and the construction will be affected.

As the use time increases, the thrust spring loses its elasticity, and the joint surface of the cutting ring and the wear plate will be worn, resulting in an increase in the gap between the two. When the gap is too large, it needs to be adjusted immediately, otherwise the mortar will enter through the "gap". Once mortar enters the friction surface, the wear rate of the cutting ring and wear plate will be greatly accelerated.

Dirty of spare parts

If concrete pump parts such as fuel filters, oil filters, air filters, hydraulic oil filters, and various filters are too dirty, the filtration effect will deteriorate, and too many impurities will enter the oil circuit cylinder, aggravating the problem. The wear and tear of mechanical parts may lead to malfunction. If it is severely blocked, it will also cause the vehicle to not work properly.

If the water tank radiator, air-cooled engine block and cylinder head radiator, cooler radiator and other parts are too dirty, it will lead to poor heat dissipation and excessive temperature. Therefore, such "dirty" parts must be cleaned and maintained in time.

Fire the spare parts

Rubber products such as tires, triangular tapes, cylinder liner water rings, and rubber oil seals will easily age, deteriorate, or be damaged if they are close to a fire source. On the other hand, they may also cause fire accidents. Especially in winter, the engine is difficult to start. Some drivers often use blowtorches to heat the engine. Be sure to prevent burning of wiring and oil lines.

Afraid of "crossing"

Various parts in the diesel engine fuel system, the main and driven gears in the main reducer of the drive axle, the hydraulic control valve block and valve stem, the valve core and valve sleeve in the fully hydraulic steering gear, etc., these matching parts are after special processing and grinding in pairs, the fit is very precise. They should always be used in pairs during their service life and must not be interchanged.

Some mating parts, such as piston and cylinder liner, bearing bush and journal, valve and valve seat, connecting rod head cover and shaft, etc., after a period of running-in, the fit is relatively good. During maintenance, they should also be careful to assemble in pairs and do not visit each other.

Using oil to spare parts

The paper filter element of the engine dry air filter has strong hygroscopicity. If it is stained with oil, it is easy for the mixture with a higher concentration to be sucked into the cylinder, resulting in insufficient air volume, increased fuel consumption, and reduced engine power.

If the triangular tape is stained with oil, it will accelerate corrosion and aging, and it will easily slip, resulting in reduced transmission efficiency.

If the carbon brushes of the starter motor and generator are stained with oil, the starter motor will have insufficient power and the generator voltage will be too low due to poor contact.

Tire rubber is very sensitive to corrosion by oil. Contact with oil will cause the rubber to soften or peel. Short-term contact can cause abnormal damage or even serious damage to the tire. If it is stained with oil, it will easily slip and work poorly, thus threatening driving safety.

Clean and washing spare parts

Some novice repairers may think that all concrete pump spare parts need to be cleaned. In fact, this understanding is one-sided. For the engine's paper air filter, when removing dust on it, you cannot use any oil to clean it. You only need to gently tap it with your hands or blow high-pressure air from the inside of the filter element to the outside. For leather parts, it is not advisable to use oil to clean them. Just wipe them with a clean rag. For circuit maintenance, it is forbidden to clean with water.

Reverse direction of spare parts

The engine cylinder gasket cannot be installed backwards during installation, otherwise it will cause premature ablation and damage to the cylinder gasket;

Some special-shaped piston rings cannot be installed backwards and should be assembled according to the requirements of different models;

There are also directional requirements when installing engine fan blades. Fans are generally divided into two types: exhaust and suction. They cannot be reversed, otherwise it will cause poor heat dissipation and excessive temperature of the engine.

For wear plates and cutting rings, if installed in the wrong direction, not only will they not work, but they may also damage the pumping system.

Spare parts missing

When repairing vehicles, some small parts may be missed due to negligence. Some people even think that it does not matter whether they are installed or not. This is very dangerous and harmful.

Engine valve locking plates should be installed in pairs. If they are missing or missing, the valve will be out of control and the piston and other parts will be damaged;

Once the anti-loosening devices such as cotter pins, locking screws, safety sheets or spring washers installed on the engine connecting rod bolts, flywheel bolts, and drive shaft bolts are missed, serious malfunctions may occur during use;

Once the oil nozzle used to lubricate the gears in the engine timing gear chamber is missing, it will cause serious oil leakage there and make the engine oil pressure too low;

Loss of the water tank cap, oil port cap, and fuel tank cap will cause the intrusion of sand, gravel, dust, etc., exacerbating the wear of various parts.

Reuse concrete pump parts

Some parts should be used once, but individual drivers or repairmen reuse them in order to save or because they do not understand the "taboos". This can easily lead to accidents.

Generally speaking, disassembly of engine connecting rod bolts, nuts, imported diesel engine injector fixing bolts, cylinder liner water blocking rings, sealing copper pads, various oil seals and sealing rings of the hydraulic system, and pins, cotter pins and other important parts Finally, it must be replaced with a new one;

For the engine cylinder gasket, even if no damage is found during maintenance, it is best to replace it with a new one, because the old one has poor elasticity, poor sealing, and is easily ablated and damaged. It will need to be replaced after a short period of use, which is time-consuming and labor-intensive. Therefore, if there is a new one, try to replace it better.

Conclusion

To effectively troubleshoot concrete pump truck failures, we must first clearly understand the equipment's component composition spare parts, working characteristics and working principles. When analyzing these faults, we must start from its basic working principle.Determine the cause of the failure and confirm whether it is caused by design and manufacturing defects or improper installation. Wrong diagnosis will inevitably lead to high repair costs, long downtime, and a series of adverse consequences such as reduced production efficiency.

When a fault occurs, concrete pump spare parts must be replaced and repaired in time. Only in this way can the machinery be guaranteed to perform better and long-term maintenance costs be reduced.

Due to frequent pumping operations, the moving spare parts of the pumping unit wear out relatively quickly. Correct maintenance will improve work efficiency and extend the service life of wearing parts. Therefore, operators are required to conduct daily inspections after each construction operation.