Concrete pump trucks, a machine designed specifically for conveying concrete, have played an indispensable role in the construction industry with their excellent pumping speed, high degree of automation, convenient operation and excellent maneuverability. They can easily achieve long-distance vertical and horizontal concrete delivery, and can handle high-rise buildings, elevated highways and underground projects with ease.
However, the concrete pump truck system has a complex structure, a harsh working environment and a high failure rate.
Los camiones bomba de concreto, máquinas diseñadas específicamente para el transporte de concreto, han desempeñado un papel indispensable en la industria de la construcción gracias a su excelente velocidad de bombeo, alto grado de automatización, manejo práctico y excelente maniobrabilidad. Permiten el transporte de concreto vertical y horizontal a largas distancias, y pueden manejar edificios de gran altura, autopistas elevadas y proyectos subterráneos con facilidad.
Sin embargo, el sistema de camión bomba de hormigón tiene una estructura compleja, un entorno de trabajo hostil y una alta tasa de fallas.
The following are common fault classifications, diagnostic methods and maintenance solutions.
1. Hydraulic system core fault diagnosis and maintenance/Diagnóstico y mantenimiento de fallas del núcleo del sistema hidráulico
1). Abnormal pressure (no pressure or insufficient pressure)/Presión anormal (sin presión o presión insuficiente)
reason:
Overflow valve failure: valve core stuck, damping hole blocked, spring failure.
Internal leakage or wear of the main pump: Damage to the transfer case fork and wear of the gears lead to interruption of power transmission.
The output pressure of the pressure reducing valve is too low (for example, the standard 21 MPa is reduced to 4 MPa), which affects the charging speed of the accumulator.
Repair steps:
Check the overflow valve: clean the damping hole, replace the spring, and grind the valve core 38.
Test the transfer case: disassemble and inspect the gears and splines, and replace damaged parts (such as the case of damaged splines on the third main shaft).
Check the pressure reducing valve output: If the pressure is lower than the standard, clean or replace the pressure reducing valve.
2). Insufficient flow or abnormal sound/Flujo insuficiente o sonido anormal
reason:
Large oil suction resistance: filter is clogged, hydraulic oil viscosity is too high, liquid level is too low.
Hydraulic pump wear: idling leading to reduced performance or failure of the variable mechanism.
The nitrogen pressure in the accumulator is insufficient (the standard is 7 MPa, and the pre-pressure is insufficient when it is lower than 5 MPa).
Repair steps:
Clean the filter, add hydraulic oil to the standard level, and replace with oil of appropriate viscosity.
Check the accumulator pressure: add nitrogen to 7 MPa.
Swap the gear pump oil pipe for test: if the flow is restored, replace the worn gear pump.
3). Leakage and overheating/Fugas y sobrecalentamiento
Leakage points: loose joints (accounting for 60% of sealing failures), flange seal failure, and oil seal overpressure damage.
Oil temperature is too high (>80℃):
Long-term high-pressure operation, cooler blockage, internal leakage (such as damage to the master cylinder seal).
Case: The boom relief valve was stuck, resulting in continuous high pressure and the oil temperature soared to 60℃.
Repair steps:
Replace the seal and tighten the fitting to the standard torque.
Clean the radiator and adjust the relief valve pressure to the rated value.
4). Vibration and shock/Vibración y choque
source:
The pump body inhales air, the coupling is not concentric (deviation > 0.1 mm), and the pipeline is not fixed and resonates.
The reversing valve buffer fails and the accumulator pre-charge pressure is insufficient.
Solution:
Repair the oil inlet pipeline seal to ensure that the oil suction height is <500 mm.
Add a pipe fixing bracket and adjust the concentricity of the coupling to ≤0.1 mm.
2. Troubleshooting of key subsystems/Solución de problemas de subsistemas clave
1). Pumping system failure/Falla del sistema de bombeo
Pipe blocking:
Causes: Foreign matter stuck in the pipe (such as falling blades of a mixer truck) and concrete segregation.
Treatment: knock to locate the blockage point, remove the pipe to remove foreign matter; reverse the pump operation to discharge material; optimize the slump of concrete (16 cm→18 cm).
Master cylinder stroke shortened:
Diagnosis: Piston seal is damaged (oil leakage in the rod/rodless cavity), and the differential pressure signal valve is leaking internally.
Verification method: Remove the oil pipe, hold the pressure, and observe whether oil is sprayed.
2). Boom system failure/ Fallo del sistema de la pluma
Slow/Jittery Movements:
The multi-way valve has internal leakage (the pressure is only 8 MPa, which is lower than the standard 30 MPa).
The balancing valve is stuck or the rotary solenoid valve is burned out (abnormal resistance).
repair:
Replace the multi-way valve control block and clean the balancing valve core.
Check the solenoid valve coil resistance (normal value 20-30Ω) and replace the burned coil.
3). Stirring system failure/Fallo del sistema de agitación
Stirring stalled/weak:
The gear pump is worn (insufficient oil outlet pressure) and the overflow valve spring is broken.
Case: Among the failures of adjusting the stirring pressure, gear pump wear accounts for 70%.
Solution: Replace the high-torque motor (such as IQJM11-1.25) and adjust the relief valve to 14 MPa.
3. Electrical and control system failure/Falla del sistema eléctrico y de control
One side of the boom does not rotate/move:
The relay is burned out (e.g. KA30 controls the bypass valve, current > 13.5A causes overheating).
The proximity switch is short-circuited (such as SQ2 damage causing PLC false alarm).
repair:
Chip relay → intermediate relay upgrade (carrying current increased to 20A).
Short-circuit the test line to locate the fault point (such as short-circuiting 40# line and I2.5 to release the alarm).
4. Preventive maintenance and operating specifications/Mantenimiento preventivo y especificaciones de funcionamiento
Hydraulic oil management:
Regularly replace filter elements (every 500 hours) and hydraulic oil (every 2000 hours), and control contamination to NAS level 9.
Monitor the oil temperature to ≤80℃, and check the cooling system immediately if the temperature exceeds the limit.
Key component inspection:
Accumulator: Check nitrogen pressure every month (standard 7 MPa).
S tube and cutting ring: Lubricate every shift and replace when the gap is >2 mm.
Electrical circuit: waterproof and dustproof, quarterly detection relay contacts.
Operation taboos:
Avoid pumping high-grade concrete (such as C40) at low pressure, as this may easily lead to overload of the main pump.
If the shutdown time exceeds 2 hours, the pipeline needs to be cleaned thoroughly to prevent the concrete from solidifying.
Summary: Troubleshooting Golden Process/Resumen: Solución de problemas del proceso Golden
Phenomenon location: record the pressure gauge value, abnormal noise location, and oil temperature changes.
Electrical priority: detection of relays, solenoid valves, sensor signals (such as PLC input/output).
Hydraulic test: Test the pressure/flow in sections to check for internal leaks (such as the master cylinder seal test method).
Final mechanical inspection: dismantle and inspect worn parts (pins, gears) and blockage points (damping holes, filter elements).
Data shows that 80% of pipe blockages are caused by improper operation, and 60% of hydraulic failures are caused by oil contamination. It is recommended to establish maintenance files, record the life of components (such as the average life of a gear pump is 3,000 hours), and optimize the maintenance cycle in a targeted manner.
Ubicación del fenómeno: registre el valor del manómetro, la ubicación del ruido anormal y los cambios de temperatura del aceite.
Prioridad eléctrica: detección de relés, válvulas solenoides, señales de sensores (como entrada/salida de PLC).
Prueba hidráulica: pruebe la presión/flujo en secciones para verificar si hay fugas internas (como el método de prueba del sello del cilindro maestro).
Inspección mecánica final: desmontar e inspeccionar piezas desgastadas (pasadores, engranajes) y puntos de bloqueo (orificios de amortiguación, elementos filtrantes).
Los datos muestran que el 80% de las obstrucciones de tuberías se deben a un funcionamiento incorrecto, y el 60% de las fallas hidráulicas a la contaminación del aceite. Se recomienda establecer registros de mantenimiento, registrar la vida útil de los componentes (por ejemplo, la vida útil promedio de una bomba de engranajes es de 3000 horas) y optimizar el ciclo de mantenimiento de forma específica.
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Post time: Jun-19-2025