When concrete pump truck spare parts are worn beyond the specified limit or damaged, they must be replaced according to standard procedures to ensure quality and operational safety:
(I) Pre-Replacement Preparations
Equipment Shutdown: Park the pump truck on a flat, solid surface, retract the boom, shut down the engine, disconnect the power cord, remove the key, and place warning signs around the equipment to prevent unauthorized personnel from approaching.
Tool and Spare Part Preparation: Prepare specialized tools (such as hydraulic wrenches, pin removers, and seal installation tools) and inspect them for integrity. Verify that the model and specifications of the new spare part match the old one, and clean any rust preventative oil and impurities from the surface of the new spare part in advance.
Safety Protection: Operators must wear a hard hat, non-slip gloves, and protective glasses. If replacing hydraulic system parts, an oil pan must be available to prevent hydraulic oil leaks and contamination.
(II) Standardized Disassembly and Installation Procedures
Removing Used Parts:
For conveying system spare parts (such as concrete pistons and S-tube valves), first drain any remaining concrete from the hopper. When removing related oil pipes and connectors, properly mark them (e.g., label the pipe connections) to avoid confusion during installation.
Before removing hydraulic components (such as hydraulic pumps and cylinders), release the hydraulic system pressure (via a pressure relief valve) to prevent hydraulic fluid from spraying out and injuring anyone.
When removing the boom pin, use a dedicated puller to remove it slowly. Avoid forceful impact that may cause deformation of the boom or damage to the pin.
Installing a new spare part:
Clean any debris and oil from the mounting area (such as the inner wall of the delivery cylinder and the boom pin hole). Apply a special grease (such as hydraulic sealing grease) to the seal mounting area to improve sealing performance.
Install the new spare part in the reverse order of disassembly, ensuring that the connecting parts (such as bolts and nuts) are securely in place. Use a torque wrench to tighten to the torque specified in the equipment manual (for example, the boom pin bolts should be torqued to 500-600 N·m).
After installing the hydraulic spare part, bleed the hydraulic system: start the engine, slowly operate the boom, and repeatedly extend and retract the hydraulic cylinder to expel air from the system to prevent any jerking or unusual noise.
(III) Post-Replacement Commissioning and Acceptance
No-load Commissioning: Start the pump truck and conduct no-load operation (e.g., boom fully extended and retracted, delivery cylinder reciprocating motion). Check the operating status of spare parts:
Delivery System: Observe the S-tube valve for smooth swing and binding.
Hydraulic System: Check the hydraulic oil pipes and joints for leaks and the hydraulic cylinder for smooth operation.
Electrical System: Test the remote control and sensors for proper operation and the PLC controller for fault codes.
Load Test: After no-load commissioning, conduct a load test (e.g., pumping water or mortar) to check for stable concrete delivery pressure and accurate boom distribution. If any abnormalities are detected (e.g., excessive pressure fluctuations, boom subsidence), immediately stop the machine for inspection and troubleshoot before retesting.
Record and Archive: Record the time, model, replacement personnel, and commissioning results of spare part replacements in the equipment maintenance file to provide data support for subsequent spare parts management and maintenance.
Concrete pump truck spare parts are critical to ensuring the continuous operation of the pump truck and the smooth progress of the project. Construction companies must prioritize spare parts management. Through precise selection, scientific maintenance, and standardized replacement, they can extend spare parts life, improve pump truck operating efficiency, and reduce operating costs. With the continuous development of the infrastructure industry, concrete pump trucks are becoming larger and more intelligent, and spare parts technology is constantly evolving (such as wear-resistant ceramic conveying elements and intelligent monitoring sensors). Companies must closely monitor spare parts technology trends and optimize spare parts management strategies to ensure efficient and safe operation of concrete pump trucks and contribute to high-quality project progress.
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Post time: Sep-05-2025