Concrete Pump Truck Maintenance And Servicing (Part 1)
Concrete pump trucks operate in harsh environments; regular and proper maintenance is crucial to ensuring the equipment's efficiency, reliability, and long-term durability. The service life of the equipment is extremely important. To ensure normal equipment operation and uninterrupted construction, operators are required to conduct frequent inspections before, during, and after construction. Check and maintain regularly. The following explains and emphasizes the relevant maintenance of the concrete pump truck's pumping unit, boom, chassis, and lubrication.
Warning: failure to perform regular maintenance may lead to pump truck malfunction. It is essential that professional personnel perform maintenance according to the required procedures.
1.1 Routine Inspection
1.1.1Routine Basic Item Inspection
1. Standard hydraulic oil should be transparent, pale yellow in color, and free from emulsification or turbidity.
2. Fill the lubricating oil tank and all lubrication points with grease, and fill the water tank with clean water.
3. Check that the concrete piston is properly sealed and that no mortar has seeped into the water tank.
4. Check the cutting ring; the gap between the spectacle plate and the cut ring is normal (maximum gap 2mm).
5. Check the lubrication system's operation. You should see the indicator rod of the progressive oil distributor moving back and forth, and lubricating oil overflowing from the bearing positions of the S-tube swing arm end and the agitator shaft bearing.
6. Check whether each electrical component is functioning properly.
7. Check the oscillation of the distribution valve and whether the stirring device operates normally in both forward and reverse directions.
8. Inspect the exterior of the cooler. If there is any dirt, clean it immediately, otherwise it may cause the oil temperature to overheat.
9. Check the vacuum gauge reading; it should be within the green zone (vacuum level must not exceed 0.04 MPa). Generally, the vacuum level for oil suction should be less than 0.01 MPa. The vacuum reading for the return oil pressure should be less than 0.35 MPa.
10. Check the wear of the concrete pipes by tapping them, and check whether the pipe joints are properly sealed.
11. Check the hydraulic system for oil leaks, and check if the oil tank cover seal is loose or if water or air is entering.
12. Check the hydraulic oil level. The oil should be pale yellow and transparent, without emulsification or turbidity; otherwise, it should be replaced.
13. Check if the hydraulic oil has excessive water content. Every 3-10 days, open the funnel-shaped bottom ball valve at the bottom of the oil tank to drain the water. And be careful not to let the hydraulic oil leak out.
14. After each maintenance, repair, or operation such as changing hydraulic oil or adding grease, the concrete pump truck must be thoroughly cleaned to remove any residual hydraulic oil or grease. Key areas to clean include the engine exhaust pipe, turbocharger and transmission area, and the area near the rear axle tires and wheel hubs.
15. Regular cleaning of oil stains on the vehicle is necessary during routine maintenance.
16. Chassis maintenance should be performed at the chassis manufacturer's service station or by the manufacturer's personnel. Unauthorized handling is strictly prohibited.
1.1.2 Maintenance after 50 hours of operation (1500-2500 m3)
1. Perform the aforementioned maintenance.
2. Inspect all threaded connections to ensure they are secure.
3. Check the piston rod connection inside the water tank to ensure that the connection is firm and reliable.
4. Check the vacuum gauge reading and the filter cartridge's filtration status.
1.1.3 Maintenance after 100 hours of operation (3500-5000 m3)
1. Perform the aforementioned maintenance.
2. Inspect the wear of the spectacle plate and cutting ring; replace the cutting ring if necessary.
3. Inspect the wear of the concrete piston; replace it if necessary.
4. Check the hydraulic oil for deterioration or emulsification; if any, completely change the oil and thoroughly clean the oil tank.
1.1.4 Maintenance after 500 hours of operation (15,000-25,000 m3)
1. Perform the aforementioned maintenance.
2. Inspect the wear condition of the S-tube and its bearing.
3. Inspect the wear of the stirring device, stirring blades, and stirring bearings.
4. Check the hydraulic oil. Replace the hydraulic oil if necessary. New hydraulic oil must be the brand recommended by our company. Generally, the oil should be completely changed after pumping 10,000 m³ of concrete.
5. Check if the accumulator pressure is sufficient. The charging pressure for large accumulators is 8-9 MPa.
6. Inspect the connections and welds of the structural components.
7. Check the transfer case oil level to see if it needs to be topped up or changed.
1.1.5 Maintenance after 750 hours of operation
1. Perform the aforementioned maintenance.
2. Inspect the concrete cylinder for wear; replace it if the chrome plating is severely worn.
3. Conduct a comprehensive commissioning of the pump to ensure that all performance parameters meet the requirements.
1.1.6 Other maintenance
1. Check the cleanliness of structural components, walkways, rear axle, etc. If any parts are covered with concrete or oil, clean them promptly.
2. Users are advised to regularly clean the underside of the concrete pump truck frame, removing oil stains at least once per quarter.
1.2 Maintenance of Automobile Chassis
For detailed maintenance and upkeep instructions for the truck chassis, please refer to the chassis owner's manual. At least the following checks should be performed each time the concrete pump truck is started:
1.Check the engine oil level and condition.
2. Check the engineoil pressure.
3. Check the engine coolant level, coolant temperature, and coolant level.
4. Check tire wear and pressure.
5. Check the electrical system (e.g., lighting, indicator lights, and stop lights).
6. Check the rearview mirror visibility.
7. Check the brake system air pressure.
8. Check the operation of all guide lights.
9. Check for oil and gas leaks (tighten any connections if leaks are found).
10. Check safety devices (e.g., limit switches, safety latches).
11. Before moving the concrete pump truck, ensure all moving parts (e.g., outriggers, boom, etc.) are securely fixed in their designated positions.
