CONCRETE PUMPS
There is an oil chamber at the front of the pump. The oil is taken from this chamber and the entire system is powered by the hydraulic movement generated by this oil.
The oil drawn from the chamber by the main pump through the FFH system (where the valves have suction and outlets) located beyond the section where there is water, from there the movement of the piston is ensured. There are suction outlets and relief valves here.
Thanks to the group of valves in front of the top, the stube is activated. With the 4 groups to the right of it, the mixer is activated.
Oil from the boiler is transmitted to the ramps through capillary pipes and the ramp moves up and down. It rises through the valve on one side of the boom and descends through the valve on the other. There are valve and safety (fine) inlet and outlet pipes. The capillary tubes of the 1st ramp decrease the maximum number of tubes that go up.
The nitrogen tube strengthens the work of the piston. There is a buoy in the tube, air on one side, oil on the other, and vacuum when the two meet. This is how you get power.
The section with the ahzne water cools the pistons and the wedges.
On the side where the shipping cylinder is the hopper, the drive cylinder is on the other side.
The 230 mm or 260 mm diameter and 2.1 m long piston moves back and forth in cylinders. There is a sealing element called a wedge on one side of the piston, so that the water and the concrete in the middle do not mix. The wedge is prevented from slipping thanks to the sleeve-like element located in the chamber part. There is also a sealing element at the port of the chamber with the drive cylinder so that oil and water do not mix.
Hopper snores and presses the choke system behind him. With this hydraulic system, one of the two inlets opens and the other closes.
The piston drives and moves back and forth in the propulsion cylinder. When you squeeze the oil on one hand, it squeezes the concrete on the other.
36,43,49 open 52 and 56 closed systems. Open system; After the task is completed, the oil passing through the fan enters the reservoir and is returned from the chamber to the system. This oil which arrives in the closed system is not sent back, the cold oil goes into the system by another suction.
Inside the control cabinet on the right side of the pump there are controls that open and close the arrows, where the movements are initiated and the arms just behind here open and close the feet with the control d ‘here.
On the left side is the pump brain, where all electrical devices are available. There are 2 PLCs, which control all the movements in the middle, and on the right is the system which allows the pistons to work, and in the system the right is the receiver system of the remote control. On the left side is the system which is connected to the electronic indicator.
The engine and gearbox operate hydraulically, not electrically. At the bottom there is the movement of the motor which is transmitted to the return pinion via the pinion above and the rotation begins. The higher the number of gears, the greater the movement.
Main pump; provides the movement of the pistons. the stube in front of it also provides the bustle at the front. There is another PTO to the right of the anapompa, and to the right is the pump that allows the arrows to move. It is connected to the pumps with the PTO stiebel in the truck and the mechanical power from the PTO is converted into hydraulic power by the pumps. The oil that passes through the filter into the suction chamber passes through the poma, transforming the hydraulic power, which is transferred to the relevant places to transform into mechanical energy.
There are two hoses that go into the drive cylinder, one in the front and one in the back. Oil comes out of both, and there is also a relief valve. There are therefore two inlets and two outlet pipes for two cylinders.
This is the filling chamber above the oil chamber. The filter is elsewhere.
The main pump is located under the truck and is connected to the PTO via a shaft (Stiebel). In automatic transmission trucks, it connects directly to the truck via an occasional part.
Manual chance, pump 7. It is activated in speed. It is not necessary in the automatic transmission.
The cleaning ball is sent from the suction chamber of the suction pump to the pipes according to the principle of the reverse operation of the pump.
It is a water reservoir for your feet.
The basis of hydraulic power transmission is the transmission of mechanical power from a power source to the point of use into the convert sing into hydraulic power, where it is converted back into mechanical power by hydraulic motors. is the use of .
There are valves on the pump, these are directional valves.
In other words, the working principle of the pump is hydraulic energy. Everything is done by hydraulic power provided by oil.
Pumps 6-180 pairs.
The number 46 hydraulic oil used in the concrete pumps is completely replaced according to the checks to be carried out by sonar after 1000 hours of operation. As soon as water, burrs or different substances, discrepancy and loss of fluidity are noticed, the oil must be completely cleaned from the system and renewed.
Pumps are also typically used in tank suction filters, high pressure filters and boom filters.
High pressure filter; This filter, made of a mixture of metals and synthetic materials, operates under high pressure.
Tank suction filters; Suction line suction filters of anapompas, which operate under vacuum, are also usually paper-based. There is a vacuum clock indicating its pollution.
Filter replacement intervals;
After starting the pump, the filters must be replaced during the first maintenance (100 hours).
A machine that has worked for 1000 hours should be replaced in its filters when changing the oil depending on the result of the check.
A concrete pump that has been in the park for a long time, given the possibility of bacterial activity in the oil tank, all filters should be changed when the oil change is to be carried out.
The machine’s suction filters, which may have been “swollen” due to bacterial activity or other reasons, should be replaced before the vehicle is started.
It is recommended for system safety to renew the suction filter cartridges every 125 working hours (100 hours depending on the working environment) regardless of the vacuum clock indicator.
It is important; Suction filters are typically 10 micron porous filters for every gram of oil that the main pump sucks up. When the permeability of the filters begins to become clogged with dirt or contaminants, the vacuum in the suction line increases. The formation of a high vacuum can cause air to enter the system.
The concrete pump must be greased. Especially the arrow ports. Additionally, the Lincoln automatic greasing system is available in concrete pumps.
Remote;
Start a truck on the left side. There is a horn on the right. There are three arms from right to left. 3rd arm 1-2 boom and right turn left. 2. Arm 3-4 arrow and right turn left, 1st arm 5-6 arrow and right turn left Right button buzzer. Sets the amount of bottom right flow. Start pumping to the far left. Either way, next to him is the turtle rabbit next to him.
Weldox steel is used in the booms. Stube is made of chrome steel.
The legs open independently of each other.
The front ones are lateral and the back ones are direct.
There is dual fan cooling at 52-56.
When we lift the pump, the tires should be off the ground. There are weight blocks under the feet.
It takes the command and sends it to the PLC. He goes through the relay and checks the Swics. It returns from the relay to the PLC, then it leaves the output relay.
The piston shim is worn due to friction.
In mobile concrete pumps, movements are provided by a hydraulic valve. Two different types are used in hydraulic valves. One of them is the on/off valves used mainly in old and 4 ramp pumps. The other is proportional hydraulic valves. More or less on/off systems have single speed movements, while in proportion you get movements as fast as you move the joystick. The common feature of these hydraulic valves is that they are electrically wound. Whether you have a wired or radio controlled control, you can operate the concrete pump by connecting the outputs to these coils. Of course, the principles of operation of these coils depending on their brand and model are different, such as those operating from 100-800 mA or those operating from 6-18 V.
OPERATION AND MAINTENANCE
Before use, the operator should check the machine as follows:
A. The power take-off must be positioned on “PTO”, the “PTO” indicator must be on; If the PTO switched control switch is present, it must be carefully removed and removed.
b. The gear lever must be in posi tion of direct operation.
vs. Meters for engine speed, water temperature, engine oil pressure, etc. should be within the normal operating range.
d. The hunting irons must be extended to the specified position according to the regulations.
e. The machine must be set horizontally; the tires must be off the ground.
F. The Avara iron and all switches or pump control arms must be in the non-operating position.
2. When extending the concrete casting lever, the check should be carried out as follows.
A. Check that the caster irons are extended to the specified position and that the tires are off the ground when the caster irons are resting on the ground.
b. The seal of each section of the crane arm must be filled with oil.
vs. The thickness of each supply pipe can meet the requirements of use.
d. Working conditions can meet the above requirement.
3. When the concrete is pumped, the control should be carried out as follows.
A. The pumping operator must be in
contact with end pipe operator when pumping is started or stopped.
b. Check that the lubricating pump is working normally and if each lubricating point is filled with oil.
vs. Check that the oil absorption and return gauge and the vacuum gauge are working normally.
d. Check that the motor rotation speed reaches the maximum value. (With an ambient temperature below 0°C, slow down the engine for 15-20 minutes, simultaneously leading the pumping cylinder to preheat the hydraulic system first. Thus, the constant pressure pump operation, which may lead to Insufficient oil absorption and pump. Damage when cold air can be avoided.)
2.3.2 Operation of the concrete pouring arm
The operation of the concrete pouring arm can be completed by means of an electric control box or a remote control.
1. Thanks to the electric control switches and multiple valves of the avara irons, the coyopherous irons can be fully extended (semi-extension is prohibited). Check that the whole machine is fixed horizontally (the air bubble should be in the middle of the leveling tool).
2. Flip the “Panel/Remote” switch on the control panel to the “Remote” position. Note: The controller command switch function is illustrated in the operator’s manual supplied with the machine.
3. If there is air in the hydraulic cylinder and hydraulic pipe, the crane arm will descend rapidly during operation and may damage the machine or injure someone.
In the following cases, the air must be evacuated before pumping the concrete.
4. Open and bend each section of the crane arm starting from the first crane arm in a small angle, then the degree of the angle to achieve full relief and bend each crane arm.
5. Open the crane arm repeatedly according to the signal on the controller. For different machines, the opening sequences of the crane arms may vary depending on the type of folding.
Before the concrete is pumped, a small amount of water and mortar should first be pumped in to lubricate the supply pipe.a. The pumping operator must be in contact with the pipe end operator.
Set the mixing mechanism control switch on the control panel to the automatic mixing position, then after the tank is filled with concrete, the remote control or electric control panel press the pump button.
The pumping rate can be adjusted according to business needs.
If the crane arm is to be operated while pumping, first gear should be used to operate the crane arm.
If the machine is equipped with a high-low pressure switch function, high-pressure pumping is prohibited when the crane arm is moving.
If pumping is stopped for 10 to 15 minutes, continue pumping or reverse pumping intermittently to maintain good concrete flow.
After a longer downtime, the concrete in the pipes should be sucked into the chamber and thoroughly mixed in the chamber before being pumped out again. If a clog occurs, stop pumping immediately and pump back continuously.
After the pumping process is completed, press the pumping stop button, the pumping will stop.
After the machine is stopped, the pressure inside the accumulator and the hydraulic hose can be released; however, for safety, turn the blend knob and cleaning knob to the off position respectively. (This is the process is only applied to the truck mounted concrete pump with the vanelectromagnetism of the mixing system).
3. Cleaning the concrete pipe and the machine
A. After pumping, intermittently pump backwards to empty the concrete inside the tank; Open the chamber drain cover to empty the residual concrete inside the chamber and clean the tank with water.
b. Remove the elbow pipe from the chamber outlet mouth, clean it with water and reconnect it.
vs. Fill the tank with water, place a sponge ball in the pipe and clean the pipe by automatic pumping.
d. Or put a sponge ball inside the end pipe, the sponge ball will be pulled into the elbow pipe to clean it by reverse pumping.
e. Use high pressure water pump to clean the whole machine.
2.4 Operation from operating state to transport state
1. After the pumping and cleaning processes are completed, if the ambient temperature is lower than 0°C, the remaining water in the water tank and the system should be drained.
2. Fold the concrete pouring arm according to the crane arm opening procedure and place the crane arms on the concrete pouring arm bracket.
2. Fold the concrete pouring arm according to the crane arm opening procedure and place the crane arms on the concrete pouring arm bracket.
3. Pull all Coerk bars back and lock them carefully.
4. The power take-off must be moved from the working state to the transport state.
1.1.1 Daily inspection of basic parts
1 . Normal hydraulic oil should be crystal clear, its color should be
light yellow, it should not become emulsion or hazy.
2 . Fill the lubrication tank and the lubrication points with the lubricant and fill the water tank with clean water.
3. The insulation of the concrete plunger should be good, and there should be no mortar in the water tank.
4. Check that the gap between the cutting ring and the wear plate is normal (max. 2 mm).
5. Check the working condition of the lubrication system, the indicator arm of the progressive distributor should move back and forth, and there should be no leakage of lubricant from the bed of the mixing shaft with the valve” S”.
6. Check the electrical parts are normal.
7. Check that the movement, mixing and reverse mixing of the dispense valve is normal.
8. Check the exterior of the cooler. If there is dirt, clean it to prevent the oil from overheating.
9. Check that the gauge of the vacuum gauge is in the green zone (it should not exceed 0.04 MPa). As a general rule, the vacuum rating for fat absorption should be less than 0.01 MPa. The vacuum rating for oil shrinkage should be less than 0.35MPa.
10. Check concrete pipes for erosion by tapping them. Check that the pipe insulation is in good condition.
11. Check for leaks in the hydraulic system, loose insulation of the oil tank cover, and water or air in the oil tank.
12. Check the hydraulic oil level. The oil should be crystalline, its color should be light yellow, it should not become an emulsion or hazy. Otherwise, the oil must be replaced.
13. Check the hydraulic oil to see if too much water is involved in the oil. Every 3-10 days, the operator should open the ball valve at the bottom of the oil tank and be careful not to overflow the hydraulic oil.
1.1.2 Maintenance after 50 working hours (1500~2500 m3)
1. Perform maintenance as listed above.
2. Check the connection of all bolts to ensure tightness.
3. Check the piston arm connection in the water tank to make sure it is in good condition.
4. Check gauge and vacuum gauge filter.
1.1.3 Maintenance after 100 working hours (3500~5000 m3)
1. Perform maintenance as listed above.
2. Check wear plate and replace if necessary.
3. Check concrete piston for erosion and replace if necessary.
4. Check that the hydraulic oil is not degenerated and does not become an emulsion. If not, replace the oil completely and clean the oil tank thoroughly
1.1.4 Maintenance after 500 working hours (15000~25000 m3)
1. Perform maintenance as listed above.
2. Check S-valve and bearing for wear.
3. Check overcling of mixing device, mixing wings and mixing shaft etc.
4. Check the hydraulic oil. If necessary, replace the oil. The brand of oil should be according to our company’s recommendation. It is recommended to completely replace the hydraulic oil after pumping 10,000 m3 of concrete.
5. Check that the pressure inside the accumulator is sufficient.ist. The filling pressure of the accumulator is 8-9 MPa.
6. Check the connection and sources of building elements.
7. Check the PTO oil level. If necessary, fill or replace.
1.1.5 Maintenance after 750 hours of operation
1. Perform maintenance as listed above.
2. Check the erosion of the concrete cylinder. If the chrome coating is badly damaged, replace the cylinder.
3. Carefully repair the machine to ensure that all performance parameters are normal.
1.2 Chassis maintenance
Please refer to the chassis user manual for details. Before use, please check the following points:
1. Check engine oil level and condition.
2. Check engine oil pressure.
3. Check coolant and coolant level, check water temperature.
4. Check tire wear and pressure.
5. Check the electrical system (eg lighting, turn signals, parking lights, etc.).
6. Check the view range of the mirror.
7. Check brake system pressure.
8. Check all directional lights.
9. Check for oil or air leaks (if leaking, please tighten the connections).
10. Check safety devices (eg boundary switch, safety pin, etc.).
11. All moving parts (eg 77 irons, concrete casting lever and so on) to ensure that they are connected at the specified places.
1.3 Maintenance of the pumping unit
Frequent pumping will cause rapid wear of the moving parts of the pumping unit. However, regular and thorough maintenance and servicing will help increase productivity and long life. Therefore, apply the daily check items as follows:
1. For each shift, fill the lubricating oil tank, each lubricating point with lubricant, and the water tank with water.
2. For each shift, check that the functions of electrical parts are normal.
3. For each shift, check whether the reverse pumping, distribution release will
Blender speed and rotation are normal.
4. After pumping 2000 m3 of concrete, check the gap between the wear plate and the cutting ring. If the clearance is more than 2 mm and the erosion is co-distributed, adjust the gap according to the procedure below:
A. Clean the chamber and the “S” valve; b. Remove bracket bolt 4;
vs. To reduce the opening between the cutting ring and the wear plate, tighten bolt 5 and pull the “S” pipe towards the rear wall of the chamber.
d. Tighten bracket bolt 4.
5. Replace cutting ring.
A. Shut off the engine, drain the pressure from the accumulator and remove the grid from the chamber.
b. Loosen bolt 5 by 20mm. Be careful not to loosen too much; otherwise, when the S pipe rolls back, it may come out of the rolling sign, which will damage the insulation of the bed and shorten the service life of the S pipe.
vs. Remove the flange from the outlet mouth, push the S-pipe towards the outlet until the gap between the cutting ring and the wear plate is approximately 20mm and remove the cutting ring.
d. Check the tire arch for damage. If it’s damaged, replace it.
e. Attach the new cutting rings following the reverse steps.
6. Replace wear plate
A. Repeat the procedure to change the cutting ring.
b. Remove all the connecting bolts from the wear plate and shake the plate slowly, it will come out easily.
vs. Install the new wear plate.
7. Check the wear condition of the S-hose, S-hose bearing, mixing device, mixing paddles and mixing bed every shift. If the wear is too great, they must be replaced. (The replacement method is specified in this manual).
8. Check that the insulation of the concrete piston is good and if sand has entered the water tank. If there is excess concrete in the water tank, it should be checked whether the concrete plunger needs to be replaced. The replacement method is as follows:
A. Remove the water tank cover.
b. In low pressure pumping mode, lift the cover plate and remove the bedding.
vs. Close the ball valve in the U-pipe at the tail of the pumping cylinder.
d. Once the piston is fully pushed out of the concrete cylinder impacting the main cylinder, stop the engine, manually operate the main cylinder switch and zero. The dismantling and installation of the concrete ram depends on the condition of stopping the machine and releasing the pressure.
e. Remove the bolts that connect the piconcrete ston to the connecting flange.
f) Remove the concrete waste (corner).
g. The concrete piston installation procedure is the opposite of the disassembly procedure.
1.4 Maintenance of the hydraulic system
1. Before starting the machine, drain the accumulated water from the base of the oil tank. At the same time, open the drain valve at the bottom of the oil tank to drain the water every 50 hours. Be careful not to let the hydraulic oil leak out.
2. Check the hydraulic oil for each shift. The hydraulic oil level is above 3/4 of the oil level indicator. The quality of the oil should be primula and transparent. If the oil becomes contaminated or emulsified or muddy, it is mandatory to replace the oil. Hydraulic oil has a great effect on the machine. To clean the oil tank and filters, it is usually necessary to completely replace the hydraulic oil after pumping 10,000 m3 of concrete, then every 20,000 m3 of concrete is pumped out.
3. Check the exterior of the radiator. If there is dirt, it should be cleaned immediately. Otherwise, the oil temperature will rise further.
REDUCER
Filler cap and breather
Fill and vent cap
Oil level plug
Oil level plug
Brake filler cap
Brake drain plug
Brake relief plug
Service line port
Service line port
Drain plug
Discharge cap
Brake release port
Drain relief port
Service line port
Housing drain port
Slot discharge port
1.8 Concrete pipe maintenance
To reduce risks and breakdowns when pumping, pipes of the correct diameter and thickness, the correct type of couplings and safety locks must be used. Periodically check for blocked fittings and excessive wear in the hoses.
1. To ensure the co-dispersed erosion of the concrete pipe, all the pipes should be turned clockwise 120° and the bent pipes 180° after pumping about 3000 m3 of concrete, such as indicated on the side. Shown in the right side’
3. Check concrete pipe erosion every time before pumping. If their thickness is less than the specified value, replace the worn pipes. To measure the thickness, listen for the sound of hitting the pipe with a hammer. A more scientific way to measure the thickness of a pipe is to use thickness measuring equipment.
4. The minimum tube meat thickness is linearly proportional to the pumping pressure as shown below:
X – Minimum pipe thickness
Y – Pumping pressure
A – Curve with a pipe inside diameter of 100 mm
B – Curve with
125 mm pipe inner diameter
C – Curve with a pipe inside diameter of 150 mm
According to the table on the right, the thickness of the pipe should be greater than the corresponding pumping pressure requirement.
1.9 Maintenance of the cleaning system
The machine is equipped with a high pressure cleaning water pump. When the engine is in idle mode, the pump speed and water pressure are low; as the engine speed increases, the water pressure will also increase. If high pressure cleaning is required, the motor should be at the maximum specified speed.
Clean water should be used. Impurities in the water lead to easy clogging in the water pipe, and especially in the connection of the water tank. It also affects the life of the water pump. For cleaning dirt, filter, water tank, etc. should be cleaned periodically.
In cold weather, the water in the system must be completely drained to prevent the water pump from freezing and other parts from breaking.
1.10 Maintenance of the electrical system
For the operation and daily maintenance of the electrical system, please refer to the electrical manual. Be sure to check the following points:
1. Check that all electrical parts work normally.
2. To avoid damage to parts, make sure that cables, especially cable connections and cables under pressure, are well insulated.
3. Check that the connectors are plugged in backwards and oxidized.
4. Check that the electrical system is well connected to the ground. In principle, all parts must be replaced with the same parts as the original parts. The fasteners to be replaced must be products regularly checked in the same class and standard.
2.1 Failures of the pumping system
2.1.1 Unable to start automatic pumping
1. Pump start button connection is loose. Reconnect the cable connector.
2. The auxiliary relay is burnt out. Maintain it or replace it.
3. The solenoid is burnt out. Dmplacer (the strength of general solenoids is about 22 Ω).
4. The pump pressure is too high or the pressure relay is defective. Maintain it or replace it.
5. Proportional amplifier malfunctions without control pressure.
6. Chassis gearing is incorrect. Depending on the indicator added to the cabinet, select the correct gear.
2.1.2 Pumping cylinders do not move
1. The main cylinder pulse shift button is loosely connected. Reconnect the cable connector.
2. The auxiliary relay is burnt out. Maintain it or replace it.
3. Faulty solenoid flow reversal valve, usually burnt solenoid. Change it. (the strength of general solenoids is about 22 Ω).
4. There is no output in the API. Enter the program (the flashing error light indicates a fault in the CPU and the light indicator indicates a program failure).
5. The other control cable is defective.
6. The main oil pump displacement adjustment knob is incorrectly adjusted.
7. The oil in the oil tank is not enough.
8. The filter is extremely clogged
The 9th control circuit ports are plugged.
2.1.3 The main cylinder cannot change direction
1. The solenoid of the solenoid backwash valve is burned out or the valve core is clogged enough to explode.
2. The solenoid of the solenoid valve is connected in the wrong position.
3. There is no pressure in the system.
4. The small hydromatically controlled valve is clogged enough to burst.
5. Insufficient direction change pressure.
2.1.4 The main cylinder cannot move at normal speed and force
1. The main oil cylinder check valve is damaged.
2. The main oil pump displacement adjustment knob is incorrectly adjusted.
3. Control pressure is not sufficient. The control pressure must be recalibrated: the supply pump drain valve pressure must be 3.5 MPa and the air exhaust valve pressure must be 3.0 MPa (below the direction of the ZOOMLION technical expert).
4. The filter is clogged or the hydraulic oil is insufficient.
5. The control circuit ports are plugged.
6. The Solenoit reverse flow valve is faulty and the valve core cannot move to the specified position.
7. When pumping concrete to the upper floor, due to the lack of oil compensation, the hydraulic oil in the closed chamber of the pumping cylinder decreases, and the impact of the pumping cylinder becomes shorter.
2.1.5 Insufficient concrete production
1. Concrete pistons are worn.
2. Gap between wear plate and cutting ring is too wide.
3. So bad that the concrete suction will be very bad.
4. Pipe S is partially clogged.
2.1.6 Unstoppable pumping
1. Auxiliary relay contact is on fire.
2. The stop button is faulty.
2.1.7 S-valve cannot be turned
1. Faulty dispense valve impact switch or loose wires.
2. The valve core of the electro-hydraulic changeover valve is stuck or the solenoid is burnt out.
3. S-valve clogged with objects.
4. The failure of the drain valve makes the rotation pressure insufficient.
5. Failure of constant pressure
The pump makes the rotation pressure insufficient.
6. Weak concrete is pumped out, and the machine is stopped for a long time to increase the resistance to rotation, so that the S pipe cannot rotate.
7. S pipe bed is worn to increase rotational resistance.
8. Auxiliary relay burnt out.
2.1.8 Tube S rotates slowly and weakly
1. The accumulator pressure is not sufficient or the bag is damaged. Fill with nitrogen gas to the set value or replace the accumulator bag and fill with nitrogen gas to the set value.
2. The shutoff valve is not closed.
3. Rotating cylinders have a large oil leak.
4. Worn pressure relief valve core will cause rotational pressure less than 15MPa.
5. The solenoid valve is faulty and the electro-hydraulic backwash valve core breaks so that the arc valve coil cannot reach the specified position. Erosion of the valve core will cause internal leakage.
2.1.9 Pipe S does not return to the correct position
1. The rotary cylinder nylon bed is worn, deformed or of different thickness.
2. The concrete hardens.
3. The concrete granule is very large and prevents the concrete from meeting the pumping requirements.
4. Insufficient hydraulic oil pressure.
2.1.10 Low pumping frequency
1. Hydraulic pump failure such as excessive leakage inside the hydraulic pump or obstructionion of the fixed power adjuster.
2. Damage to hydraulic parts, the maximum pressure valve cannot be opened due to dirt or damage.
3. Excessive leakage from the concrete piston, wear plate or cutting ring and similar wear from the pumping mechanism.
2.1.11 Concrete pump congestion
1. Leak in pump line system, e.g. between the cutting ring and the S-valve, between the discharge mouth and the S-valve, between the concrete piston, the concrete pipe and the quick-release couplings of the pipes.
2. Hydraulic system pressure is not sufficient.
3. Pumpability of concrete is not very good.
4. There is air in the concrete.
Solutions:
A. Check and replace cutting ring or wear plate; for pressing gaskets, tightening bolts and replacing worn parts such as concrete cylinder piston etc.
b. Check the hydraulic pump and adjust the drain valve pressure.
vs. If it doesn’t fit, change the concrete ratio.
d. Check the pipe joints.
2.1.12 Reverse Pumping Failure
Possible causes:
1. Mechanical failure due to directional control valve core clogging or high oil temperature. Check the core by pushing the rubber cover on the end of the valve. If the core cannot move, unplug it and clean it. Check the filter and the cooling system.
2. Failure of electrical installation such as solenoid burning (pumping valve reversed), relay burning, or connector oxidation.
Solution:
Switch off the device. Check the core by pushing the rubber cover on the end of the valve to see if the core can move. If the core cannot move, unplug it and clean it; if the core moves freely, remove the solenoid; If there is no magnetism in the voltage solenoid, check the solenoid or relay for damage.
2.1.13 Mixing system failures
1. Due to its poor pumpability, the mixing force is too high or the mixing wings are clogged. When the mixing wings are locked, rotate the wings in the opposite direction.
2. The drain valve setting pressure is not sufficient. Use wood to block the wings and set the pressure to 14 MPa.
3. The mixer motor is damaged. Check and replace if necessary.
4. The mixing system gear is damaged. Check and replace.
5. Damaged mixer shaft or shaft housing. Clean or repair shaft or shaft sleeve.
2.2 Concrete casting arm failures
2.2.1 Cast concrete lever cannot move (normal manual operation)
1. Crane handle/wrought iron knob is defective. Maintain it or replace it.
2. The F3/F4 fuse in the remote control box is blown. Change the fuse.
3. The solenoid of several valves is faulty. Replace the solenoid.
4. Other control cables are defective.
2.2.2 The crane arm cannot be opened or moved to a specific position
1. Hydraulic system pressure is not sufficient.
2. There are other exceptional loads on the crane arm.
3. The solenoid valve is stuck or burnt out.
Solutions:
A. If the pressure of the multivalve safety valve is lower than the specified pressure value, check that the maximum pressure valve is set correctly. If the fault cannot be solved, please replace the hydraulic pump.
b. Remove any other exceptional loads on the crane arm.
vs. If the crane arm cannot operate normally according to the above procedures, it is necessary to check whether the valve part that controls the relevant crane arm section operates normally. If the valve part does not work normally, the valve core may be blocked or the solenoid valve may be burned. Replace all damaged parts.
2.2.3 Too much vibration when opening or extending the crane arm
The possible cause is the abnormal ope
connection quality.
1. Between the axis and the fixed bearing in the fittings.
2. Between the fixed part of the pressure bed and the rotating part.
3. Pressure bearing bolts are loose.
Solutions:
A. Replace damaged parts and ensure the frequency of lubrication of the kinematic pair.
b. Replace pressure bearing and secure as specified.
vs. Tighten or replace bolts.
2.2.4 The concrete casting arm descends automatically
1. Air enters the cylinder of the crane arm. Since the air compressibility is too high, the load on different parts of the crane arm will be different. As the load increases, the concrete pouring arm descends because the compression causes the crane arm to extend or return.
2. The cylinder dThe crane arm has an internal leak.
3. There is an internal leak in the balancing valve.
Solutions:
A. Air enters the cylinder of the crane arm. According to the above method, bend the crane arm repeatedly to release the air.
b. If there is an internal leak in the crane arm cylinder, check the concrete piston seals for damage. If there is no damage, please check whether the oil cylinder pipe is damaged and whether the inner surface of the oil cylinder is swollen.
vs. If there is an internal leak in the balancing valve, remove and clean the valve. If any parts of the balancing valve are damaged, service or replace them; if badly damaged, replace the balancing valve assembly.
2.2.5 The oil cylinders of the crane arm are not synchronized (the first crane arm has two oil cylinders)
1. The drive pressures of the two balancing valves are different. If the drive pressures are higher than the load, when the drive pressures are different, the low drive pressure balancing valve will open first and the affected oil cylinder will move first. When the movements of the oil cylinders are not synchronized to some extent, the pressure will increase due to the mechanical limit and the other oil cylinder will move.
2. The friction of the two oil cylinders is different. The friction of the oil cylinder is equal to the load. Too much difference in friction will ensure that the movements of the oil cylinders are not out of sync.
3. The inclined loads of the two oil cylinders will first cause the cylinder to move at low load.
4. Oil inlet and oil return pressure are different. The cores differ because they are stuck or clogged with sediment, which can cause different oil inlet and return pressures and, therefore, cause the crane arm oil cylinders to become out of sync.
Solutions:
Once the mechanical failure has been repaired, the hydraulic system can be adjusted. First, adjust the pressure of the balance valve in the oil return space of the oil cylinder.
2.2.6 Concrete pouring arm stops slowly after rotating
Part 1 valve is clogged with dirt.
2. The machine is not stable horizontally.
3. Eroded brake disc.
4. Braking arc is broken.
Solutions:
Clean or replace pinch valve; adjust the height of the coking iron so that it is level with the machine; brake disc; change the brake arch.
2.2.7 The first crane arm is only raised, cannot be lowered
1. The retainer of the first crane arm is defective. Service or replace retainer.
2. The KA40 relay is faulty. Change the relay.
2.2.10 Shafts not sufficiently lubricated
1. Lubrication port is blocked or damaged.
2. The lubrication pipe is clogged with dirt.
Solutions:
Replace the lubrication mouth; remove the pin and check the cause of the jam, wear and opening.
2.2.11 Avara iron cannot move
1. Crane handle/wrought iron knob is defective. Maintain it or replace it.
2. The KA24 relay in the electrical control box is faulty. Maintain it or replace it.
3. The retainer of the first crane arm is defective. Maintain it or replace it.
4. The solenoid of several valves is faulty. Replace the solenoid.
3.5 Notes on the pumpability of concrete
Pumpable concrete is the material that can pass through the pipe. The cement should have lubricating properties provided by fine sand and water less than 0.2 mm.
3.5.1 Factors determining the pumpability of concrete
Four factors that determine the pumpability of concrete: fine sand, quality of aggregates, water/cement ratio, homogeneity of concrete.
1. Fine aggregate content should be at least 350~400kg/m3. (Fine sand and cement less than 0.2 mm in diameter). The following table shows the fine sand content as the maximum aggregate size. In terms of crushed aggregates, it is generally higher than 10% for fine sand, because the aggregate is more difficult to pass through the pipe due to its large surface of aggregates.
2. Concrete aggregate size
Good concrete is approximately pumpable concrete. Ideal for pumping, concrete has a good grain size consisting of aggregate species, the small
most of which can fit through the gaps between the larger ones. The table below shows the rate of pumpable concrete and all kinds of aggregate sizes. A change in composition is usually possible within the pumpability range, but it can also exceed the pumpability rangeity. Clearly, fine sand and aggregates play a predominant role in the composition.
The mismatch of the pipe and the pump increases for the following reasons:
A . Geometric shape of the aggregate: sharp-angle crushing aggregate, if the concrete moves in the pipe, acts like sandpaper in the pipe, forming fine particles, and the cement tends to break the oil film. The friction between different parts of aggregates and some crumbs increases the likelihood of getting stuck and causing a blockage in the pipe.
b. Hardness: Although hardness affects wear, it has no effect on pumpability. A rule based on experience accepts that concrete can be pumped if the maximum aggregate size is less than 1/3 of the pipe diameter. If the maximum aggregate size does not exceed 10%, the maximum aggregate size can be increased slowly.
3. Density
It is an important pumpability factor that determines the use and shape change of fresh concrete. Density is measured by collapse (see figure). The density depends on:
A. amount of cement
b. overall composition
vs. percentage of thin material
d. amount of water
Dry concrete is barely pumped. Suction difficulty can lead to low production, intermittent pumping and severe wear. To improve pumpability, these problems must be reduced or eliminated. Additives that increase fluidity are recommended.
The absorption of flowing concrete (slump greater than 15 cm) is not difficult, but it tends to break down, causing clogging of the pump and the pipe. Use plasticizing additives in concrete or increase the percentage of fine materials, sand and cement by 0.2 mm.
4. Homogeneity of the concrete
A quality measurement system can provide excellent precision in the special component. Likewise, a quality mixer is important to obtain a homogeneous concrete that does not cause clogging.
5. Additives
Different types of additives with thinning and plasticizing are available in the market. The pumpability of concrete can be increased when additives are used correctly. We recommend using additives according to the specifications given by the manufacturer.
2.1 Three side support support modes
Truck mounted concrete pumps with X type cara bars have three side support modes: left side support, front V support and right side support.
Description of module No. Name Explanation
1 Operator’s cabin Inside is the remote control receiver and drive/operate mode switch panel.
2 Accumulator On the right side of the truck mounted concrete pump is a power control switch.
3 Coolant On the other side of the truck mounted concrete pump are two coolers.
4 Landing foot switch box The truck mounted concrete pump is equipped with landing foot switch box on both sides.
5 Main valve Controls the hydraulic valve.
6 Clearance lamp The landing legs have four clearance lamps and one clearance lamp at the end of the first crane arm.
7 Horn Another horn is located on the rotating platform.
8 Electric control cabinet
9 Chamber side button area It is equipped with an emergency button and a buzzer button.
10 Mesh Braided Restraint
1.2 Control cabinet panel
The user controls the truck mounted concrete pump by the buttons on the control cabinet panel, and the message of the truck mounted concrete pump is indicator lights again.
1.2.1 Drive/Operation Mode Change Panel
HL18 HL15 S2B HL17 HL16
Boom Work Driving/working Driving Crane arm in place
It is located in front of the main driver of the operator’s cabin (next to the gear lever).
The chassis has two modes: “driving” and “working”. The driving/working mode can be changed using the “Driving/Working” button.
in the middle of the changing panel. The lights next to the button are used to indicate the current status.
The square-shaped “OK” button with indicator light is used to power the pumping system.
The “First crane arm in place” indicator indicates whether the first crane arm is in place.
1.2.2 Control cabinet panel
HMI: human-machine interface
TA1: “Emergency stop” button
SA1: panel/remote control button
Panel: Control Panel
Remote control: remote control
SA2: “Panel/Remote control” button
Pros: Positive pumping
Rev: Reverse Pumping
RP1: “Broadcast” button
SA3: “Engine speed timing” button
RPM+: Acceleration
RPM- : Slow down
SA4: “Main cylinder point” button
Left: left main cylinder point
Right: point ofright main cylinder
SA5: “Point of the tilted cylinder” button
Left: point of cylinder tilted to the left
Right: cylinder point tilted to the right
HL1: “Overpressure” indicator
S5E: “Cleaning Engine”
ON: Cleaning motor enabled
OFF: cleaning motor disabled
S5E: “vision lamp” button
ON: Vision lamp on
OFF: Vision lamp off
SA7: “Churning and backflip”
Pros: positive churn
Rev: Backhand Shake
SA6: “Cooler” switch
ON: Manual cooling
AUTO: Automatic cooling
SB8: “Lubrication” switch
ON: Manual lubrication
AUTO: Automatic lubrication
SA8: “Pressure gauge” switch
ON: Vision lamp on
OFF: Vision lamp off
S5E: “Piston replacement” switch
ON: Start piston exchange
OFF: Stop piston change
SB9: “high or low voltage switching” switch
High: High pressure pumping
Low: low pressure pumping
1.2.3 TA2 Landing Foot Button Box
TA2 Emergency stop TA3 Emergency stop
S3B Foot control S3A Crane arm/foot
S3C foot control
The landing foot button box in the middle of the truck mounted concrete pump is used to control the movement of the foot with the foot holding pole.
The right landing foot button box has a switch with a switch. The “crane arm/foot” is used to replace the power supply. The crane arm can prevent the movement of the foot when moving.
The “foot operation” button is used to energize the directional control valve to prevent wrong foot movement.
The crane arm movement button is located behind the movable arm of the crane arm. The function of the crane arm movement button is similar to the function of the foot movement button.
1.2.4 Control box for X bracket (optional)
1. X-bracket control box
A. LEDs indicate support modes accepted by the system
HL20: Indicator light for full support
HL21: Indicator for left support
HL22: Indicator for right support
HL23: Indicator for front support
b. SA12: support model selection button
vs. SA13: model confirmation button
The SA12 button is used to select a different media model. SA13 is the model confirmation button. You cannot choose the bracket model until the crane arm is installed on the crane arm trolley. Process steps: put the four-position selection button to the required position, then long press the SA13 “confirmation” button (about 3 seconds), finally, if you succeed in choosing a model, the support model indicator light will light up.
2. Control box for special support
A. Run Select Button Backward
b. Model select button support
vs. LEDs indicate support modes accepted by the system
HL20: Indicator light for full support
HL21: Indicator for left support
HL22: Indicator for right support
HL23: Indicator for front support
d. SA13: Model confirmation button
The “mode entry” button is used to select a different media model. The “OK” button is used to confirm after entering the mode.
1.2.5 Bedroom side buttons area
SA11 TA4, TA5 EMERGENCY HORN
The “emergency stop” button (there is an “emergency stop” button on each side of the chamber) and the “horn” button.
The “emergency stop” button is a red mushroom-shaped self-holding button. Used to stop the whole process in an emergency.
“Horn” is a green auto-restart button. It serves to sound the alarm!
1.2.6 Panel Remote Transmitter
1 Motor escapes 7 Fast/Slow
2 Antenna 8 Emergency stop
3 Crane arm function arm (rotation + crane arm operation) 9 Flow rate
4 Horn 10 Acceleration/deceleration
5 Pump on/off 11 Remote opening
6 Pumping/reverse pumping 12 Switch
1.3 Hardware logic
Signal flow
power distribution electric wire
Control signal flow
PTO
Battery
power distribution
HMI
Control Panel
Remote
Remote
Arrow/leg
Crane arm/foot
thigh box
Landing Foot Button Box
Controller
Leg Boom Wire Net
Foot Crane Arm Cable Network
Amplification of the control signal
Control signal upgrade
Valve relays
Valve relays
Valves
Boom leg
Foot Crane Arm
Execution Device
Run a device
Frame
power, speed, pressure temperature and angle and so on
The signal
of the chassis and the execution device
Chassis and device start signal
Electrical equipment
The new man-machine interface systeme of truck mounted concrete pump is a kind of industry external display imported from Germany. The degree of defense is IP67. Compared with the old screen, the new screen is better in dustproof or waterproof, highlight viewing, service life, etc. There are 6 buttons with lamps and a rotary button with lamp. With these 7 buttons, all kinds of operations are performed. To prolong the service life, be careful not to crush or scratch yourself.