CONCRETE PUMPS

CONCRETE PUMPS
CONCRETE PUMPS

CONCRETE PUMP

 

  • There's an oil chamber at the front of the pump. Oil is taken from this chamber and the whole system is fed by the hydraulic movement generated by this oil.
  • The oil taken 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 here the movement of the piston is provided. There are suction outlets and relif valves here.
  • Thanks to the valve group in front of the top, the stube is activated. With the 4 groups to the right of this  , the mixer is activated.

 

  • The oil from the boiler is transmitted to the booms through capillary pipes and the boom is moving up and down. It lifts up through the valve on one side of the boom and goes down through the valve on the other. There are in and out of the valve and safety pipes (thin). The capillary pipes in the 1st boom are decreasing the  maximum number of pipes going up.

 

  •  The nitrogen tube makes the piston work stronger. There's a buoy in the tube, air on one side, oil on the other, and a vacuum when the two meet . That's how you get power.

 

  • The section with the water ahzne cools the pistons and wedges.
  • On the side where the dispatch cylinder is the hopper , the drive cylinder is on the other side.
  • The 230mm or 260mm diameter and 2.1m-long piston comes and goes in cylinders. There's a sealing element called a wedge on one side of the piston, so the water and concrete in the middle don't mix. The wedge is prevented from slipping with the sleeve-style element located in the part of the chamber. There is also a sealing element at the port of the chamber with the drive cylinder so that the oil and water do not mix.
  •  Hopper's snoring and pressing through the stube system behind him. With this hydraulic system, one of the two entrances opens and the other closes.
  • The piston  drives and goes back and forth in the propulsion cylinder. When you squeeze the oil on the one hand, it presses concrete on the other.
  • 36,43,49 open 52 and 56 closed systems. Open system; After completing the task, the oil that passes through the fan comes to the reservoir and is transferred back from the chamber to the system. This oil that comes in the closed system is not sent again, cold oil goes to the system through another suction.
  • Inside the control cabinet on the right side of the pump  , there are controls that open and close the booms, where movements are initiated and the arms just behind here open and close the feet with the command from here.
  • On the left side is the brain of the pump, where all electrical apparatus is available.There are 2 PLC's, which commands all the movements  in the middle, and the right is the system that allows the pistons to work, and in the system to the right is the receiver system of the remote control. On the left side is the system that is connected to the electronic indicator.
  • The engine and gearbox work hydraulically, not with electricity. At the bottom there is the engine movement  that transmits to the return gear via the gear above and the rotation begins. The higher the number of gears, the greater the movement.
  • Main pump ; provides the movement of pistons. the stube in front of it  also provides the stirring stirring at the front  . There's  another pto to  the right of the anapompa, and to the right is the pump that allows the booms 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 through the pumps. The oil that passes through the filter in the suction chamber  passes through the poma, transforming the hydraulic power, which is transferred to the relevant places to turn into mechanical energy.
  • There are two pipes that go into the drive cylinder, one in the front and the other in the back. The oil comes out of one and the other, and  there's also a relief valve. So there are two inlets and two exit pipes for two cylinders.
  • It is the filling chamber above the oil chamber. Filter is elsewhere.
  • The main pump is under the truck and connected to the PTO via a shaft (Stiebel). In trucks with automatic transmissions, it connects directly to the truck through an occasional piece.
  • Manual luck, pump 7. It's activated in gear.  This  is not required in the oyomatic transmission.
  • The cleaning ball is sent from the suction pump suction chamber to the pipes on the principle of reverse operation of the pump.
  • It's a water tank for your feet.
  • The  basis of hydraulic power transmission is the transmission of   mechanical power from a power supply to the  point  of  use by converting it to  hydraulic power, where it is  converted back to mechanical power by hydraulic movers.  is the use of .
  •  There are valves on the pump  , these are directional valves.
  • In other words, the principle of operation of the pump   is  hydraulic energy.  Everything is done by the  hydraulic energy provided by the oil.

 

  • There are 36-43 190 lt/d single  pump; 49- 190-130; 52-56-180 pair pumps.

 

The number 46 hydraulic oil used in concrete pumps is completely replaced according to the controls to be made of sonar after 1000 hours of operation. As soon as water, burrs or different substances, discord and fluidity loss are seen, the oil should be completely cleaned from the system and renewed.

  • Pumps are also generally used in tank suction filters, high pressure filters and boom filters.

 

  • High Pressure Filter;  This filter, which is metal blended and synthetic, is operated under high pressures.
  • Tank Suction Filters;  The suction filters in the suction line of the anapompas, which operate under vacuum, are also paper-based in general. There is a vacuum clock indicating its pollution.
  • Filter replacement intervals;
  • After the pump starts to start, the filters must be changed at the first maintenance time (100 hours).
  • A machine that has worked for 1000 hours must be replaced in its filters in the oil change according to the result of the control.
  • A concrete pump that has been in the park for a long time, taking into account the possibility of bacterial activity in the oil tank, all filters must be changed in the oil change to be made.
  • Suction filters of the machine, which may have been "swollen" due to bacterial activity or other reasons, should be renewed before the vehicle is started.
  • It is recommended for system safety to renew suction filter cartridges every 125 working hours (100 hours according to the working environment) regardless of the vacuum clock indicator.
  • It's important; Suction filters are usually 10 microns of porous filters for each gram of oil that the main pump suctions. When the permeability of the filters begins to be clogged with dirt, or contaminants, the vacuum in the suction line rises. The formation of high vacuum can cause air to enter the system.
  • The concrete pump must be   greased. Especially boom ports.  In addition, the lincoln automatic grease system is available in concrete pumps.
  •  

Remote control;

Start    a  truck on the left side.   There's  a horn on the right. There are three arms from right to left  .  3rd arm 1-2 boom and right left turn. 2.arm 3-4 boom and right left turn, 1st arm 5-6 boom and right left turn Right button  vibrator.  Sets the  amount of flow on the lower right.   Starts  pumping on the far left  . Back and  forth  next to  him is the turtle  rabbit next to him.

 Weldox steel is used in booms  . Stube is chrome steel.

The feet  open independently of each other.

The ones in front are  sideways and the ones in the back are direct.

 There's double-fan  cooling at 52-56.

 When we lift the pump, the tires must be cut off the ground.  There are  weight blocks under the feet.

 He's taking the command and sending it to the PLC.  He's going through the relay and checking the Swics.  He comes back from the relay to the plc  , then he goes out of the exit relay.

Piston wedge is worn due to friction.

In mobile concrete pumps, movements are provided by hydraulic valve. Two different types are used in hydraulic valves. One of them is the on/off valves used mainly in old and 4 boom pumps. The other is proportional hydraulic valves. More or less, on/off systems have movements at a single speed, while in proportion you get movement as fast as you move the joystick. The common feature of these hydraulic valves is that they are electrically coiled. Whether you have a wired or radio-controlled controller, you can use the concrete pump by connecting the outputs to these coils. Of course, the principles of working in these coils according to their brand and model are different, such as those working from 100-800 mA or those working from 6-18 V.

 

OPERATION AND MAINTENANCE

 Before operation,  the operator must  check the machine as follows: 

a. PTO  must be positioned as "PTO", the "PTO" indicator must be lit;   If the PTO's switched control switch is  present,  it must be carefully removed and  removed.

b. The gear lever  must be in a direct operating position.

c.  Meters for  engine speed, water temperature, engine oil pressure, etc.  should be in the normal operating range.

d. The hunting irons should be extended to the specified position according to the  regulation.

e. The machine must be set  horizontally;  tires must be separated from the floor.

f. The avara iron and  all control switches or arms of the pump must be in a non-operating position.

2.  When extending the concrete pouring lever, the control should be carried out as follows. 

a. Verify that the hunting irons are extended  to the  specified position and  that the tires are separated from the  ground when  the hunting irons are resting on the ground.

b. The joint   of each section  of the crane arm must be filled with oil.

c. The thickness of each  supply pipe may meet the requirement of use.

d. Working conditions  may meet the above-mentioned requirement.

3. When concrete is pumped, the control should be carried out as follows. 

a. The pumping operator  must be in  contact  with the  end hose operator when pumping is  started or stopped.

b.  Check  that the lubrication pump is functioning normally  and if each  lubrication point is filled with  oil.

c.   Check that the oil absorption  and feedback  pressure gauge and vacuum gauge are functioning normally.

d.  Check  that     the rotational speed of the motor reaches the maximum value. (With ambient temperature below 0°C,    idle  the motor for 15~20 minutes,  simultaneously  leading to the pumping cylinder to preheat  the  hydraulic system first.  Thus,  the  operation of the  constant pressure pump  , which can result in insufficient oil absorption and pump damage  when the air is cold, can be prevented.)

2.3.2  Operation of the concrete pouring arm

 The operation  of the concrete pouring arm  can be completed by means of an electrical control box  or remote control.

1.  Through the electrical control switches and multiple valves of the avara irons, the coyopherous irons  can be completely extended (semi-extension  is prohibited).   Verify that the entire machine  is fixed horizontally  (the air bubble must be in the  middle of the leveling tool).

2. Switch the  "Panel/Remote" switch on the control panel to the "Remote" position. Note:      The controller's  control switch function is  shown  in the manual of use supplied  with the machine.

3. If there is air in the hydraulic  cylinder and hydraulic pipe,  the crane arm will quickly come down during operation and  may cause machine damage or personal injuries.

In the following cases,  the air must be discharged before the concrete is pumped.

4. Opening   and folding each  section of the crane arm from the first crane arm within a small  angle,  then the  degree     of the angle to achieve full discharge and  folding  each  crane arm.

5. Open the crane arm  repeatedly according to  the signal on  the controller.  For different machines, crane arm opening sequences  may vary depending  on the different folding type.

Before the concrete is pumped,   a small amount of water and mortar must be pumped first  to lubricate  the supply pipe.a. The pumping operator  must be in contact with the end hose operator.

Place the  mixing mechanism control switch on the control   panel to the automatic mixing position  and  then after  the tank is filled with concrete,  the remote control or electrical control panel  press  the pumping button on  it.

The pumping flow  can be adjusted according to the business requirement.

If the  crane arm must be operated during pumping,  the first gear should be used to operate the crane arm.

If the machine has a high-low pressure switch function,  high pressure pumping is prohibited when the crane arm is  moving.

If pumping is stopped for  10~15 minutes,  continue  pumping  or reverse pumping  intermittently   to maintain good concrete fluidity. 

After a longer downtime,  the concrete in the pipes should be pulled into the chamber and  completely mixed  in the chamber before being pumped again.     In case of obstruction,  immediately stop pumping and  pump backwards continuously  .

After the pumping process is finished,  press the  stop pumping button,  the pumping will stop.

After the machine is stopped,  the pressure inside the accumulator and hydraulic pipe can be released;   however,  for safety, please put the mixing button  and cleaning button in  the stop position respectively. (This is  the process is applied only to the  truck-mounted concrete pump with the  mixing system electromagnetism valve).

3. Cleaning the concrete pipe and machine

a.     After pumping,  pump  intermittently backwards to empty the  concrete inside the tank;   Open the  drain cover of the chamber  to empty the   residual concrete  inside the chamber  and  clean the tank with water.

b. Remove the elbowed pipe from the outlet mouth  of the chamber,  clean it with water and reconnect it.

c. Fill the tank with water, place a  sponge ball  in the pipe and  clean the pipe by automatic pumping.

d. Or place a  sponge ball  inside the  end hose,  the sponge ball  will be pulled into the elbowed pipe to clean   it by reverse pumping.

e.  Use a  high pressure water pump to clean the entire machine.

2.4 Operating from operating to transport status

1. After the pumping and cleaning processes are completed, if the environmental temperature is below 0°C, the remaining water in the water tank and system should be discharged.

2. Fold the concrete pouring arm according to the process procedure of opening the crane arm and place the crane arms on the concrete pouring arm support.

2. Fold the concrete pouring arm according to the process procedure of opening the crane arm and place the crane arms on the concrete pouring arm support.

3. Pull back all the coerk bars and lock them carefully.

4. PTO must be moved from working state to transport state.

 

1.1.1  Daily inspection of basic parts

1  . Normal hydraulic oil should be crystalline, its color should be  light yellow,  it should not become emulsion  or blurred.

2  . Fill the lubrication tank and lubrication points with the lubricant and  fill the water tank with clean water.

3. The insulation of the concrete piston 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. 2mm).

5.   Check the  operating status of the lubrication system,  the  indicator arm of the progressive dispenser must  move back and  forth, and   there should be no lubricant leakage from the mixing shaft bed  with the   "S" valve. 

6.   Check that electrical parts are normal.

7.   Check that the movement, mixing and reverse mixing of the dispensing valve is normal.  

8.   Check  the  outside of the cooler.   If there is dirt,  clean the dirt  to prevent the oil from overheating. 

9.   Check to ensure  that the gauge of the vacuum  meter is within the  green area (it should not exceed 0.04 MPa).  Usually,  the  vacuum rating for fat absorption should be below 0.01MPa.  The vacuum rating for oil  retracting must be below 0.35MPa. 

10.  Check the  eroding of the concrete pipes by hitting them.   Check that  the insulation of the pipes is in  good condition.

11.  Check the hydraulic system    for leakage,  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 blurred. 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 allow hydraulic oil to overflow.

1.1.2  Maintenance after 50 hours of work (1500~2500m3)

1. Carry out maintenance  as stated above.

2.   Check the  connection of  all bolts to  ensure their tightness.

3.    Check the  piston arm connection in the water tank  to make sure it is in good condition.

4.   Check the gauge and filter of the vacuum meter.

1.1.3  Maintenance after 100 hours of work (3500~5000m3)

1. Carry out maintenance  as stated above.

  2.  Check  the wear and tear plate and  replace if necessary.  

3.   Check the eroding of the concrete piston and  replace it if necessary.

4.   Check that the hydraulic oil  is not degenerated and  does not become an emulsion.  Otherwise,  replace the oil completely and  thoroughly clean the oil tank.

1.1.4  Maintenance after 500 hours of work (15000~25000m3)

1. Carry out maintenance  as stated above.

2.  Check  the  wear of the S valve and bearing.

3. Check the  overcling of the mixing  device, mixing wings and mixing shaft,  etc.

4.  Check the hydraulic oil.   If necessary,  replace the oil.  The oil brand  must comply with the recommendation of our company.  It is  recommended  to  completely replace hydraulic oil after pumping  10000m3 concrete.

5.  Check  that the pressure inside the accumulator is sufficient.  The  filling pressure for the accumulator is 8~9MPa.

6.  Check  the  connection and sources of the building parts.

7.   Check the  oil level of the PTO.  If necessary, refill  or replace. 

1.1.5  Maintenance after 750 hours of operation

1. Carry out maintenance  as stated above.

2.  Check  the eroding of the concrete cylinder.   If the chrome coating is  severely   damaged,  replace the cylinder.

3.   Thoroughly repair the  machine  to ensure that all performance parameters are  normal.

1.2 Chassis maintenance

Please   refer to the chassis operating manual for details.  Before operating, please check  the following:

1.  Check  the  level and condition of the engine oil.

2.  Check  the  pressure of the engine oil.

3. Check the  level  of   cooling  water and  coolant,  check the water temperature.

4.  Check the wear and pressure of the tires.  

5.  Check the electrical system  (e.g.  lighting, indicator, parking light and so on).

6.  Check the  view range of the rearview mirror.

7.  Check  the pressure of the braking system.

8.  Check all directional lights.

9.   Check for oil  or air leakage (if there is a leak, please tighten the connections).

10.  Check the security devices (e.g.  border switch, safety pin and so on).

11. All moving parts (e.g.  77 irons, concrete   pouring lever  and so on)  to make sure they are connected to the specified places.

1.3 Maintenance of the pumping unit

Frequent pumping will cause rapid wear of moving parts of the pumping unit. However, regular and comprehensive maintenance and service will help increase productivity and long working life. Therefore, apply the daily control items as follows:

1. For each shift, fill the lubrication oil tank, each lubrication point with the lubricant and the water tank with water.

2. For each shift, check that the functions of the electrical parts are normal.

3. For each shift, check whether reverse pumping, release of the dispensing valve and rotation of the mixing device are normal.

4. After pumping 2000m3 concrete, check the gap between the wear plate and the cutting ring. If the clearance is more than 2mm and the eroding is co-distributed, adjust the gap  according to the procedure below:

a.  Clean the chamber and the "S" valve; b.  Remove holder bolt 4;

c.  To reduce the  opening between the cutting ring and the  wear plate, tighten bolt 5  and  pull the  "S" pipe towards the  back wall of the chamber.

d.  Tighten holder bolt 4.

5. Replace the cutting  ring.

a.  Turn off the motor,  drain the accumulator pressure and  remove the chamber grille.

b. Loosen bolt 5 by 20mm.   Be careful not to loosen too much;    otherwise,  when the S pipe moves  back, it  can come out of the bearing sign,  resulting in bed insulation damage and  shortened service life of the S pipe.

c. Remove  the flange from the outlet mouth,  push the   S" pipe towards the outlet mouth until the  opening between the cutting ring and  the  wear plate is about 20mm  and  remove the cutting ring.

d.   Check the tyre bow for damage.   If it is damaged, replace it.

e. Attach the new cutting rings  according to the  reverse steps.

6.  Replace the wear plate

a.  Repeat the procedure for changing the cutting ring.

b.  Remove all connection bolts of the wear plate  and  shake the plate slowly,  it will come out easily.

c. Install the new wear plate.

7.   Check the  wear status of the S pipe, S pipe bearing, mixing device, mixing blades and mixing bed at each shift.  If the wear is  too much, they need to 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 piston needs to  be replaced.   The method of replacement  is as follows:

a. Remove  the lid of  the water tank.

b. In low pressure pumping mode, lift the cover plate and remove the bedding.

c.  Close the  ball valve in the U  pipeline at the tail of the pumping cylinder.

d. After the piston     is pushed  completely out of the concrete cylinder  by  impacting the main cylinder,  stop the engine,  manually operate the switch of the main cylinder  and   zero   .   The disassembly and installation of the concrete piston depends on the  condition that the machine is  stopped and the pressure is discharged.

e. Remove the bolts that connect the concrete piston to the connection flange.

f)  Remove the concrete waste(wedge).

g. The procedure of installing the concrete piston is the opposite of the disassembly procedure.

1.4 Maintenance  of hydraulic system

 

1. Before starting the machine, drain the water accumulated at 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 allow hydraulic oil to flow out.

2. Check hydraulic oil for each shift. The level of hydraulic oil is above 3/4 of the oil level indicator. Oil quality should be primula and transparent. If the oil becomes contaminated or emulsion or sludged, 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 10000 m3 of concrete and then every 20000 m3 of concrete is pumped.

3. Check the outside of the radiator. If there is dirt, it should be cleaned immediately. Otherwise, the oil temperature will increase more.

REDUCER

Filling and breather plug

Filling and ventilation plug

Oil level plug

Oil level cork

Brake filling plug

Brake filling plug

Brake drain plug

Brake discharge plug

Service line port

Service line port

Drain plug

Discharge cork

Brake release port

Drain discharge port

Service line port

Service line port

Case drain port

Slot discharge port

1.8 Maintenance of the concrete pipe

To reduce risks and failures during pumping, pipes of the right diameter and thickness, the right type of couplings and safety lock should be used. Periodically check if the couplings are locked and if the pipes wear too much.

1. To ensure the co-dispersed eroding of the concrete pipe, all pipes must be rotated clockwise 120° and elbow pipes 180° after pumping approximately 3000m3 concrete, as shown on the side. Shown in the right-hander'

3. Check the eroding of concrete pipes each time before pumping. If their thickness is below the specified value, replace the worn pipes. To measure the thickness, listen to the sound by hitting the pipe with a hammer. A more scientific way to measure pipe thickness is to use thickness measuring equipment.

4. The minimum tubular meat thickness is linearly proportional to the pumping pressure as shown below:

X – Minimum pipe thickness

Y – Pumping pressure

A – Curve with pipe inner diameter of 100mm

B – Curve with pipe inner diameter of 125mm

C – Curve with pipe inner diameter of 150mm

According to the chart on the right, the pipe thickness 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; with the increase in engine speed, the water pressure will also increase. If high pressure cleaning is required, the motor must be at the specified maximum speed.

Clean water should be used. Impurities in the water lead to easy obstruction in the water pipe, and especially in the water tank connection. It also affects the working life of the water pump. To clean dirt, the filter, water tank, etc. must be cleaned periodically.

In cold weather, 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. We must be careful to check the following points:

1. Check that all electrical parts are functioning normally.

2. To prevent damage to parts, make sure that the cables, especially the cable connections and pressurized cables, are well ins isolated.

3. Check that the connectors are connected in reverse and oxidized.

4. Check that the electrical system is well connected to the soil. In principle, all parts should be replaced with the same parts as the originals. Fasteners for replacement must be products that are regularly checked in the same class and standard.

2.1 Pumping system failures

2.1.1 Unable to start automatic pumping

1. The connection of the pumping start button is loose. Reconnect the cable connector.

2. The auxiliary relay is burned. Maintain or replace it.

3. Solenoit is burned. Replace (the strength of general solenoites is about 22 Ω).

4. Pumping pressure is too much or pressure relay is defective. Maintain or replace it.

5. The proportional amplifier malfunctions without control pressure.

6. Chassis gear is wrong. According to the indicator added to the cabinet, select the right gear.

2.1.2 Pumping cylinders are not moving

1. The main cylinder's pulsed roading button is loosely connected. Reconnect the cable connector.

2. The auxiliary relay is burned. Maintain or replace it.

3. Solenoit reverse flow valve defective, generally solenoite burned. Change it. (the strength of general solenoites is about 22 Ω).

4. There is no output in the PLC. Enter the program (The flashing fault lamp indicates a fault in the CPU and the glowing lamp indicates program failure).

5. The other control cable is defective.

6. The displacement adjustment button of the main oil pump is set incorrectly.

7. The oil in the oil tank is not enough.

8. The filter is extremely clogged

The orifis in the 9th control circuit are clogged with corks.

2.1.3 The main cylinder cannot change direction

1. Solenoit reverse flow valve solenoidine burned or the valve core is clogged enough to explode.

2. Solenoidi of the electromagnetic valve is connected in the wrong position.

3. There is no pressure in the system.

4. The small valve controlled by hydromatics is clogged enough to burst.

5.The change of direction pressure is insufficient.

2.1.4 The main cylinder cannot move at normal speed and strength

1. The check valve on the main oil cylinder is damaged.

2. The displacement adjustment button of the main oil pump is set incorrectly.

3. Control pressure is not enough. The control pressure must be recalibrated: the pressure of the drain valve of the feed pump should be 3.5 MPa, and the pressure of the air escape valve should be 3.0 MPa (under the guidance of the ZOOMLION technical expert).

4. The filter is clogged or the hydraulic oil is insufficient.

5. The orifis in the control circuit are clogged to the cork.

6. Solenoit reverse flow valve is defective and the valve core cannot move to the specified position.

7. When pumping concrete to the higher 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 Concrete output not enough

1. Concrete pistons are worn out.

2. The gap between the wear plate and the cutting ring is too wide.

3. So bad that concrete suction will be very bad.

4. The S pipe is partially blocked.

2.1.6 Pumping unstoppable

1. The auxiliary relay contact is on fire.

2. The stop button is defective.

2.1.7 S valve cannot be rotated

1. The impact roading switch of the distribution valve is defective or the cables are loose.

2. The valve core of the electro-hydraulic reverse flow valve is blocked or solenoite is burned.

3. The S valve is clogged with objects.

4. Failure of the drain valve makes the rotational pressure insufficient.

5. Failure of the constant pressure pump makes the rotational pressure insufficient.

6. Weak concrete is pumped and the machine is stopped for a long time to increase rotational strength, so the S pipe cannot rotate.

7. The bed of the S pipe is worn to increase rotational resistance.

8. The auxiliary relay is burned.

2.1.8 The S pipe rotates slowly and weakly

1. The pressure of the accumulator is not sufficient or the pouch is damaged. Fill the nitrogen gas up to the setting value or replace the sac of the accumulator and fill the nitrogen gas up to the setting value.

2. The closing valve is not closed.

3. Rotating cylinders leak oil severely.

4. The valve core of the worn pressure relief valve will result in rotational pressure below 15MPa.

5. Solenoite is defective and the valve core of the electro-hydraulic reverse flow valve breaks so that the arc valve coil cannot reach the specified position. The eroding of the valve core will result in internal leakage.

2.1.9 The S pipe does not return to the correct position

1. The nylon bed of the rotary cylinder is worn, distorted or of different thickness.

2. The concrete is hardening.

3. The concrete granular is very large and prevents the concrete from meets the pumping requirement.

4. Insufficient hydraulic oil pressure.

2.1.10 Low pumping frequency

1. Hydraulic pump failure such as excessive leakage inside the hydraulic pump or obstruction of the fixed power adjustment device.

2. Damage to hydraulic parts, maximum pressure valve cannot be opened due to impurities or damage.

3. Excessive leakage from concrete piston, wear plate or cutting ring and similar wear in the pumping mechanism.

2.1.11 Concrete pump congestion

1. Leakage in the pumping pipeline system, e.g. between the cutting ring and the S valve, between the discharge mouth and the S valve, between the concrete piston, concrete pipe and quick-opening couplings of the pipes.

2. The pressure of the hydraulic system is not sufficient.

3. The pumpability of concrete is not very good.

4. There's air in the concrete.

Solutions:

a. Check and replace the cutting ring or wear plate; to press the seals, tighten the bolts and replace worn parts such as the concrete cylinder piston and so on.

b. Check the hydraulic pump and adjust the pressure of the drain valve.

c. If not suitable, change the concrete ratio.

d. Check the pipe seals.

2.1.12 Reverse pumping failure

Possible causes:

1. Mechanical failure due to obstruction of the core of the directional control valve or high oil temperature. Check the core by pushing the rubber cover at the end of the valve. If the core cannot move, unplug and clean it. Check the filter and cooling system.

2. Electrical installation failure such as solenoid burning (reverse pumping valve), relay burning or oxidation of the connectors.

Solution:

Turn off the machine. Check the core by pushing the rubber cover at the end of the valve to see if the core can move. If the core cannot move, unplug and clean it; if the nucleus is moving freely, remove the solenoidi; in case of no magnetism in the tension solenoit, check for damage to the solenoid or relay.

2.1.13 Mixing system failures

1. Due to its poor pumpability, the mixing strength is too great or the mixing wings are clogged. When the mixing wings are blocked, rotate the wings in the opposite direction.

2. The adjustment pressure of the drain valve is not sufficient. Use wood to block the wings and set the pressure to 14MPa.

3. The mixing engine is damaged. Check and replace if necessary.

4. The gear of the mixing system is damaged. Check and replace.

5. Mixing shaft or shaft casing damaged. Clean or repair the shaft or shaft sleeve.

2.2 Concrete pouring arm failures

2.2.1 Concrete cast lever cannot move (manual operation normal)

1. Crane handle/forge iron button is defective. Maintain or replace it.

2. F3/F4 fuse in the remote control box is burned. Change the fuse.

3. Solenoidi of multiple valves is defective. Replace solenoidi.

4. Other control cables are defective.

2.2.2 The crane arm cannot be opened or moved in a specific position

1. The pressure of the hydraulic system is not sufficient.

2. There are other exceptional loads on the crane arm.

3. The electromagnetic valve is blocked or burned.

Solutions:

a. If the pressure of the multi-valve safety valve is lower than the specified pressure value, check that the maximum pressure valve is well adjusted. If the fault cannot be fixed, please replace the hydraulic pump.

b. Remove any other exceptional loads on the crane arm.

c. 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 is working normally. If the valve part does not function normally, the valve core may be blocked or the electromagnetic valve may be burned. Replace any damaged parts.

2.2.3 Too much vibration when opening or extending the crane arm

The possible cause is the abnormal openness of the connection.

1. Between the pin and the fixed bearing in the fittings.

2. Between the fixed part of the pressure bed and the rotating part.

3. The bolts of the pressure bearing are loose.

Solutions:

a. Replace the damaged parts and ensure the lubrication frequency of the kinematic pair.

b. Replace the pressure bearing and fix it as specified.

c. Tighten or replace the bolts.

2.2.4 Concrete pouring arm automatically goes down

1. Air enters the crane arm cylinder. Since the compressibility of the air is too much, the load on the different part of the crane arm will be different. When the load increases, the concrete pouring arm will come down as the compression results in the crane arm being extended or retraced.

2. The cylinder of the crane arm has internal leakage.

3. There is an internal leak in the balancing valve.

Solutions:

a. Air is entering the crane arm cylinder. According to the above method, fold the crane arm repeatedly to drain the air.

b. If there is an internal leak in the cylinder of the crane arm, check that the gaskets of the concrete piston are damaged. If there is no damage, please check that the oil cylinder pipe is damaged and if the inner surface of the oil cylinder is swollen.

c. If there is an internal leak in the balancing valve, remove and clean the valve. If some parts of the balancing valve are damaged, maintain or replace them; if it is badly damaged, replace the entire balancing valve.

2.2.5 The oil cylinders of the crane arm are out of sync (the first crane arm has two oil cylinders)

1. The drive pressures of the two balancing valves are different. If the drive pressures are greater than the load, when the drive pressures are different, the low drive pressure balancing valve will be opened first and the relevant oil cylinder will move first. When the movements of the oil cylinders are not synchronized to a certain degree, the pressure will increase due to the mechanical limit, and the other oil cylinder will move.

2. The frictions of the two oil cylinders are different. Frictions of the oil cylinder are equal to the load. Too much friction difference will ensure that the movements of the oil cylinders are not in poor synchrony.

3. The sloped loads of the two oil cylinders will first cause the low-load oil cylinder to move.

4. Oil inlet and oil return pressure are different. The cores differ because they are stuck or clogged with sediment, which can lead to different oil inlet and oil return pressure and, as a result, cause the oil cylinders of the crane arm to be out of sync.

Solutions:

After the mechanical failure is fixed, the hydraulic system can be adjusted. First, adjust the pressure of the balancing valve in the oil return gap of the oil cylinder.

2.2.6 Concrete pouring arm stops slowly after turning

Part 1 valve is clogged with dirt.

2. The machine is not horizontally stable.

3. Brake disc eroding.

4. The braking arc is broken.

Solutions:

Clean or replace the clamp valve; adjust the height of the coking iron to be at the same level as the machine; brake disc; change the braking bow.

2.2.7 First crane arm is only lifted, cannot be lowered

1. The restraint device of the first crane arm is defective. Maintain or replace the restraint device.

2. The KA40 relay is defective. Change the relay.

2.2.10 Pins not sufficiently lubricated

1. The lubrication mouth 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 congestion, wear and openness.

2.2.11 The Avara iron cannot move

1. Crane handle/forge iron button is defective. Maintain or replace it.

2. The KA24 relay in the electrical control box is defective. Maintain or replace it.

3. The restraint device of the first crane arm is defective. Maintain or replace it.

4. Solenoidi of multiple valves is defective. Replace solenoidi.

3.5 Notes on the pumpability of concrete

Pumpable concrete is the material that can pass through the pipe. Cement should have lubrication properties provided by fine sand and water below 0.2mm.

3.5.1 Factors determining the pumpability of concrete

Four factors that determine the pumpability of concrete: fine sand, aggregate grade, water/cement ratio, homogeneity of concrete.

1. Fine aggregate content should be at least 350~400kg/m3 . (Fine sand and cement under 0.2mm in diameter). The following table shows the fine sand content as the maximum aggregate size. In terms of crushed aggregate, it is generally more than 10% for fine sand, as the aggregate is more difficult to pass through the pipe due to its large aggregate surface. Max. aggregate size (mm)

Fine sand quality for one cubic meter of concrete (Kg)

8

525

15

450

20

430

30

400

50

350

2. Concrete aggregate size

Good concrete is approximately pumpable concrete. Ideal for pumping, concrete has a good particle size consisting of aggregate species, the smallest of which can pass through gaps between large ones. The table below shows the rate of pumpable concrete and all kinds of aggregate sizes. Change in composition is generally possible in the pumpability range, but it can also exceed the pumpability range. Clearly, fine sand and aggregate play a dominant role in the composition. We recommend the following fine percentages of sand:

Recommended percentage of fine sand (%) Concrete

Percentage of sand

Max. aggregate size (mm)

With additives

Without additives

 

Conglomerate

Pebble

Conglomerate

Pebble

 

15

48

53

52

54

 

20

45

50

49

54

 

30

42

45

45

49

 

40

40

42

42

45

 

The following table shows the maximum allowed aggregate size. Minimum supply pipe diameter (mm)

Maximum aggregate size

 

Conglomerate

Pebble

 

125

40

30

 

150

50

40

 

The recommended aggregate class composition is as follows: Aggregate diameter range (mm)

Nominal siemethole size (mm)

50

40

30

25

20

15

10

5

2.5

40-5

100

100-90

70-35

30-10

5-0

30-5

100

100-95

75-40

35-10

10-0

5-0

25-5

100

100-90

90-60

50-20

10-0

5-0

20-5

100-90

100-90

80-55

50-20

10-0

5-0

The  adephase of the  pipe and pump increases for the following reasons:

a  .  Geometric shape of aggregate: sharp angle crushing aggregate,  if the concrete moves in the  pipe,  acts   as sand sandpaper in the pipe,  forming fine particles and  cement   tends  to  break down the oil film.   Friction between different aggregate parts and some crumbs increase the   likelihood  of  getting stuck and  causing blockage in the pipe.

b. Hardness:  While hardness affects  wear,  it has no effect on pumpability.    An experience-based rule  accepts that concrete  can be pumped if the maximum  aggregate size is less than 1/3  of the pipe diameter.  If the maximum size of the aggregate does not exceed 10%,  the maximum aggregate size can be increased slowly.

3. Density

It is an important factor in pumpability that determines the use and shape-shifting of fresh concrete. Density is measured by collapse (see figure). The density depends on:

a. amount of cement

b. aggregate composition

c. percentage of thin material

d. amount of water

Dry concrete is barely pumped. Suction difficulty can result in low production, intermittent pumping and pronounced wear. To improve pumpability, these problems should be reduced or eliminated. Additives that increase fluidity are recommended.

The absorption of fluid concrete (collapse more than 15cm) is not difficult, but it tends to decompome, causing clogging of the pump and pipe. Use plasticizing additives in concrete or increase the percentage of fine material, sand and cement of 0.2mm.

4. Homogeneity of concrete

A quality measuring system can provide excellent precision in the special component. Similarly, a quality mixing machine is important in obtaining homogeneous concrete that does not cause clogging.

5. Additives

Various types of additives with fluidification and plastic coating are available on the market. The pumpability of concrete can be increased when additives are used correctly. We recommend that additives be used according to the specifications given by the manufacturer.

2.1  Three support modes of lateral support

   Truck-mounted  concrete pumps  with X-type  cara bars have  three lateral support  modes:  left-sided support, front V  support and  right-sided  support.

 

Module Description No.

Name

Explanation

1

Operator's cab

Inside is the remote control receiver and the driving/operating mode switching 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 button box

The truck-mounted concrete pump has a landing foot button box on both sides.

5

Main valve

Controls the hydraulic valve.

6

Outline lamp

The landing legs have four outline lamps and an outline lamp at the end of the first crane arm.

7

Horn

Another horn is located on the rotating platform.

8

Electrical control cabinet

9

Chamber side button area

It has an emergency button and a horn button on it.

10

Lattice braided restraint device

       

1.2 Control cabinet panel

  The  user  controls   the truck-mounted concrete pump  using the  buttons on the  control cabinet panel, and  the message of the truck-mounted concrete pump  is again   indicator lamps.

1.2.1 Driving/operating mode changing panel

HL18

HL15

S2B

HL17

HL16

Arrow

Work

Driving/working

Drive

Crane arm in place

It is  located in front of the  main driver of the operator's cab (next  to the gear lever).

 The chassis has  two  modes:  "driving" and "working".  The driving/operating mode can be changed using the  "driving/working" button located in the middle of the  changing panel.   Indicator lamps next to the button are  used to  indicate the current status.

The   square-shaped "OK" button with indicator lamp is  used to power the pumping system.

The "First crane arm in place" indicator lamp  signals  if the first crane arm is in place.

1.2.2 Control cabinet panel

HMI: Human machine interface

TA1: "Emergency stop" button

SA1: Panel/remote button

Panel: Control panel

Remote: Remote control

SA2: "Panel/Remote" button

Pro: Positive pumping

Rev: Reverse pumping

RP1: "Streaming" button

SA3: "Timing engine speed" button

RPM+: Acceleration

RPM-: Slowing down

SA4: "Main cylinder point" button

Left: Left main cylinder point

Right: Right main cylinder point

 

SA5: "Tilted cylinder point" button

Left: Left-inclined cylinder point

Right: Right-inclined cylinder point

HL1: "Overpressure" indicator lamp

S5E: "Cleaning engine"

ON: Cleaning engine on

OFF: Cleaning engine off

S5E: "Vision lamp" button

ON: Vision lamp on

OFF: Vision lamp off

SA7: "Churning and backflip"

Pro: 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 Landing foot button box TA2

TA2

Emergency stop

TA3

Emergency stop

S3B

Foot operation

S3A

Crane arm/foot

S3C

Foot operation

The  landing foot button box in the middle of the truck-mounted concrete pump is  used to  control foot movement along with the foot holding pole.

The right landing foot button box has  a switch with  a switch. "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 power the  directional control valve to  prevent the  wrong movement of the foot.

The crane arm movement button is  located  behind the crane arm moving 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-support (optional)

1. Control box for X-support

a. Lamps show system-accepted support modes

HL20: Indicator lamp for full support

HL21: Indicator lamp for left support

HL22: Indicator lamp for right support

HL23: Indicator lamp for front support

b. SA12: Selection button for support model

c. SA13: Confirmation button for model

The SA12 button is used to select a different supporting model. SA13 is the model confirmation button. You cannot choose the support model until the crane arm is installed on the crane arm car. Process steps: put the four-position selection button in the required position, then press the SA13 "confirmation" button for a long time (about 3 seconds), finally, if you succeed in choosing a model, the indicator light for the support model will light up.

2. Control box for special support

a. Run backward selection button

b. Support model selection button

c. Lamps show system-accepted support modes

HL20: Indicator lamp for full support

HL21: Indicator lamp for left support

HL22: Indicator lamp for right support

HL23: Indicator lamp for front support

d. SA13: Model confirmation button

The "mode input" button is used to select a different supporting model. The "OK" button is used to confirm after mode entry.

1.2.5 Chamber side button area

SA11

HORN

TA4, TA5

EMERGENCY

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  self-holding button in the  form of a red mushroom.   Used to stop the entire process in an emergency.

"Horn" is  a green   self-restarting  button. It's  used to sound the alarm!

1.2.6 Remote transmitter panel

1

Motor escapes

7

Fast/Slow

2

Antenna

8

Emergency stop

3

Crane arm function arm (rotation+crane arm operation)

9

Flow

4

Horn

10

Speeding Up/Slowing Down

5

Pump on/off

11

Remote opening

6

Pumping/reverse pumping

12

Switch switch

1.3 Hardware logic

Signal flow

Power distribution electrical wire

Control signal flow

PTO circuit

PTO circuit

Battery

Battery

Power distribute

Power distribution

HMI

HMI

Panel

Control panel

Remote

Remote control

Boom/leg

Crane arm/foot

Leg-box

Landing foot button box

Controller

Controller

Leg-boom wire-net

Foot-crane arm cable network

Control-signal amplify

Control signal upgrade

Relays to valves

Valve relays

Valves

Valves

Leg-boom

Foot-crane arm

Execute-device

Run a device

Chassis

Chassis

Power, speed, pressure temperature and angle and so on

Power, speed, pressure temperature and angle, etc.

The signal of chassis and execute-device

Chassis and device start signal

Electrical equipment

The new human machine interface system of the truck-mounted concrete pump is a kind of external industry display display brought from Germany. The degree of defense is IP67. Compared to the old screen, the new screen is better in dust or waterproofing, in highlighted viewing, working 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 extend the working life, please be careful not to crash or scratch.

Transition of the new human machine interactive system: Menu – Submenu – Details. Each page is divided into three sections: the title bar, monitor or setting area, and function key note area. Fields

Fields

Function

Title bar

Generalizes the function of the existing page

Monitor or setting area

Monitoring or adjusting system parameters

Function key note field

F1-F6 function key note

Process area

All kinds of operations are done with these 6 buttons and a rotary button

Title bar

Title bar

 

Engine speed

Engine speed

 

Pump revolution

Pump rotation

 

Pump pressure

Pump pressure

 

Monitor or setting area

Monitor or setting area

 

Function key note area

Function key note field

 

Operation area

Process area

 

A rotary button with lamp

Rotary button with lamp

 

6 Buttons with lamp

6 buttons with lamps

 

HMI communication error

HMI communication error

 

MENU

MENU

 

Low pump stop

Stop pumping low

 

Main

Mother

 

Swing

Return

 

Lubricate

Oil

 

Potenciometer

Potentiometer

 

Oil temp

Oil temperature

 

Throttle

Butterfly

 

Fault description

Reason

Solution

Driving/operating mode does not change normally

1. Receiving no empty array signal.

2. Ka12 switch is defective.

3. The fuse wire in the cabin is burned.

1. Fold the crane arm and place it on the base.

2. Change KA12.

3. Replace the fuse wire.

The power control cabinet cannot power

1. The air pressure is too low to turn off the ignition of the position switch on the inter-transmission.

2. The switch in the operator's cab is not switched on or the power switch is not working.

3. The KA1 relay (in the control cabinet) does not work.

1. Start the motor and increase the pressure.

2. When the truck-mounted concrete pump is in a neutral position, turn the switch on the working side and press the power button until it works and the power indicator light lights up.

3. Check that wire 88 is working normally and replace the relay.

Pumping cannot be done with both control panel and remote control

1. Controller failure.

2. No pump inlet signal.

3. No pump output signal.

1. Replace the controller.

2. Check the input circuit.

3. Check the HIM alarm message and respond to the problem with the information provided by HIM.

Error warning or pumping stops

Enter the real-time warning area on the touch screen to detect the error and its solution. Enter the history field to check when the error occurred and the time of troubleshooting.

Under remote control, the crane arm can move, but automatic pumping cannot be performed

1. The remote control output may be too low or there may not be an output.

2. If displacement is normal, there may be an incorrect pumping signal or the relay may be damaged.

3. The comparison that adjusts the pressure valve may be distorted.

1. Measure line 29 for 0-10V.

2. Enter the control input area on the touch screen to check the relevant signals. Locate the faulty entry and change the program or relay.

3. Change the comparison that adjusts the pressure valve.

Fault description

Reason

Solution

 

Crane arm can be opened

can't stand it

1. Approach boundary switch pre-activated  .

2.  No  control signal for folding the first crane arm.

1.  Check the  approach limit switch for malfunction  or damage  leading to the wrong signal.

  2.   Check the  control circuit  and remote control output for closing the first crane arm.

 

 Unable to receive signal from remote control

1. HF initiative.

2. The receiver antenna is not in  good condition.

3. The  ambient temperature of the receiver is too high.

4. The absorbent antenna has not been replaced.

5. Communication structure is impaired.

1. Turn off and on the power  of the remote control to  change the frequency.

2.  Tighten the receiver antenna.

3.  Lower the ambient temperature.

4.  Replace the absorbent antenna.

5. Connect the wired remote control.

 

Unable  to pump or reverse pump under the control panel

1. The remote control and control panel switching button is defective.

2. Output regulator circuit is defective.

3. The  pump button on the panel  is broken.

1.   Check the remote control and control panel switch button.  

2.   Check the output button and strength in order.

3.  Check the pump button on  the panel.

 

Hydraulic pump pressure cannot be adjusted to the specified value

1. The flow limit is not correct.

2. The  pocinciometer on the panel or remote control is  incorrect.

3. The balance valve is defective.

4. The dirt wire in the control box does not come into   good contact.

1. Limit the flow again.

2. Change the posiometer.

3. Replace the defective balance valve.

4. Connect  the dirt wire next to the control box  to the wire  6  in the box.

 

Fault description

Reason

Solution

The electric siren makes a sound, but there's no other movement under the remote control.

1. The remote control is subject to HF interference.

Class 2 protection is working.

1. Press the electric siren button for 10 seconds or turn the transmitter off and on.

2. Reset all class 2 guards (such as crane arm movement) and reactivate the remote control.

The temperature is too high, the electric cooling fan does not work

1. Electrical appliance KA3 and KA4 defective.

2. The temperature sensor is broken or cannot receive the temperature signal emitted to the controller.

3. Fan defective.

4. The controller cannot access the engine speed.

1. Check and replace the electrical appliance KA3 and KA4 inside the cab.

2. Check that the temperature sensor is normal and is well placed.

3. Change the fan.

4. Check that the chassis speed signal is pulsed, if it is pulsed, the controller may be broken.