
Vehicle Maintenance Technical Information
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1. Repair and maintenance of concrete mixer truck
For the safe operation of the vehicle and prolong the service life of the vehicle, please repair and maintain it in a timely manner according to the user manual, and if necessary, contact the customer service department of CIMC Special Vehicles or the local maintenance service station in time.
1. Daily inspection and maintenance
1.1. For the daily inspection and maintenance of the chassis and engine, please refer to the "Instruction Manual" provided by the chassis manufacturer, and strictly follow its requirements. If necessary, go to the chassis manufacturer's service station for repair and maintenance.
1.2. Before starting the concrete mixer truck, a comprehensive inspection must be carried out to check whether the components are normal and reliable, whether the bolt connections are tight, and whether the operation is flexible.
1.3. Whether the hydraulic and pneumatic system pipelines are tightly sealed, whether there is wear, whether there is oil leakage, air leakage, etc. should be checked and eliminated in time.
1.4. After each use, the inside of the mixing drum and the feed hopper, chute, discharge chute, etc. should be cleaned. Before leaving get off work, the whole vehicle, the feeding hopper, the inside and outside of the mixing drum, and the discharge chute must be cleaned. If you find that there is a concrete block in the local area, it should be removed as soon as possible, but the machine parts should not be damaged.
1.5. When maintenance personnel enter the mixing drum for maintenance, the engine must be turned off, and the mixing drum must be locked from rotating to prevent injury to people.
1.6. Contents of daily inspection and maintenance
Serial |
Check content |
Check cycle |
Actions |
1 |
Chassis and Engine |
Daily |
Check and maintain according to the instructions |
2 |
Is there any loose bolts in each connection part |
Daily |
Tighten as required |
3 |
Whether there is concrete and dirt in each part |
Daily |
Clean and repair in time |
4 |
Whether the oil pipes and joints of the hydraulic system leak oil |
Daily |
Tighten fittings or replace seals |
5 |
Reducer, oil pump and motor for oil leakage |
Daily |
Replace the seal |
6 |
Is the hydraulic system noise normal? |
Daily |
If the noise is loud, replace the filter and try again |
7 |
Whether the water pipe is leaking |
Daily |
Tighten the hoop or replace the hose |
2. Regular inspection and maintenance
2.1. For the regular inspection and maintenance of the chassis and engine, please refer to the "Instruction Manual" provided by the chassis manufacturer, and strictly follow its requirements. If necessary, go to the chassis manufacturer's service station for repair and maintenance. New cars must undergo the first mandatory maintenance.
2.2. Regularly check the hydraulic oil tank and reducer oil level.
2.3. Regularly check the wear of the stirring blades and repair them in time.
2.4. Regularly add lubricating oil and grease to all parts.
2.5. Important note: After the first 50 hours of work, use a torque wrench to fasten the connecting bolts everywhere.
2.6. Regularly check the filter element and vacuum gauge of the hydraulic oil tank to prevent the filter element from causing too much resistance to oil return due to poor oil quality.
2.1. Contents of regular inspection and maintenance
Serial |
Check content |
Check Cycle |
Actions |
1 |
Chassis and Engine |
As requested |
Check and maintain according to the instructions |
2 |
Whether there is excessive wear and damage on the raceway surface |
Timely |
Appropriately apply a layer of grease |
3 |
With or without concrete blocks in the mixing drum |
Monthly |
Scrape off |
4 |
Is the discharge chute flexible? |
Timely |
Add grease in time |
5 |
First hydraulic oil change |
500 hours |
Oil change and filter |
6 |
Hydraulic system oil change |
2000 hours or one year |
Oil change and filter |
7 |
First gear oil change |
150 hours |
Oil change |
8 |
Reducer oil change |
2000 hours or one year |
Oil change |
9 |
Drive shaft lubrication |
Monthly |
Add grease |
10 |
Roller lubrication |
Timely |
Add grease |
11 |
Insufficient reducer oil level |
Monthly |
Add oil |
12 |
Insufficient hydraulic oil level |
Monthly |
Add oil |
13 |
The vacuum gauge indicates whether it is in the red area |
Monthly |
Replace filter |
14 |
Inflexible operating system |
Monthly |
Add grease |
15 |
Whether the hydraulic hose is aging |
2~3 years |
Replace the hose |
Note: 1. Please use environmentally friendly methods to dispose of discarded hydraulic oil, lubricating oil and grease.
2. The oil spilled around must be wiped off. Leaving it around could contaminate the vehicle and even cause a fire.
1. Maintenance when not in use for a long time
3.1. If the mixer truck is not used for a long time, it should be stored in a ventilated and moisture-proof garage, and should not be stored in the open air. At the same time, the coolant and fuel should be drained, the power supply should be cut off, and the doors and windows should be locked. If it is stored in the open air for a short period of time, it should be covered with canvas, especially at the mouth of the feeding hopper and mixing drum. Otherwise, rainwater will enter the mixing drum and cause a large amount of water accumulation, which will cause indentation between the roller and the raceway of the mixing drum, and make the Corrosion occurs inside the mixer drum.
3.2. Important measures to be launched regularly:
Method |
Standard |
Start the engine |
idling |
Drum rotation |
1 r/min |
time interval |
1 month |
Runtime |
30 min |
3.3. If it is not used for a long time, the lubricating grease of the moving parts will dry up, and the rotating parts of the hydraulic drive part will also lose oil, which will cause accidental damage. Check the entire lubrication system before each start, and add oil or replace if necessary.
3.4. If it is not used for a long time, it is necessary to carry out a maintenance of the whole vehicle, and to protect the surface of the feeding hopper, discharge chute and mixing drum to prevent corrosion.
3.5. For the deactivation and maintenance of the chassis, please refer to the requirements of the "Instruction Manual" of the chassis.
2. Rules for the use of oil products
4.1. Requirements for oil products:
Anti-wear hydraulic oil: Cleanliness: ISO 18/13 Viscosity: ISO VG 46 & ISO VG 68
Gear Oil: Grade API GL 5 Grade: SAE 80W/90 or SAE 85W/140
Grease: No. 2 lithium base grease
project |
Capacity (l) |
grade |
Viscosity vs Ambient Temperature |
|
-10℃/+30℃ |
+20℃/+45℃ |
|||
Hydraulic oil |
27 |
ISO 18/13 |
ISO VG 46 |
ISO VG 68 |
reducer oil |
11.5 |
API GL 5 |
SAE 80W-90 |
SAE 85W-140 |
Oil for ZF PLM9 |
21.5 |
-API CD/CE/CF/SF/SG |
SAE 10W-40 |
SAE 15W-40 |
Note: The hydraulic oil filled in CIMC mixer truck is AW68, the gear oil of reducer is 85W-90, and the oil of ZF integral reducer is SAE 15W-40.
4.1. Different brands of hydraulic oil cannot be mixed. When replacing the hydraulic oil, the original hydraulic oil in the tank must be completely drained before adding new hydraulic oil.
4.2. Gear oils of different brands cannot be mixed. When replacing gear oil, the original gear oil in the reducer must be completely drained before adding new gear oil.
4.3. Hydraulic oil change cycle: 500 working hours for the first time, and every 2000 working hours or one year thereafter.
4.4. Reducer oil change cycle: 150 working hours for the first time, and every 2000 working hours or one year thereafter.
4.5. When the user replaces the oil of another brand, the oil of the same grade must be used.
4.6. When changing the oil, it must be ensured that no impurities enter the system.
2. Common faults and maintenance
Common faults |
Cause of failure |
Exclusion method |
||
Empty car can be turned, but not after loading |
Dirty hydraulic oil |
Clean the hydraulic oil tank and replace the hydraulic oil |
||
Insufficient oil |
Additional |
|||
Internal wear of oil pump motor |
Overhaul after disassembly, replace worn parts |
|||
Only unilateral rotation |
The servo mechanism is not working well |
Replace or Repair |
||
One-sided failure of high pressure relief valve |
Replace or Repair |
|||
Joystick is in stop position and still turning |
The joystick center position adjustment is not good |
Rescale |
||
Servo regulator not tuned |
Rescale |
|||
The leakage of the pump is too large |
Repair or Replace |
|||
Mixing drum pulsating rotation |
The servo regulator does not work well |
Repair or Replace |
||
Joystick loose |
Rescale |
|||
The mixing drum cannot be rotated |
Abnormal control mechanism |
Dislodged or damaged |
Reinstall or adjust as normal |
|
The servo mechanism cannot be moved by hand |
Servo failure |
Replace servo valve or disassemble for repair |
||
The boost pressure is normal |
High pressure relief valve failure |
Replace high pressure relief valve or disassemble for repair |
||
Motor damaged |
Replace motor |
|||
Reducer damage |
Replace the reducer or disassemble it for repair |
|||
Boost pressure lower than standard value |
Failure of booster pump |
Replace hydraulic pump |
||
Failure of boost relief valve |
Replace boost relief valve or disassemble for repair |
|||
Damage of hydraulic pump |
Replace hydraulic pump |
|||
Insufficient hydraulic pump pressure |
Dirty or insufficient hydraulic oil |
Clean hydraulic tank , replace or replenish hydraulic oil |
||
Internal leakage in manual servo valve |
Replace the seal |
|||
The orifice is blocked |
Cleaning |
|||
Internal leakage of hydraulic motor |
Replace the seal or motor |
|||
Abnormal hydraulic pipeline |
Hydraulic line damage |
Replace hydraulic lines |
||
Slow speed of mixing drum |
Dirty hydraulic oil, insufficient oil absorption |
Clean or replace hydraulic tank suction filter |
||
Oil leakage in hydraulic system |
Repair or replace gasket or apply sealant |
|||
Control mechanism stuck |
Overhaul |
|||
The mixing drum rotates without material |
Severe water loss of concrete |
Add appropriate amount of water, and then discharge after stirring |
||
Severe blade wear |
Repair or Replace |
|||
Noise |
Pump suction |
Oil suction filter clogged |
Change filter |
|
Oil Foam |
Insufficient oil |
Additional |
||
Air filter clogged |
Clean or replace |
|||
The amount of oil is too high |
Continuous time too long |
Shutdown cooling |
||
The hydraulic motor is noisy |
There are debris such as iron filings in the motor |
Cleaning or overhauling |
||
Noise in hydraulic pump |
There are debris such as iron filings in the hydraulic pump |
Cleaning or overhauling |
||
Noise in the reducer |
Too much debris in the reducer |
Change gear oil, clean or overhaul |
||
Heavily worn |
Overhaul |
|||
Inflexible Manipulator |
The joystick is seriously deformed |
Correction, adjust screw |
||
Rust or concrete stuck |
Remove rust and concrete, add butter |
|||
The mixing tank jumps up and down |
Uneven wear of raceways and idlers |
Repair or Replace |
||
Worn or damaged roller bearings |
Replace bearing |
|||
The idler nut is loose |
Relock |
|||
Reducer seepage (leak) oil |
Damaged seal |
Replace the seal |
||
Oil seepage at the junction of motor and reducer |
Damaged seal |
Replace the seal |
||
Joystick Heavy |
Rust control mechanism span> |
Derusting, Grease, Replace |
||
Servo valve control force is heavy |
Replace |
|||
Hopper clogged |
The feeding is not evenly stirred, and the feeding is too fast |
Use tools to pound through the blockage to control the discharge speed |
||
Hopper funnel |
The rubber ring of the hopper is worn out |
Replace with a suitable size rubber sheet |
||
Concrete discharge is not smooth |
Adhesion in the mixing drum |
Remove Adhered Concrete |
||
Concrete water loss |
Add appropriate amount of water, and then discharge after stirring |
|||
Segregation of concrete |
The rated speed of the mixer is low |
Appropriately increase the speed |
||
Insufficient agitation before discharge |
Agitate before discharge |
|||
Severe blade wear |
Replace the blade |
3. Common faults and countermeasures of each component
Part |
Common malfunctions |
Failure analysis |
Troubleshooting |
Pump and horse up to |
The shaft of the motor does not rotate (no power transmission) |
Is the input shaft of the oil pump rotating? Make sure the drive shaft is connected |
Connect the drive shaft |
No oil in the tank |
Fill up the hydraulic oil to the upper limit of the oil level |
||
Vacuum gauge indicates abnormal |
It is easy to cause vacuum at low temperature, so it is necessary to carry out when driving a cold car.10~20minutes of warm-up operation. |
||
Replace the filter element |
|||
The inlet of the charge pump is oil-free. |
Loosen the connection at the charge pump inlet to confirm that there is no oil passing through. |
||
Oil charge pressure is abnormal |
Replacement product or part |
||
The above confirmation results are normal. If the motor still does not rotate, there is a problem inside the oil pump. |
Replacement product or part |
||
The motor does not reach the specified torque (with power transmission) |
System has pressure but no RPM |
Replacement product or part |
|
The speed is there but the system pressure is not |
Insufficient motor torque to replace products or parts |
||
High pressure in the low pressure line |
Replacement product or part |
||
The motor only rotates in one direction |
The external connection structure of the control valve is not suitable |
Adjustment |
|
The neutral position of the control valve is not suitable |
Replacement product or part |
||
The high pressure relief valve has a bad direction |
Replace components |
||
Shuttle spool stuck in one direction |
Replacing the Manifold Assembly |
||
One-way valve one-way failure |
replace |
||
Defective servo piston |
replacement product |
||
The neutral position of the lever has been changed |
1There is a difference between the neutral position of the external controller and the joystick. |
Adjustment |
|
The lever can be turned lightly without resistance |
Replacing components or performing supplemental installations |
||
Lever does not return to neutral position |
Replace components |
||
The control relationship of the servo cylinder is normal but cannot enter the neutral position |
Replace pump or components |
||
Oil temperature is too high |
Insufficient fuel in the tank |
Add the same brand of hydraulic oil to the neutral position |
|
There is dirt accumulation in the cooler and the outside is blocked |
clean up |
||
Filter is clogged |
Replace the filter element |
||
Suction pipe is seriously deformed |
Correct or replace the oil suction pipe |
||
The high pressure relief valve is always open |
Replace components |
||
Pump and motor noise |
Insufficient fuel in the tank |
Fill up the hydraulic oil to the upper limit of the oil level |
|
The suction pipe joint is loose |
Tighten the joint |
||
Welding of oil pump bracket |
Repair welding |
||
Motor connecting bolts loose |
tighten |
||
Internal damage of oil pump and motor |
Replace the oil pump motor or supplement |
||
Relief valve interference of oil pump and motor |
Replace or adjust relief valve |
||
Low-speed rotation (below 600rpm) is very noisy |
Product replacement |
||
Insufficient acceleration and deceleration |
Insufficient hydraulic oil or changes in oil quality |
Replace or top up hydraulic oil to the upper limit of the oil level |
|
Insufficient charge pressure |
Replacement of products or parts |
||
Bad control valve |
Replacement of products or parts |
||
Low engine input speed |
Negotiate with engine manufacturers |
||
Oil leaking from oil seal |
There is an abnormally high pressure in the oil pump motor housing |
fix |
|
Damage to mechanical seal and oil seal |
Replace the seal assembly |
||
Metal dust load in oil |
Abnormal noise of oil pump and motor |
Replace oil pump and motor components |
|
Metal powder in the fuel tank and filter |
Replace oil pump and motor components |
||
add dirty oil |
Replace oil pump and motor components |
||
Reducer |
Box overheating |
Insufficient lubricating oil |
Top up the gear oil to the upper limit of the oil level |
Oil smells bad |
Deterioration of lubricating oil |
Change gear oil |
|
Internal noise of reducer |
Insufficient lubricating oil |
replace |
|
Internal damage |
Replacing the reducer or component |
||
oil spill |
Oil seal damage |
replace |
|
Loose plugs and bolts |
tighten |
||
Fuel tank radiator |
oil spill |
loose joint |
tighten |
box crack |
Repair welding or replacement |
||
Add too much hydraulic oil |
Adjust the hydraulic oil to the upper limit of the oil level |
||
Fan does not turn |
The oil temperature does not exceed the lower limit of the temperature control switch. |
|
|
The temperature control switch fails |
replace |
||
Damaged fan motor |
replace or repair |
||
The power cord is disconnected |
turn on |
||
fan reverse |
Power cord reversed |
correct |
|
High-pressure pipeline |
Oil leakage from joint |
loose joint |
tighten |
O Ring damage |
replace |
||
The joint is not fastened firmly |
Replace the oil pipe |
||
oil pipe burst |
System pressure too high |
Adjust system pressure, replace parts or components |
|
Oil pipe is damaged |
Replace the oil pipe |
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