In the high-intensity operation of concrete mixer trucks, sudden malfunctions such as feed blockages and mixer drum shutdowns are like "time bombs," potentially causing concrete to become unusable and delaying project schedules. Statistics show that project delays caused by mixer truck malfunctions can result in an average economic loss of tens of thousands of yuan each time. Today, based on 10 years of frontline maintenance experience, we will detail emergency solutions for six common and potentially fatal malfunctions.
Clogged feed inlet is a common malfunction of concrete mixer trucks. When this happens, concrete cannot enter the mixing drum normally, severely impacting work efficiency. The first step to solve this problem is to shut down the machine and disconnect the power; this is a crucial safety procedure. Then, use a specialized tool to clear the feed inlet while simultaneously adding water at low pressure to soften the material. It is extremely important to emphasize that it is strictly forbidden to put hands or body parts into the feed inlet; this is a safety red line that must never be crossed. According to investigations, accidents caused by improperly placing body parts into the feed inlet account for approximately 20% of all concrete mixer truck malfunctions.
Mixing drum stoppage can be categorized into two types: mechanical jamming and hydraulic failure. Mechanical jamming, such as foreign objects obstructing the blades, can be quickly identified by listening for unusual noises and observing the drum body for foreign objects. Hydraulic failures, such as insufficient oil pressure or pipeline leaks, require checking the oil pressure with a pressure gauge. When encountering a mixing drum stoppage, a discharge procedure of "manually prying the mixing drum + connecting an emergency power source" can be used to ensure that the concrete does not solidify due to prolonged stagnation. Related data shows that timely and correct discharge measures can reduce losses caused by concrete solidification by 80%.
Abnormal noises in hydraulic systems can be caused by factors such as insufficient oil supply, cavitation, or component wear. Different noise characteristics indicate different problems. We can first check the oil level, then check for air leaks in the pipeline. Following this quick troubleshooting procedure can effectively resolve abnormal noise problems in hydraulic systems. According to maintenance experience, approximately 70% of abnormal noise problems in hydraulic systems can be quickly resolved using this method.
The main causes of non-discharge during reverse rotation are insufficient discharge angle and material condensation/jamming. For insufficient discharge angle, it can be adjusted to 15°-18°; for material condensation/jamming, high-pressure water flushing of the cylinder wall is an effective solution. Practice has shown that correctly adjusting the discharge angle and flushing the cylinder wall can resolve over 90% of the non-discharge problem during reverse rotation.
To help everyone quickly locate and handle faults, we have prepared a "Fault Troubleshooting Checklist", which condenses the core judgment points and operation steps of various faults into a table that can be directly referenced.
| Fault type | Key judgment points | Operating steps |
|---|---|---|
| Inlet blockage | Concrete cannot be fed normally | Power outage and machine shutdown; use special tools to unclog the blockage; add water under low pressure to soften the material. |
| The mixing drum stops rotating | Mechanical jamming with abnormal noises or foreign objects; hydraulic malfunction with abnormal oil pressure. | Mechanical jamming: check for foreign objects; hydraulic faults: test oil pressure, manually pry open the mixing drum + connect emergency power source. |
With this form, drivers can locate and initially handle faults within 5 minutes without needing professional repair knowledge, minimizing economic losses and project delays caused by the faults.
If you would like to learn more about troubleshooting concrete mixer truck malfunctions, please click here .
.jpg?x-oss-process=image/resize,h_1000,m_lfit/format,webp)
