(updated 7/13/05)
DISCLAIMER: Official REED Service
Manuals deal with the various aspects of Operation, Preventative Maintenance,
System Care and Maintenance, Component Adjustment, Repair and Replacement.
However, like anything mechanical and due to application of pumping concrete,
the possibility exists that at one time or another conditions may arise that
will cause the machine to malfunction.
These conditions may not be as apparent as a
broken part, etc., but recognizing the symptoms will assist in determining the
cause and repair and reduce the downtime. This Troubleshooting Guide depicted
below is designed to assist you in recognizing the possible symptoms, a
probable cause and a suggested corrective action. The format used identifies a
major component or system and categorizes the potential failure for that
specific area with the symptom. The items listed are based on symptoms and
malfunctions derived from our experience with the REED Pump and from your calls
to our Service Department. It is also our intent to upgrade this website
periodically. Please email any questions or suggestions for improvement to mike.newcomb@reedmfg.com
3. OPERATING
AT VERY LOW R.P.M.
4. BOGS
DOWN WITH FULL THROTTLE, FULL VOLUME AND PUMP SWITCH ON
5. FAILS
TO DELIVER REQUIRED VOLUME AND PRESSURE
7. FAILS
TO DELIVER REQUIRED VOLUME AND PRESSURE
9.
CYLINDERS NOT FULLY EXTENDED SHORT STROKE
10.
MATERIAL CYLINDERS NOT FILLING WITH CONCRETE
12.
PISTON CUPS SQUEAL IN OPERATION
13.
S-TUBE DOES NOT SHIFT PROPERLY
14.
S-TUBE DOES NOT COMPLETELY SHIFT OVER
COVERING MATERIAL CYLINDERS
17. RADIO
CONTOLLER NOT FUNCTIONING
[PROBABLE CAUSES & CORRECTIVE ACTIONS]
· NO FUEL fill up fuel tank with a good grade of diesel fuel. No dirt or particles
· DIRTY FUEL FILTER replace filter.
· CLOGGED FUEL LINE (a) check and clean in-line filter (b) disconnect fuel line and air blow clean
· LEAK IN FUEL SUPPLY LINE (a) check all connections and hoses including the return lines (b) pressure test if necessary
· FUEL SOLENOID - (a) check for voltage (b) remove and see if trigger activates
·
DIRTY INJECTORS clean or replace injectors
[PROBABLE CAUSES & CORRECTIVE ACTIONS]
·
LOW
·
·
IGNITION KEY SWITCH IS FAULTY check power across contacts,
replace if damaged
·
STARTER FAULTY (a) check for power at starter (b) replace
3.
OPERATING AT VERY LOW R.P.M.
[PROBABLE CAUSES & CORRECTIVE ACTIONS]
·
THROTTLE NOT ADJUSTED PROPERLY reset using throttle control
·
THROTTLE
·
THROTTLE CONTROL CABLE (a) check that cable moves freely when control is
pulled (b) check cable for any kinks (c) check connection at throttle lever
·
RPM SPEED NOT PRESET PROPERLY (a) adjust to correct speed;
idle speed 800 RPM (b) maximum high speed no load (refer to specification
sheet)
4.
BOGS DOWN WITH FULL THROTTLE, FULL VOLUME AND PUMP SWITCH ON
[PROBABLE CAUSES & CORRECTIVE ACTIONS]
·
DIRTY AIR CLEANER clean or replace
·
DIRTY FUEL FILTER check or replace
·
MAIN RELIEF VALVE SET TOO HIGH readjust as necessary
·
ENGINE OVERLOADED OR SUBJECT TO EXTREMELY HIGH PRESSURE
CONDITIONS (a) back off (decrease) volume control on main pump
·
HORSEPOWER LIMITER ON
5.
FAILS TO DELIVER REQUIRED VOLUME AND PRESSURE
[PROBABLE CAUSES & CORRECTIVE ACTIONS]
·
ENGINE SPEED TOO LOW (a) adjust throttle control to full open (b)
readjust engine maximum no load speed to specified RPM
·
VOLUME CONTROL SET TOO LOW adjust control to full on (open)
·
PRESSURE GAUGE DEFECTIVE
- (a) install test gauge to verify (b) replace if defective
·
LOAD SENSE VALVE NOT WORKING PROPERLY (a) improper adjustment (b)
contamination, remove and clean (c) defective replace
·
PRESSURE SETTINGS INCORRECT check pressure and adjust
accordingly (refer to Adjustment section of your pumps manual for proper
pressures)
·
EXCESSIVE PUMP WEAR (a) loose or worn parts (b) flow test to determine
if pump output is satisfactory
[PROBABLE CAUSES & CORRECTIVE ACTIONS]
·
INSUFFICIENT OIL (a) check oil level in tank (b) suction strainer
clogged clean
·
AIR IN SYSTEM (a) check for vacuum leak in suction line,
connection (b) aeration bubbles of fluid in reservoir
·
EXCESSIVE SYSTEM PRESSURE (ABOVE PUMP RATING) check relief valve operation
and setting
·
EXCESSIVE PUMP WEAR loose or worn pump parts replace
·
ENGINE RPM HIGHER THAN THE PUMP RPM RATING adjust RPM as necessary
7.
FAILS TO DELIVER REQUIRED VOLUME AND PRESSURE
[PROBABLE CAUSES & CORRECTIVE ACTIONS]
·
INSUFFICIENT OIL suction strainer clogged clean
·
AIR IN SYSTEM (a) check for vacuum leak in suction line,
connection (b) aeration (bubbles of fluid in reservoir)
·
WORN OR DAMAGED PARTS replace pump
·
SYSTEM RELIEF SET TOO LOW OR BYPASSING (IF APPLICABLE) install pressure gauge in
circuit and dead head. Adjust relief
[PROBABLE CAUSES & CORRECTIVE ACTIONS]
·
PUMP SWITCH IS NOT ON turn to on position
·
ENGINE SPEED TOO LOW increase RPM to maximum
·
VOLUME CONTROL TOO LOW open to full on
·
ELECTRICAL (a) check fuses (b) check connection to pump
switch, continuity to terminals (c) check for broken wires, dirty terminals (d)
check electrical connection and voltage on main cycle valve (e) proximity
sensor gap too large check using key gauge (f) proximity sensor faulty (g)
check prox (proximity) switches on machine by passing a piece of steel under
each prox switch with engine running and pump switch off. S-tube (swing tube)
should swing each time either prox switch is signaled.
·
LOW VOLTAGE check battery, voltage to solenoid main cycle
valve
·
FAULTY BLACK BOX - replace
9.
CYLINDERS NOT FULLY EXTENDED SHORT
STROKE
[PROBABLE CAUSES & CORRECTIVE ACTIONS]
·
PROXIMITY SWITCHES ARE MISADJUSTED (a) check that switches are
positioned for full stroke reposition. Do not exceed 200 PSI spike on
pressure gauge when at full volume and full RPM. Pressure spike indicates
cylinders are bottoming out (b) check that both proximity switches are in
identical positions
·
TOO MUCH HYDRAULIC OIL ON ROD SIDE OF HYDRAULIC CYLINDERS (a) actuate and hold TEST
switch, turn pump switch ON and actuate either CYL A B switch until
cylinder being extended bottoms out (full extension). Resume normal operation
(b) inspect check valve on barrel side of cylinder clean or replace if faulty
(c) cylinder piston seals are leaking - replace
10.
MATERIAL CYLINDERS NOT FILLING WITH
CONCRETE
[PROBABLE CAUSES & CORRECTIVE ACTIONS]
·
BAD CONCRETE MIX check mix design
·
PUMP SPEED TOO FAST adjust to suit type of mix
·
FAULTY PISTON O-RINGS/PISTON CUPS replace
·
PUMP OPERATING IN REVERSE place pump switch in FORWARD
[PROBABLE CAUSES & CORRECTIVE ACTIONS]
·
PISTON CUPS IN MATERIAL CYLINDER ARE WORN OR LOOSE (a) check tightness (b) replace
with new cups
·
CONCRETE CYLINDERS EXCESSIVELY WORN (a) replace
12.
PISTON CUPS SQUEAL IN OPERATION
[PROBABLE CAUSES & CORRECTIVE ACTIONS]
·
IMPROPERLY INSTALLED CUPS piston plate mounting bolts over-tightened
causing piston cups to distort (*note* - during break-in of new cups, squealing
is normal)
13.
S-TUBE DOES NOT SHIFT PROPERLY
[PROBABLE CAUSES & CORRECTIVE ACTIONS]
·
CONCRETE BUILD-UP IN AREA OF WEAR RING OR WEAR PLATE IN
HOPPER clean out and remove build-up
·
S-TUBE ADJUSTED TOO TIGHT loosen large nut at bellcrank one-two flat turns
·
BINDING CAUSED BY MATERIAL BUILD-UP BEHIND THRUST RING AND
WEAR RING remove and clean up area replace thrust ring if damaged
·
INSUFFICIENT LUBRICATION check and lubricate shaft housing and outlet
housing
·
ACCUMULATOR PRE-CHARGE PRESSURE TOO LOW (a) pre-charge to 1000 PSI (b)
replace bladder if pressure does not hold
·
SHIFT CIRCUIT PRESSURE TOO LOW (a) check engine RPM (b) check
system pressure relief to be typically set at 2000 PSI (consult your manual)
(c) check gear pump replace if faulty
·
UNLOADER MANIFOLD check relief valve cartridge works properly free
of contamination (b) solenoid cartridge connections tight (c) solenoid coil
in good condition and shows 12 volts (d) solenoid spool shifts easily (e)
directional control valve in working condition (f) inspect check valve for
contamination
·
SHIFT CYLINDER SEALS BYPASSING OIL (a) check by disconnecting one
of the hoses from cylinder. as example: if rod is extended, disconnect rod side
hose. Pressure barrel side of cylinder. If oil comes out of rod side port or
hose, then seals are bypassing oil. (b) replace seals or cylinder
·
SWING VALVE NOT SHIFTING PROPERLY (a) check voltage to solenoid,
12 volts or more (b) check for contamination clean or replace
14.
S-TUBE DOES NOT COMPLETELY SHIFT
OVER COVERING MATERIAL CYLINDERS
[PROBABLE CAUSES & CORRECTIVE ACTIONS]
·
CHECK FOR OBSTACLE IN HOPPER SUCH AS CONCRETE, WEAR PLATE,
WEAR RING BINDING, ETC. clear obstacle
·
SHIFT CYLINDER OUT OF ADJUSTMENT adjust cylinder rod at clevis.
Loosen locknut and turn rod with wrench. Make sure wrench is placed on flats
provided on cylinder rod
·
BELLCRANK NOT INSTALLED PROPERLY disconnect attaching parts and
remove bellcrank from spline adjust S-tube and reposition bellcrank on
spline. Reinstall attaching parts, adjusting cylinder
[PROBABLE CAUSES & CORRECTIVE ACTIONS]
·
OIL COOLER NOT FUNCTIONING PROPERLY (a) restricted air flow to
cooler clean outside cooler fins (b) open engine compartment doors (if
applicable) to dispense hot air (c) on electric fan unit, check fuse and
electrical connection, fan rotating in wrong direction, motor burned out
·
FILTER ELEMENT CLOGGED replace
·
BREATHER
·
SUCTION STRAINERS CLOGGED drain tank, remove strainers, clean or replace
·
RELIEF VALVE SET TOO LOW (a) reset to proper specified pressure (b) replace
cartridge if faulty
·
OPERATING TOO LONG AT HIGH PRESSURE (a) use larger size delivery
line over long distances (b) mix may be bad causing higher pump pressure
·
HYDRAULIC OIL LEVEL TOO LOW fill to proper level
[PROBABLE CAUSES & CORRECTIVE ACTIONS]
·
CHECK CONNECTION OF AGITATOR TO DRIVE SHAFT broken or missing bolt
·
FROZEN IDLER PIN remove, clean, and lubricate
·
BROKEN
·
NO HYDRAULIC FLOW TO MOTOR (a) needle valve closed open
(b) control valve malfunctioning check valve operation
·
NO OR VERY LITTLE OIL FLOW TO CONTROL VALVE check flow replace tandem pump
·
HYDRAULIC MOTOR FAULTY - replace
17.
RADIO CONTOLLER NOT FUNCTIONING
[PROBABLE CAUSES & CORRECTIVE ACTIONS]
·
·
ANTENNA NOT FUNCTIONING check antenna and connections