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Turbosol Beton Master, Operation And Maintenance Manual

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Turbosol Beton Master Operation And Maintenance Manual Download Page 9

 

 

GENERAL INFORMATION 

2 

 

561270 - IS19/07 - EN

 

9/58 

 

2    -    GENERAL INFORMATION 

2.1 

IMPORTANCE OF MANUAL 

The present Operation and Maintenance Manual has been prepared following the guidelines contained in the relevant 
European  Directives.  Its  purpose  is  to  provide  a  simple  and  full  understanding  of  the  subjects  dealt  with  to  the 
persons  authorized  to  operate  and  perform  maintenance  on  the  machine  described.  The  manufacturer  has  prepared 
this manual with the greatest care. However, should any operators find any part of the manual difficult to understand, 
they  should  contact  the  manufacturer  immediately  and  request  explanations  and/or  further  information  in  order  to 
avoid misunderstandings that might compromise the user's safety. Before using the machine, operators are required 
to read and understand this manual in every part and strictly follow its instructions, in order to ensure their own and 
others’ safety, to make the machine work at its full potential and to ensure a long-lasting and efficient service life to all 
the  machine  parts.  This  manual  should  be  safely  stored  and  kept  close  to  the  machine  at  all  times  for  immediate 
consultation by operators. 
 
Only specifically trained and authorized personnel may be allowed to operate and perform maintenance on the machine. 
Operators must follow all the instructions regarding the prevention of accidents and the regulations on workplace safety in force 
in the country of use. 
The  Manufacturer  shall  not  be  responsible  for  any  damages  resulting  from  changes  made  to  the  machine  and/or  from 
unauthorized tampering. 
Users  are  advised  to  take  note  of  the  machine’s  serial  number;  it  must  be  presented  along  with  every  request  for  technical 
assistance or for spare parts, and will facilitate processing such requests. 
This  manual  reflects  the  latest  information  available  at  the  time  of  marketing  the  machine  and  should  not  be  considered 
inadequate only because newly acquired information may require its updating. Reprinting or reproducing this manual, in whole 
or in part, is not allowed unless authorized by ourselves in writing. 
 
THE  MANUFACTURER  DECLINES  ANY  RESPONSIBILITY  FOR  DAMAGES  TO  PERSONS,  ANIMALS  OR  PROPERTY 
CAUSED FAILURE TO OBSERVE THE INSTRUCTIONS AND WARNINGS CONTAINED HEREIN. 
 

2.2 

ABBREVIATIONS 

ca. 

around 

min 

minutes 

cap.  chapter 

N. 

number 

DPI 

device of individual protection 

pag.  page 

DX 

right 

par. 

paragraph 

h 

times 

pos.  position 

EN 

European Norm 

RIF.  reference 

Es. 

example 

s 

second 

FIG.  figure 

SX 

left 

max.  maximum 

TAB.  table 

min.  minimum 

v. 

see 

 

TAB. 01 
 

2.3 

INFORMATION ON CONSULTING THE MANUAL 

Boldface: 
Highlights important parts in the text. 
 

2.4 

MEANING OF SYMBOLS 

Information and warnings that are particularly important are indicated in this manual by the following symbols: 
 

 

 

 CAUTION: This symbol indicates safety regulations regarding the operator. 

 

 

 NOTE: This symbol indicates additional information regarding the operation under way. 

 

 

 DANGER: This symbol indicates an electric shock hazard. 

 

 

 IMPORTANT: This symbol indicates further useful information. 

 

Summary of Contents for Beton Master

Page 1: ...Serial number Year OPERATION AND MAINTENANCE MANUAL BETON MASTER IS19 07 561270 EN ORIGINAL ...

Page 2: ......

Page 3: ... 6 NAME OF MACHINE PARTS 13 4 TRANSPORTATION AND HANDLING 15 4 1 TRANSPORTING THE MACHINE AS A VEHICLE TRAILER 15 4 2 LIFTING 17 5 INSTALLATION 19 5 1 POSITIONING THE MACHINE 19 5 2 PIPING 19 5 2 1 Piping layout 20 HORIZONTAL PUMPING 20 VERTICAL PUMPING 20 DOWNWARD PUMPING 20 5 3 CONCRETE PIPING FITTINGS 21 5 4 CONNECTIONS 21 5 4 1 Concrete grid and vibrator 21 5 4 2 Remote control 22 5 4 3 Connec...

Page 4: ...PING PISTONS 40 8 3 ADJUSTING THE S VALVE 43 8 4 REPLACING THE WEAR DISC THE WEAR PLATE AND THE S VALVE 44 8 5 CHANGING THE FIRST OIL FILTER 46 8 6 CHANGING THE SECOND OIL FILTER 46 8 7 TO BE CARRIED BY QUALIFIED PERSONNEL 48 8 7 1 Maintenance after 50 hours 48 8 7 2 Maintenance to be performed every month or every 125 hours 48 8 7 3 Maintenance to be performed every 250 hours 48 8 7 4 Maintenance...

Page 5: ...11 2 WARRANTY 57 ...

Page 6: ......

Page 7: ...CE DECLARATION 1 561270 IS19 07 EN 7 58 1 CE DECLARATION 1 1 CE DECLARATION OF CONFORMITY An original copy of the CE Declaration of Conformity is supplied separately from the manual ...

Page 8: ...1 CE DECLARATION 8 58 561270 IS19 07 EN ...

Page 9: ...orce in the country of use The Manufacturer shall not be responsible for any damages resulting from changes made to the machine and or from unauthorized tampering Users are advised to take note of the machine s serial number it must be presented along with every request for technical assistance or for spare parts and will facilitate processing such requests This manual reflects the latest informat...

Page 10: ...ecial attention to quality contributes to guarantee that Turbosol machines are built to last are highly reliable and work with low operating costs MAINTENANCE AND CARE Proper maintenance and care are essential for the machine to work as designed It is extremely important that users observe the recommended maintenance intervals and carry out any maintenance required both to keep the machine in perf...

Page 11: ...ne s serial number T With road approved tow Position of CE nameplate As the figure shows the manufacturer plate FIG 02 REF 1 is fixed to the base of the machine Machine s serail number and road tow plate position The machine s serial number FIG 02 REF 2 is punched on the machine s base and on the manufacturer s plate The vehicle s identification number FIG 03 REF 1 is punched and an approval ident...

Page 12: ...size that can be pumped mm 25 30 Maximum useful distance m 150 200 Maximum useful height m 100 120 Flow collector inches 4 5 Hopper capacity litres 200 Diesel tank capacity litres 27 Oil tank capacity hydraulic plant litres 75 Hydraulic oil recommended ELF OLNA DS 46 Maximum height above s l of the place of installation without sensitive loss of power m 1000 Acceptable environmental temperature C ...

Page 13: ... 17 FIG 05 LEGEND FIG 04 REF 1 Casing FIG 05 REF 18 Hydraulic pumping cylinder FIG 04 REF 2 Upper hopper FIG 05 REF 19 Solenoid valves FIG 04 REF 3 Grid FIG 05 REF 20 Switching jack control sensor FIG 04 REF 4 Vibrator FIG 05 REF 21 Switching jack control sensor FIG 04 REF 5 Control column FIG 05 REF 22 Pumping control sensor FIG 04 REF 6 Control panel FIG 05 REF 23 Pumping control sensor FIG 04 R...

Page 14: ...3 TECHNICAL DESCRIPTION 14 58 561270 IS19 07 EN ...

Page 15: ...ition FIG 06 1 4 2 5 1 3 FIG 06 FIG 07 Check the efficiency of the drawbar the hook on the vehicle and the coupling mechanism Remove the safety pin FIG 07 REF 1 Unscrew the handle FIG 07 REF 2 completely Pull the stickers off the side discs with a strong upward pull to the left and to the right Use only the handle FIG 07 REF 3 to adjust the height The middle section can be adjusted upward by 50 an...

Page 16: ...IG 08 FIG 09 Release the parking brake and remove the chocks FIG 06 REF 1 Unhitching the machine from the towing vehicle Lower and block the towing wheel Pull the parking brake Unhitch the machine from the towing vehicle When unhitching on a slope block the machine using the parking brake and the chocks so that it won t move after unhitching BETON MASTER can also be carried on motor vehicles loadi...

Page 17: ... replace it 1 2 3 FIG 10 Lifting should be carried out in strict observance of all the relevant safety rules and the equipment used must be in good order and conforming to regulations The lifting apparatus must be operated by specifically trained and authorized personnel Use only hooks and ropes certified for lifting 2000 kg Make sure the area is clear of any bystanders before lifting the machine ...

Page 18: ...4 TRANSPORTATION AND HANDLING 18 58 561270 IS19 07 EN ...

Page 19: ...the side support legs and the main wheels in a stable manner 5 2 PIPING Lay out the piping using the shortest lengths possible to reduce handling time and limit wear and make sure the pipes are in good conditions Use rubber hoses only for the last section of the piping and for lengths no longer than 4 metres using rubber hoses elsewhere along the piping may compromise pumpability causing water to ...

Page 20: ...FIG 14 REF 1 DOWNWARD PUMPING Downward sections should be fastened and supported by collars FIG 15 REF 1 Measures should be taken to prevent the concrete from dropping too fast along downward sections for example by installing a curve and a reverse curve as in FIG 15 or by laying out a sloping section With this kind of layout lubricating the pipes with slurry should be carried out as follows intro...

Page 21: ...tor Connect the electric vibrator s plug FIG 19 REF 1 to the machine socket FIG 19 REF 2 located on the hydraulic tank Close the door after connection When pumping shotcrete you will need to use the shotcrete nozzle and the 15 mm slotted grid with the electric vibrator Unscrew the shock absorber s anchoring bolts FIG 18 REF 1 Remove the concrete grid replace it with the shotcrete grid and fasten i...

Page 22: ...osing kit is optional 1 2 FIG 20 Accelerating additives are harmful Protect any exposed surfaces adequately Handle additives with care and follow the manufacturer s instructions 5 4 2 Remote control The machine is supplied with a cable remote control Plug the cable FIG 21 REF 1 into the connector socket FIG 21 REF 2 located on the machine s casing Turn the selector FIG 21 REF 3 to 1 to start the m...

Page 23: ... 22 REF 2 Press the button FIG 22 REF 3 to switch the remote control on and off Press the button FIG 22 REF 4 to start pumping Press the button again to stop pumping To reverse pumping i e sucking the mix from the pipe on the hopper make sure the button FIG 22 REF 4 is turned to ON and press the button FIG 22 REF 5 for the time required 2 4 5 3 1 FIG 22 ...

Page 24: ...5 INSTALLATION 24 58 561270 IS19 07 EN ...

Page 25: ...ULIC CIRCUIT A maximum pressure valve to limit the auxiliary circuit s maximum pressure is found on the proportional solenoid valve PRESSURE MANOMETER OF MAIN HYDRAULIC CIRCUIT The manometer is located in the control area and is used to indicate the pumping and S valve movement working pressure to the operator PRESSURE MANOMETER OF AUXILIARY HYDRAULIC CIRCUIT The manometer is located in the contro...

Page 26: ... force in the country of use Employers directors and operators must be acquainted with and enforce these regulations USING THE PROTECTION DEVICES INDICATED BY THE MANUFACTURER IS MANDATORY TAB 08 MANDATORY SIGNS DESCRIPTION IT IS MANDATORY TO PROTECT THE EYES IT IS MANDATORY TO PROTECT HEARING IT IS MANDATORY TO PROTECT THE HANDS IT IS MANDATORY TO PROTECT THE FEET TAB 08 6 4 RESIDUAL RISKS Follow...

Page 27: ... the vertical piping fasteners are securely fastened Do not open pipe fittings when the pipe is under pressure HOT PARTS Do not open the casing while the machine is running Do not touch the diesel engine silencer MOVING PARTS Do not open the casing while the machine is running Do not lift the hopper protection grid while the machine is running Do not introduce foreign matter through the grid ...

Page 28: ...6 SAFETY 28 58 561270 IS19 07 EN ...

Page 29: ...he conveying pipe alternately The pumping is oil hydraulically operated with a variable displacement hydraulic pump This type of pump makes it possible to change the concrete s flow rate through a manually operated oil hydraulic control Pumping is monitored by sensors that send their readings to the electronic control panel the panel controls the pumping assembly s switching sequence There are fou...

Page 30: ...30 Check the motor oil level FIG 31 REF 1 the level should be close to the maximum mark The motor oil refilling cap FIG 31 REF 2 is located on the cylinder head to add oil unscrew the cover on the machine casing above the engine FIG 31 Check the hydraulic oil level through the inspection window FIG 32 REF 1 as a rule the oil level should reach the middle of the window with the machine switched off...

Page 31: ...sion to avoid the forming of condensate inside the tank when the machine cools down Make sure there is water inside the tank FIG 34 REF 1 21 FIG 34 The water in the tank may freeze at low temperatures Add a small amount of liquid antifreeze to the water to prevent ice from forming inside the tank and in the parts close to it ...

Page 32: ...7 USE AND OPERATION 32 58 561270 IS19 07 EN 7 4 CONTROLS 1 BETON MASTER START ON OFF h 2 3 18 19 4 5 6 8 7 9 10 11 12 13 14 15 16 17 FIG 35 3 2 4 5 6 1 FIG 36 ...

Page 33: ...longer possible to work as the engine automatically turns off after it is started Avoid the battery discharging by intervening to restore charge correct operation Request the authorised after sales assistance intervention Diesel oil level alarm FIG 35 REF 12 This alarm is signalled when the tank level drops below minimum We recommend topping up It is possible to work but with the risk of completel...

Page 34: ...ed hydraulic supply is interrupted and the controls are disabled The operator must check the pumping circuit manometer during the first few pumping cycles for best perception of relation between the effective work pressure and the maximum pressure The effective work pressure on hydraulic circuit oil varies based on used mix and layout of the piping line The manometer indicates the hydraulic cylind...

Page 35: ...the S valve Continue until you see only clear water coming out of the hopper 1 2 FIG 37 Stop pumping and close the discharge chute Let the diesel engine idle for 2 3 minutes and stop the engine Make sure no residues of concrete remain inside the hopper the S valve and the front delivery flange Lubricate the hopper walls and the S valve with oil or other lubricants This will reduce the chances of d...

Page 36: ...n mind that the hopper s capacity will let you recover about 200 litres of slurry FLUSHING WITH WATER Soak a pipe sponge FIG 39 REF 1 and put it inside the pipe Connect the pipe to the machine and open the gate valve if present Connect the basket FIG 39 REF 2 designed to catch the sponge to the end of the hose using a Victaulic coupling complete with rubber gasket Fill the hopper with water and st...

Page 37: ...flushing follow the instructions in paragraph 7 7 Be sure to discharge the pressure before you open any coupling close the valve FIG 40 REF 4 close the compressed air hose valve disconnect the compressed air hose from the coupling FIG 40 REF 6 open the valve FIG 40 REF 4 CLEANING BY REVERSE PUMPING If the pumping line is vertical introduce the rubber sponge into the delivery hose start pumping in ...

Page 38: ...ly and clean it out 1 FIG 41 FIG 42 Clogging in rubber hoses The pipe is hard and rigid near the obstruction on the contrary the hose sags upon treading Disconnect the clogged hose from the piping line once this has been pre emptively depressurised Place the hose vertically to evacuate its contents EMERGENCY STOP Use the emergency button FIG 36 REF 1 only when you must stop the machine for an emer...

Page 39: ...y at least once a week or preferably after every work session When working in a cold climate empty the tank at the end of every work session or add antifreeze CHECKING THE ENGINE COOLANT LEVEL Check the level of the engine coolant and top up if necessary see paragraph 7 3 CHECKING THE MOTOR OIL Check the motor oil level using the dipstick The level should be near the top mark but never above For t...

Page 40: ...ND OF A WORK SESSION After a work session and after cleaning the machine we recommend spraying it with a liquid that can prevent the forming of deposits Using the grease pump supplied lubricate the three greasing points FIG 46 REF 1 on the mixer support and the S valve mount Lubricate the switching jacks 8 2 REPLACING THE PUMPING PISTONS Replace the pumping pistons when the lubrication water in th...

Page 41: ...he pumping Stop the machine The following steps must be carried out with the machine switched off To facilitate operations we recommend removing the upper hopper by unscrewing its four fastening screws Be sure to remove the hopper safety sensor too Remove the screw FIG 48 REF 1 on the piston head FIG 48 FIG 49 Slip on the guide ring FIG 49 REF 1 applying the tapered part on the wear plate Holding ...

Page 42: ... the piston Remove the piston with the guide ring FIG 52 FIG 52 FIG 53 To install a new piston proceed as follows Slide the guide spacer FIG 53 REF 1 onto the cylindrical part of the guide ring FIG 53 REF 2 with the countersunk part facing outward Lubricate the piston FIG 54 REF 1 with Vaseline and slide the piston into the tapered part of the guide ring ...

Page 43: ...y between the wear plate and the wear disc and make them seal to each other Play is caused by wear on the two elements produced by scraping Imperfect sealing can be detected during washing when water seeps out from between the disc and the plate and during pumping when slurry seeps out from between them As a rule the S valve should be adjusted when the distance between the disc and the wear plate ...

Page 44: ...TE screws FIG 59 REF 2 and remove the delivery flange Remove the TE screw FIG 58 REF 1 remove the lever locking the adjustment nut FIG 59 REF 2 and remove the adjustment nut FIG 59 REF 3 If you only need to replace the wear disc and the wear plate pull the S valve out as far as necessary to do so If you need to replace the S valve too strike it with a hammer to facilitate removing 2 1 2 1 1 3 4 FI...

Page 45: ...e wear disc FIG 62 REF 1 with the O ring FIG 62 REF 2 on the S valve Reinstall the S valve Reinstall the tapered connecting rod aligning the little hole between the flanges with the hole on the S valve 1 2 FIG 62 Put back the lever locking washer FIG 63 REF 1 the adjustment nut FIG 63 REF 2 the nut locking lever FIG 63 REF 3 and fasten it with the TE screw FIG 63 REF 4 Put back the two pins FIG 63...

Page 46: ...ith two filters Replace the filter on the cover every 500 hours and the filter inside the tank every 1000 hours To change the filter FIG 64 REF 1 unscrew the four screws on the oil filter inspection cover on the fixed casing Unscrew the filter cap FIG 64 REF 2 and remove and replace the filter cartridge Screw the cap back on FIG 64 REF 2 and fasten the inspection cover with the screws 3 1 2 FIG 64...

Page 47: ...ank after inspecting the conditions of the gasket replace if necessary Open the cap FIG 66 REF 4 and fill the tank with 75 litres of ELF OLNA DS 46 hydraulic oil Check the oil level through the inspection window FIG 66 REF 5 Reinstall the fixed casing and fasten it with the screws Start the engine and let the hydraulic pump run idle for a few minutes while checking the oil level through the inspec...

Page 48: ...e engine Check the tightness of the fittings in the hydraulic system Check the tightness of the nuts and wheels Adjust the brakes on versions equipped with vehicle towing gear 1 1 2 FIG 67 FIG 68 8 7 2 Maintenance to be performed every month or every 125 hours Change the motor oil Use TOTAL RUBIA TIR 7400 Remove the plug FIG 67 REF 1 and drain the oil Put the oil drain plug back on Remove the refi...

Page 49: ...the cooling circuit Remove and clean the engine breather pipe Check the functioning of the alternator the starter motor etc Inspect the electric system 8 7 6 Maintenance to be performed every 2500 hours Replace the engine breather pipe 8 8 TOWING GEAR MAINTENANCE Service and clean every 10 000 km or every 12 months Replace the shock absorber on the overrun brake if very weak if air bubbles are pre...

Page 50: ...8 MAINTENANCE 50 58 561270 IS19 07 EN All maintenance work should be carried out by trained personnel in authorized workshops or service centres ...

Page 51: ...ow the local regulations at the time of scrapping the machine Separate the machine parts according to the type of material plastic rubber iron etc The oil the coolant and the storage cell must be handed over to authorized firms specializing in the disposal of polluting products ...

Page 52: ...9 SCRAPPING 52 58 561270 IS19 07 EN ...

Page 53: ...piston ends its suction phase and is ready to start the pumping phase When the LED FIG 71 REF 1 is on meaning that the piston is ready for pumping move the lever m1 to position 1 When the LED FIG 71 REF 3 turns on the pumping phase is completed Now move the lever m1 to position 2 to switch the position of the S valve LEDs FIG 71 REF 2 and LED FIG 71 REF 4 will light up Move on to the lever m2 and ...

Page 54: ...if required Check alternator and diode bridge WATER TEMPERATURE ALARM ON AND DIESEL ENGINE SWITCHES OFF Insufficient cooling liquid level and or dirty engine cooling radiator Top up the cooling liquid level and clean the radiator Faulty water pump Replace water pump PUMPING STOPS Unsuitable mix and pumping pressure at limit Make mix suitable for pumping Open hopper grid Check the grid is properly ...

Page 55: ...TROUBLESHOOTING 10 561270 IS19 07 EN 55 58 ...

Page 56: ...10 TROUBLESHOOTING 56 58 561270 IS19 07 EN ...

Page 57: ...thorised by the Manufacturer The end consumer shall be responsible for having the defective machinery brought to the designated repair facility during regular working hours Defective parts must be sent free port to the Manufacturer which shall either repair said parts or replace them free of charge when and if in the final judgement of the Manufacturer said parts show defects in quality The replac...

Page 58: ...11 RESPONSIBILITY OF THE OPERATOR 58 58 561270 IS19 07 EN ...

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