Turbosol BM 30 Use And Maintenance Manual Download

Page: 49 / 57

BM 30

IS13/02 - 561291

8 - MAINTENANCE

Pag. 12/15

THIS MANUAL IS PROPERTY OF

ANY TOTAL OR PARTIAL REPRODUCTION IS STRICTLY FORBIDDEN

Cap.

FIG.61

8.9

ROAD TOW MAINTENANCE

- Perform maintenance and cleaning every 10000 km or every 12 months.
- Replace the inert brake's shock absorber:

• if force is extremely weak.

• With air bubbles.

• If stem is easily removed.

• With oil leaks.

- Grease and oil all sliding surfaces and inert brake joints (FIG.62). Use DIN 51825 multipurpose grease.

FIG.62 FIG.63

If the drawbar is adjusted at a certain height for a prolonged period, a layer of rust may form between the

toothed flanged. It causes the flanges to stick. Clean the flange on a six-monthly basis and apply water-resistant
grease (DIN 51502 KPF 2C multi-purpose grease), to eliminate this problem.

Summary of Contents for BM 30

Page 1: ... MANUAL CAREFULLY BEFORE USING THE MACHINE THIS MANUAL IS AN INTEGRAL PART OF THE MACHINE AND MUST BE KEPT FOR FUTURE REFERENCE UNTIL THE MACHINE IS DISPOSED OF USE AND MAINTENANCE MANUAL BM 30 IS13 02 561291 EN IT ORIGINALI ...

Page 2: ...THIS MANUAL IS PROPERTY OF ANY TOTAL OR PARTIAL REPRODUCTION IS STRICTLY FORBIDDEN ...

Page 3: ...ATA 2 3 4 DESTINATION OF USE 2 3 5 PRODUCTS USED FOR PROCESSING 2 3 6 NAME OF COMPONENTS 3 4 TRANSPORT AND HANDLING 1 4 1 MACHINE TRANSPORT AS ROAD TRAILER 1 4 2 LIFTING 3 5 INSTALLATION 1 5 1 PLACEMENT 1 5 2 PIPING 1 5 2 1 Piping line layout 2 Horizontal pumping 2 Vertical pumping 2 Downward pumping 2 5 3 CONCRETE PIPING FITTINGS 3 5 4 CONNECTIONS 3 5 4 1 Remote control 3 5 4 2 Radio control opti...

Page 4: ...ctions 1 8 2 OPERATOR RESPONSIBILITY 2 8 2 1 Replacing lubrication water 2 8 2 2 Engine cooling liquid check 2 8 2 3 Engine oil check 2 8 2 4 Engine air filter check 3 8 2 5 Diesel oil level check 3 8 2 6 Hydraulic oil level check 3 8 2 7 At end of work 4 8 3 PUMPING PISTONS REPLACEMENT 4 8 4 S VALVE ADJUSTMENT 7 8 5 WEAR PLATE WEAR DISC REPLACEMENT 8 8 6 I OIL FILTER REPLACEMENT 9 8 7 II OIL FILT...

Page 5: ...AL REPRODUCTION IS STRICTLY FORBIDDEN 9 DEMOLITION 1 9 1 MAIN WARNINGS 1 10 TROUBLESHOOTING 1 10 1 FAULTY ELECTRONIC BOARD 1 10 2 PUMPING SYNCHRONISM RESET 1 10 3 OPERATOR INTERVENTION 2 11 OPERATOR RESPONSIBILITY 1 11 1 RESPONSIBILITY 1 11 2 WARRANTY 1 ...

Page 6: ... CE DECLARATION Cap 1 Pag 1 1 THIS MANUAL IS PROPERTY OF ANY TOTAL OR PARTIAL REPRODUCTION IS STRICTLY FORBIDDEN 1 1 CE DECLARATION OF CONFORMITY The original CE Declaration of conformity is provided separately from the manual ...

Page 7: ...ble for any damages due to arbitrarily made changes and or tampering with the machine We recommend making a note of the machine s serial number that must always be provided whenever requesting assistance or spare parts to facilitate the work of personnel in charge This manual reflects the state of the art at time of marketing the machine and cannot be considered inadequate because subsequently upd...

Page 8: ...uous development The know how in this way acquired constitutes an essential guarantee together with the high level of attention to quality for the manufacture of long lasting greatly reliable machines and handling costs reduction MAINTENANCE AND CARE Maintenance and care are significantly important for the machine s operation to correspond to expectations Therefore in order to maintain the warrant...

Page 9: ...ls 1 Machine series 2 Machine model 3 Machine s serial number T With road approved tow Manufacturer plate position 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...

Page 10: ...inches 5 5 Hopper capacity litres 300 Diesel oil tank capacity litres 40 Oil tank capacity hydraulic system litres 75 Hydraulic oil recommended TOTAL AZOLLA HZS 46 Maximum height A S L of installation place without sensitive power loss m 1000 Admitted environmental temperature C Sound power level Lw dB 104 Equivalent continuous A Lp weighted sound pressure level dB 92 Endothermic engine PERKINS 40...

Page 11: ...figure KEY FIG 03 REF 1 Bodywork FIG 03 REF 2 Upper hopper FIG 03 REF 3 Grid FIG 03 REF 4 Vibrator FIG 03 REF 6 Control board FIG 03 REF 7 Tow FIG 03 REF 8 Exchanger FIG 03 REF 9 Engine FIG 03 REF 10 Hydraulic pump unit FIG 03 REF 11 Mixer FIG 03 REF 12 Lower hopper FIG 03 REF 13 Delivery flange FIG 03 REF 14 S Valve FIG 03 REF 15 S Valve exchange jack FIG 03 REF 16 Pumping barrel FIG 03 REF 17 Wa...

Page 12: ...FIG 05 REF 03 Pull the trailer s parking brake during parking or stop Fix the trailer with two wedges after having released it Repulsion brake adjustment Remove the split pin FIG 05 REF 01 Loosen the handle FIG 05 REF 02 and turn it until it stops Adjust the coupling element upwards 50 or downwards 10 by means of the repulsion brake handle until it stops Fasten and fix the handle hitting it with a...

Page 13: ...the wheel Activate the parking brake Release the machine from the towing vehicle Always block the machine using the parking brake and supplied wedges to avoid any movement when releasing the machine on a slope BM 30 can be transported on motor gearbox vehicles the machine s load arrangement and transport on a vehicle must respect the current highway code If having to load BM 30 onto the vehicle us...

Page 14: ...ore using it and replace it if required 1 2 3 FIG 08 Lifting must happen fully respecting all lifting standards in force equally the used means must be conform with current standards and perfectly preserved Personnel in charge of the lifting mean must be adequately trained and enabled for its use Use approved hooks and ropes for lifting 2 000 kg Ensure no one is too close to the machine before lif...

Page 15: ...ne must rest on the side stabilising feet and the wheels and this position must be stable 5 2 PIPING Lay piping limiting their length as much as possible transport and wear times are reduced checking it is in good condition Use flexible rubber hoses only in the last piping section and with length of not more than 4 m the use of rubber hoses in other position along the piping jeopardises pumping wa...

Page 16: ...upported using the appropriate collars FIG 12 REF 1 Downward pumping The downward piping section must be fixed and supported using the appropriate collars FIG 13 REF 1 Arrangements must be made to stop the concrete fall in the downward section e g assemble a bend or S bend as in FIG 13 or make tilted sections For this type of layout we recommend lubricating pipes with grout as follows introduce tw...

Page 17: ...ng the piping segments 1 2 FIG 15 5 4 CONNECTIONS Connect the electric vibrator s plug FIG 16 REF 1 to th emachine socket FIG 16 REF 2 located on the hydraulic tank Close the door after connection 1 2 3 FIG 16 5 4 1 Remote control The machine is given a remote control via cable Insert the plug FIG 17 REF 1 in the connector s socket FIG 17 REF 2 located on the machine s bodywork Activate the mortar...

Page 18: ... optional Connect the plug FIG 18 REF 1 to the connector s socket FIG 18 REF 2 Use the button FIG 18 REF 3 to switch the transmitter on and off Start pumping by pressing the button FIG 18 REF 4 press again to stop pumping Reverse pumping mix intake from hopper piping with button FIG 18 REF 4 at ON press the button FIG 18 REF 5 for as long as required 2 4 5 3 1 FIG 18 ...

Page 19: ...ctions The manual must always be carefully kept on the machine Immediately request a copy from TURBOSOL PRODUZIONE SPA or your dealer if no longer legible The operator must be in perfect physical and psychological conditions to perform his work The operator must not be occasional but have gained experience with the machine It is forbidden to use the machine to convey loads It is forbidden to use t...

Page 20: ...ton re arm Remove the causes that have entailed using the device before re activating the machine from the emergency condition The emergency conditions remains such until re arm to avoid accidental re start Proceed as follows to re arm Turn the red button in the direction of the engraved arrows The button re arms and the machine is ready for start procedure ...

Page 21: ...ximum pressure valve to limit pumping maximum pressure and S valve movement is found inside the hydraulic system MAXIMUM PRESSURE VALVE OF AUXILIARY HYDRAULIC 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 ...

Page 22: ...6 Pag 4 6 THIS MANUAL IS PROPERTY OF ANY TOTAL OR PARTIAL REPRODUCTION IS STRICTLY FORBIDDEN Cap 6 3 SAFETY SIGNALS The safety signals consist in adhesive labels applied outside and inside the machine The meaning is given below FIG 20 ...

Page 23: ...202 Danger of electrocution 561092 Moving parts 561092 Hot surfaces 561256 Danger of explosion It is compulsory to always keep the safety signals clean to guarantee good visibility It is compulsory to replace the deteriorated safety signals via request to the manufacturer by ordering code under the safety signal It is strictly forbidden to remove or damage the safety signals applied on the machine...

Page 24: ...O PROTECT HEARING IT IS MANDATORY TO PROTECT THE HANDS IT IS MANDATORY TO PROTECT THE FEET TAB 08 6 5 RESIDUE RISKS The machine was built according to the current state of the art and following the Directives and Standards prescriptions reported in the declaration of conformity Nevertheless machine faults therefore dangers for the operator or third party may occur during use Injuries to eyes due t...

Page 25: ...he pumping system is hydraulically activated with hydraulic pump at variable flow rate and valves unit distributing the oil The exchange sequence of the pumping unit is controlled by means of four sensors on the machine s board The control board manages the main machine functions Pumping start stop and reversal can be directly controlled by the operator by means of remote control via cable standar...

Page 26: ...bodywork s lid FIG 22 REF 2 above the bowl to top up FIG 22 FIG 23 Check the engine s oil level FIG 23 REF 1 it must be almost at maximum The engine oil filler cap FIG 23 REF 2 is on the head loosen the bodywork s lid above the engine to top up Check the hydraulic oil level through the sight glass FIG 24 REF 1 indicatively it must be in the centre of the sight glass with machine off and cold The f...

Page 27: ...el oil tank FIG 25 at end of work session Through the level pipe highlighted in figure check there is water inside the bowl FIG 26 REF 1 FIG 26 Anti freeze can be used with cold weather Respect the safety sheets of the chosen anti freeze during use and the laws in force with regard to the disposal of such substances We recommend emptying the bowl each working day Water in the bowl must be changed ...

Page 28: ...EN BM 30 IS13 02 561291 7 USE AND OPERATION 7 Pag 4 13 THIS MANUAL IS PROPERTY OF ANY TOTAL OR PARTIAL REPRODUCTION IS STRICTLY FORBIDDEN Cap 7 4 CONTROLS FIG 27 ...

Page 29: ...ng START Air filter alarm This alarm only appears on the console Clean or replace filters Battery charge alarm It is possible to continue working with the machine for a maximum of 200 minutes approx 4 hours to allow completing the work in progress after this alarm is signalled After this time it is no longer possible to work as the engine automatically turns off after it is started Avoid the batte...

Page 30: ...es the engine off after a variable time between 1 and 100 seconds The alarm appears on display Alarm Motor OFF BTM 3P4 Operation indicator A LED above the relative key is associated to each function the LED is on when function is active 7 5 MACHINE SWITCH ON indicating the installed software and machine s serial number Package an adequate amount of grout water and cement pumping up to 20 m 40 50 l...

Page 31: ...vice has intervened hydraulic supply is interrupted and the controls are disabled Close the grid and re start pumping by pressing the ON OFF button to restore operation 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...

Page 32: ...us sets are saved Additive percentage recommended by the manufacturer operator s selection can be modified by acting on ARROW UP and ARROW DOWN on control panel The percentage could be set before starting pumping and during pumping During the pumping cycle with the additive pump running the display shows BM30F1 Reg 10 20 6 1 6 2 Pumping cycles per minute 20 Theoretical additve flow 6 1 Actual addi...

Page 33: ...OTAL OR PARTIAL REPRODUCTION IS STRICTLY FORBIDDEN BM30F1 20 0 0 0 0 When there isn t additive flow no additive in the tank the system stops the dosing pump to avoid pump failure and the concrete pumping to avoid sprayed concrete without additive The display shows BM30F1 No additive 0 0 0 0 0 ...

Page 34: ...at all safety devices are fully functional Start engine Insert a maximum of 15 20 cm the water pipe inside the delivery manifold Activate reverse pumping Stop the engine All the cleaning and discharching operations must be done with engine switched off Open the bottom flap and discharge the hopper Continue for some cycles until only clear water comes out from the hopper All the cleaning and discha...

Page 35: ...perate the pump with clean water for a few minutes should this happen High pressure operation Parricular attention must be given to using the pump in environments with moving vehicle risking crushing or damaging the delivery pipe water gun or nozzle Wear clothing that guarantee adequate protection against incorrect movements with the pressurised fluid jet before using the pump Do not use the pump ...

Page 36: ... adequately direct the end pipe so no one near by is injured and or property damaged If deposit is present inside the piping the sponge does not exit reverse the pumping direction to drain pressure inside the piping and stop the machine Carefully read paragraph 7 7 to eliminate any deposit during cleaning Water suction cleaning Insert the rubber sponge at the end of the end pipe activate pumping b...

Page 37: ...ct the clogged pipe from the piping line once this has been pre emptively depressurised Place the pipe vertically to evacuate its contents 1 FIG 31 FIG 32 Rubber hoses clogging 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 evacua...

Page 38: ...he pressure has been discharged in all plants Never place the head body limbs hands feet or fingers inside a shear area without guards without having firstly securely blocked parts that can move Never align holes or slots with fingers use an adequate centring tool Protect yourself using goggles with side guards when using compressed air to clean parts Limit the pressure to a maximum of 2 bar Servi...

Page 39: ...ean water Through the indicator underneath the oil tank FIG 26 check correct water level FIG 33 FIG 34 The water bowl can be filled by connecting the water hose connected to the water mains to the cock FIG 33 Fill bowl up to correct level FIG 26 Anti freeze can be used with cold weather Respect the safety sheets of the chosen anti freeze during use and the laws in force with regard to the disposal...

Page 40: ...ot blow the paper filter element with compressed air The 2nd stage cartridge can be sometimes cleaned with compressed air but never washed Accurately clean the lid and filter support 21 21 21 FIG 35 8 2 5 Diesel oil level check Check the diesel oil level It is a good rule to avoid condensation problems inside the tank with machine cold to top up the tank once work is completed 8 2 6 Hydraulic oil ...

Page 41: ...NT Replace the pumping pistons when muddy water and non fine parts are found in the lubrication bowl Prepare the supplied tools 36 41 wrench FIG 38 REF 1 M24 threaded rod FIG 38 REF 2 and M27 FIG 38 REF 3 M24 nut FIG 38 REF 4 and M27 FIG 38 REF 5 guide ring for piston FIG 38 REF 6 spacer for guide FIG 38 REF 7 two spacers for rod FIG 38 REF 8 flange for piston disassembly FIG 38 REF 9 two pistons ...

Page 42: ...sure the grid is blocked using the device FIG 39 REF 1 loosen the two ring locking nuts FIG 39 REF 2 and overturn the hopper up to blocking position for safer and easier operation FIG 40 1 2 3 1 FIG 39 FIG 40 PISTON DISASSEMBLY Remove the screw FIG 41 REF 1 on the piston head 1 2 1 FIG 41 FIG 42 Slip on the guide ring FIG 42 REF 1 applying the tapered part on the wear plate Holding the guide ring ...

Page 43: ... FIG 44 REF 1 onto the piston head screw on the nut FIG 44 REF 2 and pull out the piston Remove the piston with the guide ring FIG 45 2 1 FIG 45 FIG 46 PISTON ASSEMBLY To install a new piston proceed as follows Lubricate the piston FIG 46 REF 1 with Vaseline and slide the piston into the tapered part of the guide ring FIG 46 REF 2 Introduce the guide ring s cylindrical part FIG 47 ...

Page 44: ...n Re position the upper hopper turning it into work position and block it with the two ring nuts 8 4 S VALVE ADJUSTMENT The S valve is adjusted to eliminate play between the wear plate and wear disc and restore seal between them This play is due to wear caused by friction of the two stated components Water leaks between the disc and the plate during washing and material outflowing between the same...

Page 45: ...ngine at minimum 1 2 3 FIG 51 8 5 WEAR PLATE WEAR DISC REPLACEMENT The following operations must be performed with machine off Overturn the upper hopper assemble the lighting bar careful to release the electric connection plug ensure the grid is blocked using the device FIG 39 REF 1 loosen the two ring locking nuts FIG 39 REF 2 and overturn the hopper up to blocking position FIG 40 Remove the rigi...

Page 46: ...l to re position the compensating ring in the disc s groove FIG 54 REF 2 1 2 2 2 1 FIG 54 FIG 55 WEAR PLATE Remove the wear plate by loosening the 5 fixing screws FIG 52 REF 1 Using grease assemble two new OR rings FIG 55 REF 2 the grease holds the two rings in position without excessively greasing as grease forms thickness Position and fasten the wear plate 8 6 I OIL FILTER REPLACEMENT The follow...

Page 47: ...Tighten the cap again FIG 56 REF 2 and close the inspection carter using the screws 3 1 2 FIG 56 8 7 II OIL FILTER REPLACEMENT Remove the fixed bodywork by loosening the screws on the its supports and brackets blocking it to the hydraulic tank FIG 57 2 3 4 5 FIG 57 FIG 58 Opening the cock located underneath the oil tank drain it ensuring to place an adequate container for oil collection Disconnect...

Page 48: ... pump if necessary remove the cover to hook rotor to the shaft 1 3 2 A B 0 3 mm C FIG 59 FIG 60 The stator usually works at half the rate of the auger Accordingly it may be necessary to replace only the stator while leaving the auger in place Uninstall the pump from the machine see above Put the pump in a vice and remove the auger FIG 60 REF A Lubricate the auger and the opening in the stator with...

Page 49: ...rce is extremely weak With air bubbles If stem is easily removed With oil leaks Grease and oil all sliding surfaces and inert brake joints FIG 62 Use DIN 51825 multipurpose grease FIG 62 FIG 63 If the drawbar is adjusted at a certain height for a prolonged period a layer of rust may form between the toothed flanged It causes the flanges to stick Clean the flange on a six monthly basis and apply wa...

Page 50: ... MANUAL IS PROPERTY OF ANY TOTAL OR PARTIAL REPRODUCTION IS STRICTLY FORBIDDEN Through the inspection hole FIG 63 REF 1 check the brake linings wear Adjust if required Have trained personnel perform all maintenance in qualified workshops or assistance centres ...

Page 51: ...k the pumping safety and BM30 management sensors diesel oil level hydraulic oil temperature cooling liquid temperature are fastened Check the engine is not leaking Check the fittings of the hydraulic system s ducts are fastened Check fastening of the wheels nuts Adjust the brakes in road approved tow version 1 1 2 FIG 64 FIG 65 8 10 2 Monthly check or every 125 hours Engine oil change Use TOTAL RU...

Page 52: ...g liquide 8 10 4 Six monthly check or every 500 hours Check the glow plugs Replace the hydraulic oil filters in the hydraulic tank Clean and calibrate the injectors 8 10 5 Annually check or every 1000 hours Replace the hydraulic circuit oil Check S valve play and adjust if required Check state of hydraulic circuit pipes and fittings Check the state of the diesel oil suction circuit pipes and fitti...

Page 53: ...1 MAIN WARNINGS It is compulsor to observe the standard in force in the country of use when demolishing the machine Separate the machine parts by type of material plastic rubber iron etc The oils cooling liquid and electric accumulator must be delivered to authorised and specialised companies in the disposal of these polluting products ...

Page 54: ...meter FIG 28 REF 5 shows maximum pressure when the exchange jack reaches end run levers m1 and m2 in position 2 control pumping when piston reaches end run the other piston appears in bowl Pumping sequence m3 lowered m1 position 1 m3 lowered m2 position 2 m3 lowered m2 position 1 m3 lowered m1 position 2 Intake sequence m3 lowered m1 position 1 m3 lowered m1 position 2 m3 lowered m2 position 1 m3 ...

Page 55: ...ENGINE SWITCHES OFF Faulty water pump Replace water pump Unsuitable mix and pumping pressure at limit Make mix suitable for pumping Safety system intervention and display shows the intervened sensor Check the grid is properly closed and the hopper is blocked The safety system blocks pumping when one of the sensors has the red LED on when green the safety system allows pumping High hydraulic oil te...

Page 56: ... when the plant s registration is excessively tensioned Correctly register STIFF OR BLOCKED REVERSE GEAR Blocked reverse gear lever Clean and oil the mobile parts Incorrect calibration Calibrate The braking system does not perfectly open in start direction Release the hand brake Blocked idler Make all transmission parts and linkage smooth lubricate road frame mobile parts Bent rod support Check ro...

Page 57: ...ser must ensure the machine reaches said Organisations during normal working hours The faulty pieces must be sent to the Manufacturing Company ex works which commits to gratuitously repair or replace those parts that at its undisputable judgement show quality vices The replaced parts remain the Manufacturer s property The Purchaser is responsible for the material shipment expenses and those relati...

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