Turbosol Beton Master Operation And Maintenance Manual
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Turbosol Beton Master Operation And Maintenance Manual

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ORIGINALI
OPERATION AND MAINTENANCE MANUAL
EN
IT
BETON MASTER
17341
561.184
-
Serial number
READ THIS 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

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Summary of Contents for Turbosol Beton Master

  • Page 1 ORIGINALI OPERATION AND MAINTENANCE MANUAL BETON MASTER 17341 561.184 Serial number READ THIS 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...

  • Page 2: Table Of Contents

    INDEX CE DECLARATION ..............................1 1.1 CE DECLARATION OF CONFORMITY ......................1 GENERAL INFORMATION............................1 2.1 IMPORTANCE OF MANUAL..........................1 2.2 ABBREVIATIONS ............................1 2.3 INFORMATION ON CONSULTING THE MANUAL..................1 2.4 MEANING OF SYMBOLS ..........................1 2.5 MACHINE OFF..............................2 2.6 GENERAL AND CONTACT INFORMATION....................
  • Page 3 INDEX USE AND OPERATION ............................1 7.1 OPERATING PRINCIPLE ..........................1 7.2 PUMPABLE SLURRIES ........................... 1 7.3 CHECKS BEFORE START-UP........................2 7.4 CONTROLS ..............................4 7.5 STARTING THE MACHINE..........................7 7.5.1 Accelerator pump ............................9 7.6 CLEANING THE MACHINE AFTER A WORK SESSION ................11 7.6.1 Washing the piping .............................
  • Page 4 INDEX RESPONSIBILITY OF THE OPERATOR ........................ 1 11.1 RESPONSIBILITY............................1 11.2 WARRANTY..............................1 THIS MANUAL IS PROPERTY OF ANY TOTAL OR PARTIAL REPRODUCTION IS STRICTLY FORBIDDEN...

  • Page 5: Ce Declaration

    BETON MASTER 1 - CE DECLARATION 17341 - 561.184 CE DECLARATION OF CONFORMITY An original copy of the CE Declaration of Conformity is supplied separately from the manual. Cap. - Pag. THIS MANUAL IS PROPERTY OF ANY TOTAL OR PARTIAL REPRODUCTION IS STRICTLY FORBIDDEN...

  • Page 6: General Information

    BETON MASTER 2 - GENERAL INFORMATION 17341 - 561.184 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.

  • Page 7: Machine Off

    ON/OFF button (FIG. 35-REF. 1). GENERAL AND CONTACT INFORMATION The BETON MASTER concrete pump can be supplied with a number of different accessories, therefore not all the parts described in this manual may be actually installed on your machine. The Customer Service department of Turbosol Production S.p.A. will be glad to provide any information you may need.

  • Page 8: Technical Description

    BETON MASTER 3 - TECHNICAL DESCRIPTION 17341 - 561.184 NAME OF MACHINE CE Marking FIG. 01 The machine's series (1), model (2) and serial number (3) are engraved on the nameplate, as well as its power rating. Position of CE nameplate The CE nameplate (FIG.

  • Page 9: Dimensions Of Machine

    BETON MASTER 3 - TECHNICAL DESCRIPTION 17341 - 561.184 DIMENSIONS OF MACHINE The following are the machine's overall dimensions and gross weight (in working conditions). BETON MASTER D-E LENGTH WIDTH HEIGHT WEIGHT* 3335 mm 1420 mm 1600 mm 1560 kg TAB.

  • Page 10: Materials Used

    BETON MASTER 3 - TECHNICAL DESCRIPTION 17341 - 561.184 MATERIALS USED - Concrete with maximum particle size 25 mm if aggregates obtained by crushing; maximum particle size 30 mm in case of spheroidal aggregates. - Shotcrete. NAME OF MACHINE PARTS FIG.

  • Page 11: Transportation And Handling

    4 - TRANSPORTATION AND BETON MASTER 17341 - 561.184 HANDLING TRANSPORTING THE MACHINE AS A VEHICLE TRAILER Only machines with a frame equipped with vehicle towing gear are allowed to circulate on public roads. Always respect the rules of the road when towing the machine.
  • Page 12 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; loading, securing and transporting the machine on a motor vehicle should always be done in compliance with the rules of the road. See paragraph 4.2, LIFTING, for information on using lifting apparatus to load BETON MASTER on a vehicle.

  • Page 13: Lifting

    LIFTING BETON MASTER is provided with four lifting points and supplied with a lifting beam (FIG. 10). - Fasten the ropes to the lifting beam (FIG. 10-REF. 1) and to the four lifting points, attaching the shorter ropes to the hooks shown in FIG.

  • Page 14: Installation

    FIG.11 FIG.12 - Place BETON MASTER at the point of the worksite where you can use the pipes and hoses to their full extension. - Brake the machine and block the wheels using the chocks supplied. - Make sure the machine is resting on its side support legs and then raise the wheel.

  • Page 15: Piping Layout

    BETON MASTER 5 - INSTALLATION 17341 - 561.184 5.2.1 Piping layout BETON MASTER can pump slurries horizontally, upwards or downwards. Here below are a few general rules that should be followed when setting up the various layouts. FIG.13 FIG.14 Horizontal pumping In case of horizontal pumping simply lay out the pipe in the desired layout and connect it to the first section described above.

  • Page 16: Fittings

    BETON MASTER 5 - INSTALLATION 17341 - 561.184 FITTINGS Make sure the fittings are clean and in good order at all times. 5.3.1 Victaulic couplings When coupling pipe sections, make sure the rubber gasket is in place (FIG. 17-REF. 1) and tighten the levers all the way (FIG.

  • Page 17: Remote Control

    BETON MASTER 5 - INSTALLATION 17341 - 561.184 5.4.2 Remote control The machine is supplied with a cable remote control. Plug the cable (FIG. 20-REF. 1) into the connector socket (FIG. 20-REF. 2) located on the machine's casing. Turn the selector (FIG. 20-REF. 3) to 1 to start the mortar pump, to 0 to stop pumping and to 2 to reverse the direction of rotation.

  • Page 18: Connecting The Radio Control (Optional)

    BETON MASTER 5 - INSTALLATION 17341 - 561.184 Accelerating additives are harmful. Protect any exposed surfaces adequately. Handle additives with care and follow the manufacturer's instructions. FIG.23 FIG.24 - Connect the accelerator delivery hose to the upper quick-release coupling (FIG. 24-REF. 1) on the side of the machine;...

  • Page 19: Safety

    BETON MASTER 6 - SAFETY 17341 - 561.184 SAFETY DEVICES GRIGLIA DI PROTEZIONE ALL'INTERNO DELLA TRAMOGGIA SUPERIORE All'interno della tramoggia superiore è presente la griglia che, oltre ad impedire l'accesso all'aggregato di dimensioni eccessive, impedisce il contatto con la valvola a S. L'apertura della griglia arresta il pompaggio di calcestruzzo ed il movimento della valvola a S.

  • Page 20: Personal Protective Equipment

    BETON MASTER 6 - SAFETY 17341 - 561.184 PERSONAL PROTECTIVE EQUIPMENT Wearing personal protective equipment is mandatory, in compliance with the workplace health and safety regulations in force in the country of use. Employers, directors and operators must be acquainted with and enforce these regulations.

  • Page 21: Use And Operation

    OPERATING PRINCIPLE At the core of the BETON MASTER is the pumping assembly, consisting of: the lower hopper (FIG. 29-REF. 1), which containes the S-valve (FIG. 29-REF. 2), and the mixer (FIG. 29-REF. 3). Behind the hopper are two oil-hydraulic jacks (FIG. 29- REF.

  • Page 22: Checks Before Start-Up

    BETON MASTER 7 - USE AND OPERATION 17341 - 561.184 CHECKS BEFORE START-UP The oil level and the coolant level should be checked with the machine switched off. - Check the level of the liquid inside the expansion vessel (FIG. 30-REF. 1) above the heat exchanger. To top up the liquid unscrew the cover (FIG.
  • Page 23 BETON MASTER 7 - USE AND OPERATION 17341 - 561.184 FIG.32 FIG.33 - Top up the diesel fuel tank (FIG. 33) at the end of every work session to avoid the forming of condensate inside the tank when the machine cools down.

  • Page 24: Controls

    BETON MASTER 7 - USE AND OPERATION 17341 - 561.184 CONTROLS FIG. 35 FIG.36 FIG.37 - Pag. 4/15 Cap. THIS MANUAL IS PROPERTY OF ANY TOTAL OR PARTIAL REPRODUCTION IS STRICTLY FORBIDDEN...
  • Page 25 BETON MASTER 7 - USE AND OPERATION 17341 - 561.184 FIG. REF. DESCRIPTION Display Machine switch-on/motor switch-off Motor start-up Pump start/stop Reverse pumping start/stop Mixer start/stop Mixer reverse Vibrating sieve start/stop Accelerator pump activation mode Accelerator pump start/stop High-pressure water jet start/stop...
  • Page 26 BETON MASTER 7 - USE AND OPERATION 17341 - 561.184 - Pumping (d) The left-side button (ON/OFF) starts and stops forward pumping, the right-side button (ON) reverses the pumping flow, and the light (STOP) indicates the opening of the safety grid in the hopper.

  • Page 27: Starting The Machine

    - Press ON/OFF (c1) to start the machine. - Enter the 4-digit access code (supplied together with the machine) to start using BETON MASTER. Once a correct access code has been entered it will remain valid for about 3 hours after the last time the machine is used. To enter the code (example: 5678) proceed as follows: •...
  • Page 28 BETON MASTER 7 - USE AND OPERATION 17341 - 561.184 The battery voltage appears at the top of the display so that you can check the state of charge. To start the machine press and hold the START button (c3) until the engine turns on. The display will show the following: BMT: X.X...

  • Page 29: Accelerator Pump

    BETON MASTER 7 - USE AND OPERATION 17341 - 561.184 Remote controls If you are using the cable remote control, plug the cable into the connector socket on the machine's casing (see par. 5.4.2). The LOCAL/REMOTE button lets you choose whether to use the pumping controls on the control panel (i1) (local) or on a remote device (i2), i.e., a remote control (supplied) or a radio control (optional).
  • Page 30 BETON MASTER 7 - USE AND OPERATION 17341 - 561.184 Val. (F1=Mod) P06 Access Code OK FIG. 44 - Press (n1) to go to the next parameter, P07: The following screen will appear: Val. (F1=Mod.) P07 Parameter Wc FIG. 45 - Press F1 (n3) to edit the number of kilos of cement.

  • Page 31: Cleaning The Machine After A Work Session

    BETON MASTER 7 - USE AND OPERATION 17341 - 561.184 FIG. 48 CLEANING THE MACHINE AFTER A WORK SESSION The following operations should be carried out only by specifically trained personnel. In particular, before breaking a joint make sure there is no residual pressure inside the piping and that no one is standing nearby.

  • Page 32: Washing The Piping

    BETON MASTER 7 - USE AND OPERATION 17341 - 561.184 - Lubricate the hopper walls and the S-valve with oil or other lubricants. This will reduce the chances of deposits forming inside the hopper after the next work session. - We recommend covering the hopper with a piece of material to prevent foreign matter from falling inside.

  • Page 33: Flushing With Compressed Air

    BETON MASTER 7 - USE AND OPERATION 17341 - 561.184 FIG. 52 The sponge will be violently expelled from the hose. Make sure the hose is pointing in a direction where there is no risk of harming anyone or damaging anything. If the piping is encrusted the sponge will not be expelled. In this case, reverse the direction of pumping to reduce the pressure inside the piping and stop the machine.

  • Page 34: Cleaning By Reverse Pumping

    BETON MASTER 7 - USE AND OPERATION 17341 - 561.184 In case the pipes are found to be clogged during flushing, follow the instructions in paragraph 7.7. Be sure to discharge the pressure before you open any coupling: - close the valve (FIG. 53-REF. 4) - close the compressed-air hose valve - disconnect the compressed-air hose from the coupling (FIG.
  • Page 35 BETON MASTER 7 - USE AND OPERATION 17341 - 561.184 FIG.55 FIG.56 Clogging in rubber hoses - An empty hose will yield when stepped upon, whereas a clogged tube will be stiff and unyielding. - Detach the piping upstream from the clogged hose.

  • Page 36: Maintenance

    BETON MASTER 8 - MAINTENANCE 17341 - 561.184 MAINTENANCE TO BE CARRIED OUT BY OPERATOR The following are the basic instructions for performing proper maintenance on the machine. More detailed information can be found in the diesel engine operation and maintenance manual (supplied), which operators are required to read and understand (along with the present manual) before using the machine.

  • Page 37: Checking The Diesel Fuel Level

    BETON MASTER 8 - MAINTENANCE 17341 - 561.184 Checking the diesel fuel level Check the diesel fuel level. Top up the diesel fuel tank at the end of every work session to avoid the forming of condensate inside the tank when the machine cools down.

  • Page 38: Replacing The Pumping Pistons

    BETON MASTER 8 - MAINTENANCE 17341 - 561.184 FIG. 61 REPLACING THE PUMPING PISTONS Replace the pumping pistons when the lubrication water in the tank appears cloudy and contains coarse grains. Prepare the tools supplied: - 32 mm wrench (FIG. 62-REF. 1) - M20 (FIG.
  • Page 39 BETON MASTER 8 - MAINTENANCE 17341 - 561.184 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. 63-REF. 1) on the piston head.
  • Page 40 BETON MASTER 8 - MAINTENANCE 17341 - 561.184 FIG.67 FIG.68 To install a new piston proceed as follows: - Slide the guide spacer (FIG. 68-REF. 1) onto the cylindrical part of the guide ring (FIG. 68-REF. 2) with the countersunk part facing outward.

  • Page 41: Adjusting The S-Valve

    BETON MASTER 8 - MAINTENANCE 17341 - 561.184 FIG.71 FIG.72 - Unscrew and remove the nut, remove the M16 threaded rod, the spacers, the guide ring and the guide ring spacer. - Tighten the screw and washer on the piston.

  • Page 42: Replacing The Wear Disc, The Wear Plate And The S-Valve

    BETON MASTER 8 - MAINTENANCE 17341 - 561.184 REPLACING THE WEAR DISC, THE WEAR PLATE AND THE S-VALVE The following steps must be carried out with the machine switched off. - Remove the upper hopper by unscrewing its four fastening screws.

  • Page 43: Changing The First Oil Filter

    BETON MASTER 8 - MAINTENANCE 17341 - 561.184 - Reinstall the S-valve. - Reinstall the tapered connecting rod, aligning the little hole between the flanges with the hole on the S-valve. FIG. 77 - Put back the lever locking washer (FIG. 78-REF. 1), the adjustment nut (FIG. 78-REF. 2), the nut locking lever (FIG. 78-REF.

  • Page 44: Changing The Second Oil Filter

    BETON MASTER 8 - MAINTENANCE 17341 - 561.184 FIG. 79 CHANGING THE SECOND OIL FILTER - Take down the fixed casing by removing the screws on the casing mounts and on the brackets that fasten it to the hydraulic oil tank (FIG. 80).

  • Page 45: Replacing The Additive Metering Pump

    BETON MASTER 8 - MAINTENANCE 17341 - 561.184 FIG. 81 REPLACING THE ADDITIVE METERING PUMP The following steps must be carried out with the machine switched off. - Disconnect the quick-release coupling (FIG. 82-REF. 1), unscrew the hose clamps (FIG. 82-REF. 2/3) and remove the slurry delivery manifold by loosening the tie rod locking nuts (FIG.

  • Page 46: To Be Carried By Qualified Personnel

    - Check the valve clearance and adjust if necessary. - Check the engine mountings and tighten if necessary. - Check the tightness of the pumping sensors, the safety sensors and the BETON MASTER operation sensors (diesel fuel level, hydraulic oil temperature, coolant temperature).

  • Page 47: Maintenance To Be Performed Every Month Or Every 125 Hours

    BETON MASTER 8 - MAINTENANCE 17341 - 561.184 FIG.86 FIG.87 8.8.2 Maintenance to be performed every month or every 125 hours - Change the motor oil • Use TOTAL RUBIA TIR 7400. • Remove the plug (FIG. 86-REF. 1) and drain the oil.

  • Page 48: Maintenance To Be Performed Every 2500 Hours

    BETON MASTER 8 - MAINTENANCE 17341 - 561.184 - Check the functioning of the alternator, the starter motor, etc. - Inspect the electric system. 8.8.6 Maintenance to be performed every 2500 hours - Replace the engine breather pipe. TOWING GEAR MAINTENANCE - Service and clean every 10,000 km or every 12 months.

  • Page 49: Scrapping

    BETON MASTER 9 - SCRAPPING 17341 - 561.184 GENERAL INFORMATION Follow 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 50: Troubleshooting

    BETON MASTER 10 - TROUBLESHOOTING 17341 - 561.184 10.1 PROBLEMS WITH THE ELECTRONIC BOARD In case of failures in the electronic board inside the control panel, a pumping job may be completed by manual operation. You can control the pistons' pumping and sucking operations using the small levers (m1-m2) on the side of the control panel.

  • Page 51: Operator's Intervention

    BETON MASTER 10 - TROUBLESHOOTING 17341 - 561.184 10.3 OPERATOR'S INTERVENTION PROBLEMS CAUSES SOLUTIONS • Check the battery charge state and the No electric power supply. main fuse (see wiring diagram). THE CONTROL BOARD DOES NOT • End pumping by acting manually (see...
  • Page 52 BETON MASTER 10 - TROUBLESHOOTING 17341 - 561.184 PROBLEMS CAUSES SOLUTIONS Unsuitable mixture. • Modify the mixture making it more fluid. Mixer grill open. • Close the mixer grill. Insufficient hydraulic oil level. • Top-up the hydraulic oil tank. • Check the hydraulic oil level and clean THE PUMP STOPS.
  • Page 53 BETON MASTER 10 - TROUBLESHOOTING 17341 - 561.184 PROBLEMS CAUSES SOLUTIONS DIRTY WATER IN THE PISTONS • Replace the pumping pistons (see Pumping pistons worn. paragraph 8.2). COOLING TANK. • Press the button (f1) on the control Function not active on the control panel.
  • Page 54 BETON MASTER 10 - TROUBLESHOOTING 17341 - 561.184 This section regards problems that might arise when towing the machine with a vehicle. PROBLEMS CAUSES SOLUTIONS The cylinder returns completely Check brake calibration It eliminates itself after a few braking Brake linings not run-in.
  • Page 55 WARRANTY The machinery manufactured by Turbosol Produzione S.p.A. is guaranteed for a period of twelve (12) months or one thousand (1,000) hours of operation - whichever comes first - from the date said machinery is delivered to the end consumer, and in any event not more than eighteen (18) months from its shipment.

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