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Turbosol Beton Master - User Manual

Turbosol Beton Master
55 pages
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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
OPERATION AND MAINTENANCE MANUAL
BETON MASTER
17341 - 561.184
EN
IT
ORIGINALI

Table of Contents

Questions and Answers

Summary

CE Declaration

CE Declaration of Conformity

Official document confirming the machine meets EU directives and harmonized standards for safety and performance.

General Information

Importance of Manual

Explains the manual's purpose, user responsibilities, and safe storage for effective operation and safety.

Abbreviations

List of common abbreviations used in the manual for technical terms and units of measurement.

Information on Consulting the Manual

Details on how to interpret text formatting, such as boldface, to highlight important information.

Meaning of Symbols

Explanation of safety symbols (Caution, Note, Danger, Important) used throughout the manual to convey critical information.

Machine Off Procedure

Instruction to switch off the engine before performing any maintenance or adjustments on the machine.

General & Contact Information

Provides company contact details, website, email, and information on machine features and customer service.

Technical Description

Machine Identification & Nameplate

Details on the machine's nameplate, CE marking, serial number, and manufacturer identification.

Machine Dimensions & Weight

Specifies the overall dimensions (length, width, height) and gross weight of different BETON MASTER models.

Key Technical Specifications

Lists key technical specifications including flow rate, pressure, particle size, power, capacities, and noise levels.

Machine Intended Uses

Outlines the primary applications of the machine, focusing on construction work and pumping shotcrete and concrete.

Materials Used for Pumping

Specifies the maximum particle size of concrete and shotcrete that the machine can handle.

Machine Parts Identification

Identifies various components of the machine using figures and a detailed legend for easy reference.

Transportation and Handling

Towing Machine as Trailer

Instructions for safely towing the machine, including pre-towing checks and connection procedures.

Machine Lifting Procedures

Guidelines for safely lifting the machine using designated lifting points and equipment, emphasizing safety rules.

Installation Guide

Machine Positioning Requirements

Specifies the requirements for placing the machine on site, including leveling, stability, and clearance for safe operation.

Piping Setup Guidelines

Provides guidance on laying out piping for optimal performance, minimizing wear, and avoiding clogging.

Piping Layout Options

Explains general rules for setting up horizontal, vertical, and downward pumping layouts for slurries.

Fittings and Couplings

Emphasizes the importance of clean and well-maintained fittings, specifically mentioning Victaulic couplings.

Victaulic Coupling Installation

Details on correctly coupling pipe sections using Victaulic couplings, ensuring gasket placement and lever tightening.

System Connections

Instructions for connecting various machine components like the concrete grid, vibrator, and electric systems.

Concrete Grid & Vibrator Connection

Describes how to connect the electric vibrator's plug to the machine's socket for proper operation.

Wired Remote Control Operation

Instructions for connecting and operating the wired remote control for starting, stopping, and reversing the pump.

Shotcrete Version Connections

Specific connection steps for the shotcrete version, including nozzle, grid, vibrator, and air hoses.

Optional Radio Control Connection

Guide on connecting and operating the optional radio remote control for machine functions.

Safety Procedures

Machine Safety Devices

Lists and describes internal safety features like protective grids, carterings, and pressure relief valves.

Safety Signage and Compliance

Information on adhesive labels used for safety warnings, their maintenance, and the prohibition of removal.

Personal Protective Equipment (PPE)

Mandates the use of specific PPE (eye, hearing, hand, foot protection) as indicated by mandatory signs.

Residual Risks and Precautions

Highlights potential risks like high pressure, hot parts, and moving parts, and advises precautions to mitigate them.

Use and Operation

Operating Principle Overview

Explains the core mechanical and hydraulic functions of the BETON MASTER pumping assembly.

Pumpable Slurry Types

Details the types of concrete and shotcrete mixes suitable for pumping and spraying, including mix composition requirements.

Pre-Operation Checks

Essential pre-operation checks including fluid levels (coolant, oil, diesel) and general machine condition.

Control Panel Functions

Overview of the control panel layout, including buttons, indicators, and their functions for operating the machine.

Machine Starting Procedure

Step-by-step instructions for safely starting the machine, including access code entry and preheating.

Accelerator Pump Operation

Details on the optional accelerator pump, its operation modes (auto/manual), and parameter settings for accurate dosing.

Post-Work Cleaning Procedures

Procedures for thoroughly cleaning the machine after use, including piping and hopper, emphasizing safety.

Piping Washing Methods

Methods for washing the piping using water, compressed air, or reverse pumping, including safety precautions.

Important Operational Warnings

Crucial warnings regarding operations like reverse pumping and potential clogging, emphasizing qualified personnel.

Emergency Stop Usage

Guidelines on the correct and safe usage of the emergency stop button to prevent machine damage.

Maintenance Schedule

Operator-Performed Maintenance

Basic maintenance tasks for operators, including checking fluid levels, filters, and general lubrication.

Pumping Piston Replacement

Detailed steps and tools required for replacing the pumping pistons, including safety precautions.

S-Valve Adjustment Procedure

Procedure for adjusting the S-valve to eliminate play and ensure proper sealing, indicating when adjustment is needed.

Wear Disc & S-Valve Replacement

Instructions for replacing key wear components of the S-valve system, requiring machine shutdown.

First Oil Filter Change

Steps for replacing the first hydraulic oil filter, specifying replacement intervals and safety measures.

Second Oil Filter Change

Procedure for replacing the second hydraulic oil filter located inside the tank, including oil refill.

Additive Metering Pump Replacement

Steps for replacing the additive metering pump, including disconnecting components and handling specific parts.

Maintenance by Qualified Personnel

Information that certain maintenance tasks must be performed by qualified technicians as indicated by the machine.

50-Hour Maintenance Tasks

Specific maintenance tasks to be performed after the initial 50 hours of operation, including fluid changes and checks.

Monthly;125-Hour Maintenance

Routine maintenance schedule including oil changes, cleaning, and belt tension checks.

250-Hour Maintenance Tasks

Maintenance tasks required at 250-hour intervals, focusing on wear parts and filters.

500-Hour;6-Month Maintenance

Periodic maintenance covering glow plugs, hydraulic oil filters, and injector cleaning/setting.

1000-Hour;Annual Maintenance

Annual maintenance including hydraulic oil change, S-valve adjustment, and hose inspection.

2500-Hour Maintenance Tasks

Specific maintenance for long-term operation, focusing on the engine breather pipe.

Towing Gear Servicing

Guidelines for servicing and maintaining the towing gear, including brake checks and lubrication.

Scrapping Procedures

General Scrapping Information

Instructions on following local regulations for scrapping the machine and proper disposal of materials and fluids.

Troubleshooting Guide

Electronic Board Issues

Guidance on manual operation procedures in case of electronic control panel failures.

Operator Intervention for Problems

A table listing common problems, their causes, and solutions for operator intervention.

Braking System Not Very Efficient

Troubleshooting for an inefficient braking system, including checks for calibration, linings, and friction.

Reverse Gear Hard or Blocked

Solutions for issues with the reverse gear, such as blocked levers or incorrect calibration.

Brake Overheating in Start Direction

Addresses brake overheating, suggesting checks for friction, rust, and proper adjustment.

Parking Brake Not Very Efficient

Troubleshooting for an inefficient parking brake, covering run-in linings and component friction.

Irregular and Jerky Braking

Solutions for jerky braking, including calibration and checks for gas springs and shock absorbers.

Decelerating Trailer Brakes Excessively

Addresses excessive deceleration of trailer brakes, suggesting calibration and lubrication of components.

Height Adjustment Difficulty

Solution for difficult height adjustment, involving cleaning and lubricating joints.

Balancing Issues (No Balancing)

Troubleshooting for balancing issues, focusing on gas springs and proper coupling torque.

Operator Responsibility & Warranty

Operator Responsibility Details

Defines the operator's duty to ensure awareness of manual instructions and proper machine usage.

Machine Warranty Terms

Outlines the manufacturer's warranty terms, coverage, conditions, and exclusions for the machinery.

Turbosol Beton Master Specifications

General IconGeneral
BrandTurbosol
ModelBeton Master
CategoryConstruction Equipment
LanguageEnglish

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