Turbosol Beton Master User manual

Serial number Year
OPERATION AND MAINTENANCE MANUAL
BETON MASTER
IS19/07 - 561270
EN
ORIGINAL

INDEX
1 - CE DECLARATION..................................................................................................7
1.1 CE DECLARATION OF CONFORMITY........................................................................................7
2 - GENERAL INFORMATION ......................................................................................9
2.1 IMPORTANCE OF MANUAL.........................................................................................................9
2.2 ABBREVIATIONS..........................................................................................................................9
2.3 INFORMATION ON CONSULTING THE MANUAL......................................................................9
2.4 MEANING OF SYMBOLS..............................................................................................................9
2.5 MACHINE OFF.............................................................................................................................10
2.6 GENERAL AND CONTACT INFORMATION..............................................................................10
3 - TECHNICAL DESCRIPTION..................................................................................11
3.1 NAME OF MACHINE...................................................................................................................11
3.2 DIMENSIONS OF MACHINE.......................................................................................................12
3.3 TECHNICAL DATA......................................................................................................................12
3.4 INTENDED USES ........................................................................................................................13
3.5 MATERIALS USED......................................................................................................................13
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 Connecting the radio control (optional)...................................................................................23
6 - SAFETY..................................................................................................................25
6.1 SAFETY DEVICES.......................................................................................................................25
6.2 SAFETY SIGNS...........................................................................................................................26
6.3 PERSONAL PROTECTIVE EQUIPMENT...................................................................................26
MANDATORY SIGNS ...................................................................................................................................26
DESCRIPTION..............................................................................................................................................26
6.4 RESIDUAL RISKS .......................................................................................................................26
7 - USE AND OPERATION..........................................................................................29

7.1 OPERATING PRINCIPLE............................................................................................................29
7.2 PUMPABLE SLURRIES..............................................................................................................29
7.3 CHECKS BEFORE START-UP...................................................................................................30
7.4 CONTROLS.................................................................................................................................32
7.5 STARTING THE MACHINE.........................................................................................................34
7.6 CLEANING THE MACHINE AFTER A WORK SESSION...........................................................35
7.6.1 Washing the piping....................................................................................................................36
- FLUSHING WITH WATER...........................................................................................................36
- FLUSHING WITH COMPRESSED AIR.......................................................................................37
- CLEANING BY REVERSE PUMPING.........................................................................................37
7.7 IMPORTANT WARNING .............................................................................................................37
8 - MAINTENANCE......................................................................................................39
8.1 MAINTENANCE TO BE CARRIED OUT BY OPERATOR..........................................................39
- CHECKING THE LUBRICATION WATER LEVEL .....................................................................39
- CHECKING THE ENGINE COOLANT LEVEL............................................................................39
- CHECKING THE MOTOR OIL ....................................................................................................39
- CHECKING THE ENGINE AIR FILTER ......................................................................................39
- CHECKING THE DIESEL FUEL LEVEL.....................................................................................39
- CHECKING THE HYDRAULIC OIL LEVEL................................................................................40
- AT THE END OF A WORK SESSION.........................................................................................40
8.2 REPLACING THE PUMPING 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 to be performed every six months or every 500 hours....................................49
8.7.5 Maintenance to be performed every year or every 1000 hours .............................................49
8.7.6 Maintenance to be performed every 2500 hours.....................................................................49
8.8 TOWING GEAR MAINTENANCE................................................................................................49
9 - SCRAPPING...........................................................................................................51
9.1 GENERAL INFORMATION..........................................................................................................51
10 - TROUBLESHOOTING .........................................................................................53
10.1 PROBLEMS WITH THE ELECTRONIC BOARD........................................................................53
10.2 PUMPING SYNCHRONISM RESET ...........................................................................................53
10.3 OPERATOR'S INTERVENTION..................................................................................................54
11 - RESPONSIBILITY OF THE OPERATOR.............................................................57
11.1 RESPONSIBILITY .......................................................................................................................57

11.2 WARRANTY.................................................................................................................................57

CE DECLARATION
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1 - CE DECLARATION
1.1 CE DECLARATION OF CONFORMITY
An original copy of the CE Declaration of Conformity is supplied separately from the manual.

1
CE DECLARATION
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GENERAL INFORMATION
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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.

2
GENERAL INFORMATION
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2.5 MACHINE OFF
The motor must be switched off using the ON/OFF key before performing any maintenance and/or adjustment operation (FIG.
35-REF. 1).
2.6 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.R.L. will be glad to provide any information you may need.
TURBOSOL MACHINES
Turbosol machines are the result of years of experience and constant research. This wealth of expertise, together with a
special 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 perfect running
order and to preserve the validity of the warranty.
SAFETY
The safety rules should also be made known to the maintenance personnel, and the local regulations on safety and accident
prevention should be followed at all times.
OPERATOR TRAINING
Operators must receive specific training on the operations to be carried out.
TURBOSOL SERVICE
Please contact your TURBOSOL dealer for any information regarding machine malfunctions or requests for spare
parts.

TECHNICAL DESCRIPTION
3
561270 - IS19/07 - EN 11/58
3 - TECHNICAL DESCRIPTION
3.1 NAME OF MACHINE
CE Marking
123
kg k
FIG. 01
The series (1), the machine model (2) and the machine's serial number (3) and the power data are engraved on the plate.
Below is the meaning of the used symbols.
(1) = Machine series.
(2) = Machine model.
(3) = Machine'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 identification data plate (FIG.03-REF.2) is
present in the versions fitted with road approved tow.
1
2
2
3
3
1
FIG.02 FIG.03

3
TECHNICAL DESCRIPTION
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3.2 DIMENSIONS OF MACHINE
The following are the machine's overall dimensions and gross weight (in working conditions).
BETON MASTER D
LENGTH WIDTH HEIGHT WEIGHT*
3335 mm 1420 mm 1600 mm 1560 kg
TAB. 02:
BETON MASTER D/T
LENGTH WIDTH HEIGHT WEIGHT*
4555 mm 1420 mm 1600 mm 1720 kg
TAB. 03
*Weight with full fuel tank and hydraulic oil tank and no optional accessories.
3.3 TECHNICAL DATA
Flow rate* m
3
/h 15
Maximum pressure on the concrete bar 80
Maximum number of cycles per minute - 30
Pumping cylinders (diameter x stroke) mm 120 x 700
Input power kW 37.3
Electric control plant power supply V 12 AC
Main hydraulic circuit maximum pressure bar 240/190
Auxiliary hydraulic circuit maximum pressure bar 180
Maximum particle 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 -5° ÷35°
Guaranteed sound power level LwA dB 108
Equivalent continuous A Lp-weighted sound pressure level dB 88
Endothermic motor: PERKINS 404D-22
Power kW 37.3
Motor rpm minimum rpm 1550
maximum 2900
Motor oil (recommended) TOTAL RUBIA TIR 7400
Endothermic motor: PERKINS 403D-15T
Power kW 37.3
Motor rpm minimum rpm 1550
maximum 2900
Motor oil (recommended) TOTAL RUBIA TIR 7400
TAB. 04
* Theoretical.
** Maximum particle size 25 mm if aggregates obtained by crushing; maximum particle size 30 mm in case of spheroidal
aggregates.
*** Maximum values not simultaneously obtainable.

TECHNICAL DESCRIPTION
3
561270 - IS19/07 - EN 13/58
3.4 INTENDED USES
The machine has been designed and built for the following use:
FIELD OF USE: CONSTRUCTION WORK.
INTENDED USE: PUMPING SHOTCRETE AND CONCRETE
3.5 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.
3.6 NAME OF MACHINE PARTS
1
2
3
4
56
7
8
910
11
12
FIG. 04 *Figure shows towing gear.
13
14
15 16
18
23
19
21
20
22
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-REF. 7 - Towing gear*
FIG. 04-REF. 8 - Exchanger
FIG. 04-REF. 9 - Engine
FIG. 04-REF. 10 - Hydraulic pump assembly
FIG. 04-REF. 11 - Mixer
FIG. 04-REF. 12 - Lower hopper
FIG. 05-REF. 13 - Delivery flange
FIG. 05-REF. 14 - S-valve
FIG. 05-REF. 15 - S-valve switching jack
FIG. 05-REF. 16 - Pumping tube
FIG. 05-REF. 17 - Water tank

3
TECHNICAL DESCRIPTION
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TRANSPORTATION AND HANDLING
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4 - TRANSPORTATION AND HANDLING
4.1 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.
The machine cannot be used for carrying loads of any kind, not even the removable accessories used for
its operation (pipes, fittings, gaskets, etc.).
What to do before towing the machine
- Make sure the diesel engine is switched off.
- Remove all pipes and hoses connected to the machine.
- Close and fasten the casing and check the fasteners.
- Lower the towing wheel and raise the support legs (FIG. 06).
- Fasten the light bar in its towing position (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° and downward by 10° until it reaches the limit.
- Tighten and lock the handle.
- Insert the safety pin.
- Turn the lever to raise the towing wheel (FIG. 07-REF. 4).
- After approximately 50 km, stop and tighten the handle again.
- Connect the light bar cable and make sure it works.
- Insert the snap cable through the eyelet welded on the side (guide cable grommet) (FIG. 08-REF. 1) and fasten the snap hook
to the hole (FIG. 09).
Make sure the cable is long enough to handle bends in the road. If the cable is too short it might
accidentally pull the brake.

4
TRANSPORTATION AND HANDLING
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If there is no eyelet on the towing vehicle, wrap the cable around the stem of the trailer hitch and attach the snap
hook to the cable itself. If the trailer is accidentally detached from the vehicle, the cable will pull the parking brake
(emergency brake). The cable must be correctly passed through the cable guide grommet in order for the
emergency brake to work
properly.
FIG.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; 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.

TRANSPORTATION AND HANDLING
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561270 - IS19/07 - EN 17/58
4.2 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. 10-REF. 2 and the longer ropes to the hooks shown in FIG. 10-REF. 3.
Use the lifting beam only for the lifting of Beton Master.
Don't use the lifting beam to lift any other load. Before using the lifting beam, check its integrity and in case 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.
Do not stand under suspended loads. To prevent damages to the machine, do not lift or lower it with abrupt
movements. Do not change the lifting hook's anchoring point. Move the machine only over level surfaces; avoid
sloping surfaces to prevent the risk of being hit by the machine or crushed between the machine and fixed obstacles.

4
TRANSPORTATION AND HANDLING
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INSTALLATION
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561270 - IS19/07 - EN 19/58
5 - INSTALLATION
5.1 POSITIONING THE MACHINE
Place the machine in a horizontal position; the maximum allowed gradient is 5°, both lengthwise and crosswise (FIG. 11).
140 cm 140 cm
120 cm
120 cm
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.
Be sure to leave a passageway all around the machine (FIG12) clear of any obstacles and with no potholes
or hazardous projections.
Do not use the towing wheel to support the machine during operation; the machine should rest on 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 separate from the
concrete) and increase the risk of clogging.
Use only original pipes and fittings. The pipes should be fitted by TURBOSOL PRODUCTION S.R.L. or by
companies expressly authorized by TURBOSOL.
TURBOSOL PRODUCTION S.R.L. shall not be held responsible for damages to persons or property caused by using
non-original piping or fittings.
Before starting to pump, make sure the hoses show no cracks or deformations on their inner surface.
Deformations on the inner surface of rubber hoses can lead to dangerous clogging.

5
INSTALLATION
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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.
1
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.
- VERTICAL PUMPING
Vertical sections should be fastened and supported by collars (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:
- introduce two pipe sponges into the first section of the piping (FIG. 16)
- pump the slurry
This will lubricate the entire downward section. If the downward section is very long, we recommend pumping additional
sponges and slurry.
1
2
BOIACCA
SPUGNE
DI LAVAGGIO
FIG.15 FIG.16