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brinkmann - Ramirent

1. nenne 4 23 TEN nase teen rent 4 24 FOncHionichecks n anne 4 24 Shutting down the machine after operation 4 26 Notes on winter operation 4ssnneensenennnnnnnnenn 4 26 Operation Shutting down in an emergency een 5 1 5 1 1 Re RENNER a T 5 2 Safety measures during normal operation 5 3 Checks before starting een 5 3 Interruptions IN work an 5 3 Binder in your eyes nnneseneennnnnnneneennnnen 5 3 Control panel on the machine nen 5 4 Digital control panel nenn 5 4 Analogue control panel 5 4 Control panel buttons een 5 5 Indicator lamps on the control pane 5 5 Covered buttons digital control 5 6 Special functions digital control 5 7 Fault display digital control n 5 7 Starting the machine nenn 5 9 ManSWICh ee een 5 9 Starting the diesel engine ene 5 10 Switching off the diesel engine 0 5 10 Operating the loader nnnnnn 5 11 Operating the scraper ccc ccccccesseeeeeceesetssssueeeeecesttaees 5 12 Cable Operation nun 5 13 Charging the battery ennennnnenen 5 13 Closing the cover on the mixing tank
2. 5 14 Opening the cover on the mixing tank sses 5 15 Manual depressurisation nennen 5 15 Loading the mixing tank nennen 5 16 OODFO01_0608_en Table of contents OODFO01_0608_en 5 13 5 14 5 15 5 16 5 17 5 18 5 19 5 20 5 21 6 1 6 2 BRINKMANN MASCHINENFABRIK GMBH amp CO KG Delivering material Generating tank pressure 5 17 Mixing mechanism button eenne 5 17 Flotation air button en 5 17 Adjusting the header and flotation air 5 18 Delivery types Maximum delivery pressure 5 19 Adjusting the air valves in line with the delivery type eeenensnnneenenenneneennenne 5 19 Adjusting the ventilation pressure 5 19 Detaching hose couplings after a delivery cycle 5 20 Delivery stops Blockages nennen 5 21 Locating and eliminating blockages 5 21 Stubborn blockages nn 5 22 Most frequent causes of blockages 5 23 Stopping material delivery 5 24 FiINIShINg WOK 2 sccm cvsunnadadinacacaentsgnyaedantinetenivaraciniacts 5 24 Cleaning ae eos caasecn ccnp cd ieee HBEINREG CETRIRARCEIRAENEENEELDRENONEEBERRHAR 5 25 Generalis renare ERSTER ERS RE SERERDEIERTIRENEERGERRAEENNENE 5 25 Cleaning the mixing tank nenn 5 26 Automatic mixing tank cleaner
3. 7 56 WK12 001_0605en Maintenance card 13 001 Hoses Hoses me S A Preparation BRINKMANN MASCHINENFABRIK GMBH amp CO KG Page 1 of 2 This maintenance card describes how to check the hoses and replace faulty hoses Refer to the maintenance tables in Chapter 7 2 Mainte nance intervals for details of the maintenance intervals No further maintenance cards are required No special tools required Note pe Replace the hoses if damaged only slightly or at the smallest sign of im minent damage Consider the effect of strong sunlight the action of heat and the effects of chemicals Caution There is an increased risk of injury when the machine is operated with the hood open There is a risk of burns from hot machine components Make sure that machine does not pose any kind of danger when open Do not operate the machine with the hood open for longer than neces sary Machine cooling is at its most efficient when the hood is closed Complete the following tasks before inspecting the hoses Start the machine before inspecting the hoses Leaks in the air lines can be detected only when the machine is running leaks in the oil lines are easy to spot When checking the hoses while the machine is running e g the air lines do not reach into moving machine parts and remember to avoid touching hot machine surfaces gt Shut down the machine before starting work Chapter 7
4. Significant decrease in cleaning time approx 30 minutes per day Reduced maintenance costs because the removal of material from the mixing tank prevents potential damage O3DF001_0608_en 4 Transport and connection BRINKMANN MASCHINENFABRIK GMBH amp CO KG 4 Transport installation and connection 4 1 Loading O4DF001_0605_en This chapter contains information concerning safe transportation of the machine as well as a description of work necessary for the installation and connection of the machine Steps required to start the machine will not be described until the chapter Starting up Always observe the general safety regulations included in this operating manual when handling the machine see Chapter 2 Safety regulations Outside Germany separate permission may have to be obtained depending on the country and its regulations The registration regulations applicable in the country of use shall always apply When loading the machine with a crane use the central lifting eye provided This will ensure that the machine remains horizontal secure in the hook and will not tip when suspended 1 Central lifting eye Danger of crushing Hoists lifting equipment support trestles and other auxiliary devices must be reliable and safe in operation Make sure that the load bearing capacity is sufficient The machine must only be loaded onto a suitable transport vehicle and must be secured against rolling slid
5. BRINKMANN MASCHINENFABRIK GMBH amp CO KG 7 Maintenance This chapter contains information on the maintenance work necessary for safe and efficient operation of the machine You will find the maintenance cards necessary for the machine after the general maintenance information We would like to emphasise here that all specified checks inspections and preventive maintenance work must be conscientiously carried out Otherwise we will refuse any liability or warranty claim Our After Sales department would be glad to provide you with advice and help at any time should you be in doubt 7 1 Safety instructions When maintaining the machine always observe the general safety regulations included in this operating manual Chapter 2 Safety require ments For safety reasons perform maintenance work on the machine only when shut down depressurised and secured against unauthorised inad vertent starting Should you require a different operating status for the machine while maintenance work is performed e g with the engine running this is noted on the relevant maintenance card with a descrip tion of the exact procedure Also observe the following points Always use undamaged tools that are suitable for the task Use only original spare parts Never clean machine components with flammable solvent or tetra chloromethane Wear the necessary protective clothing Continued on next page 07DF001_0605_en 7 1 7 Mainte
6. Permitted drawbar load The maximum drawbar load of the machine is imprinted in the ball head coupling Danger Check whether the vehicle coupling is designed to withstand the drawbar load of the machine Never tow the machine with a negative drawbar load as this will affect the stability of the trailer A negative drawbar load may result from poor cleaning or incorrect loading of the machine Clean the machine thoroughly before driving off The machine must be empty during transportation O4DF001_0605_en 4 9 4 Transport and connection Coupling the machine BRINKMANN MASCHINENFABRIK GMBH amp CO KG Before towing attach the coupling on the machine correctly to the trailer coupling on the towing vehicle and lock The parallel adjuster must be adjusted accordingly Attach machines with a DIN trailer coupling ring in accordance with the specifications provided by the manufacturer of the towing vehicle or the coupling Attach machines with a ball head coupling as follows gt Attach the breakaway cable Chapter 4 2 Breakaway cable gt The lever 1 must be in the top position prior to attachment The coupling indicator 2 must be red Position the machine coupling over the ball head on the vehicle coupling drive the vehicle close enough Wind up the support wheel until the drawbar load of the machine causes the coupling to audibly engage Then wind up the support wheel fully fold in and secure The c
7. Cause Remedy EMERGENCY STOP button Unlock the EMERGENCY STOP button Pull and turn the button pressed display indicates OFF Restart protection Restart protection active Wait until the LED stops flashing 30 sec Start the LED on the ON button I flashes engine Protective grille open Close the protective grille Check the circuit breaker and wiring replace if Protective grille indicator lamp necessary flashes Low battery power Check electrolyte level and charge battery Replace faulty battery Maintenance card 04 001 Battery ON button faulty Check electrical system control Magnetic switch on the starter is Replace the magnetic switch on the starter faulty Engine starts but then switches off by itself Cause Cause Fuel tank empty Check the level in the fuel tank and fill up if necessary Engine indicator lamp flashes The engine is monitored by engine oil pressure and engine temperature sensors If these sensors send critical values to the control the control switches off the engine as a precaution Faults indicated during the engine oil Check the engine oil level engine oil filter and engine oil pipes Replace faulty pressure or engine temperature test lines and clogged filter top up the engine oil if necessary If the oil filter is clogged the oil will most probably need changing Maintenance card 08 001 Engine Inspect cooler for dirt defects Check that the fan is functioning
8. 12 pin 312 007 2571 24V On 7 pin 8 312 000 0903 O4DF001_0605_en 4 Transport and connection Support wheel O4DF001_0605_en BRINKMANN MASCHINENFABRIK GMBH amp CO KG Wind up fold away and secure the support wheel on the machine before driving off Likewise fold down secure and wind down the support wheel before setting up the machine Proceed as follows Winding the support wheel up and down Fold out the crank 1 gt Wind up the support wheel Turn the crank 1 clockwise Wind down the support wheel Turn the crank 1 anticlockwise gt Fold down the crank 1 again Folding in the support wheel Pull the safety clasp 2 to release and fold the support wheel upwards The support wheel must audibly engage into position Folding out the support wheel Pull the safety clasp 2 to release and fold the support wheel downwards The support wheel must audibly engage into position Caution Wind up fold away and secure the support wheel in this position before driving off Likewise fold out wind down and secure the support wheel in this position before starting work TN 4 Transport and connection Handbrake Chocks BRINKMANN MASCHINENFABRIK GMBH amp CO KG The handbrake secures the machine at the set up site When the automatic reversing device engages the machine rolls backwards the brake automatically clamps the wheel brake
9. Maintenance card 04 001 Battery Preparation Checking the acid level Charging the battery BRINKMANN Page 2 of 3 MASCHINENFABRIK GMBH amp CO KG Complete the following tasks before maintaining the battery gt Shut down the machine before starting work Chapter 7 6 Shutting down the machine Fill the battery with electrolyte up to the mark or approx 10 15 mm above the lead plates Proceed as follows to check the acid level Put on protective equipment Open all the cells in the battery and check the acid level visually gt If required fill the cells with distilled water up to the mark or approx 10 15 mm above the lead plates Close all the cells again your protective equipment is no longer re quired This section describes how to recharge the battery using a standard charger Read the operating instructions accompanying the charger Charge slowly if possible Calculate a safe charging current in A by dividing the battery capacity in Ah by 20 Proceed as follows to charge the battery gt Disconnect both battery cables Put on protective equipment Open all the cells in the battery check the acid level visually and fill with distilled water if necessary gt Connect the charger to the battery and allow battery to charge see operating instructions accompanying the charger gt Disconnect the battery when charged Check the acid level in each cell visually and fill wit
10. _______ __ __ ______ ____ __ Before maintenance work can be performed the engine and the main switch must be switched off the EMERGENCY STOP button pressed and the machine secured against unauthorised inadvertent starting Serious or fatal injuries may be the consequence if the machine starts up unex pectedly Disconnecting the battery is the only sure way to prevent the engine from starting and machine parts from moving Always disconnect the battery before performing maintenance work on moving parts 07DFO01_0605_en 7 Maintenance 72 Maintenance intervals Daily maintenance tasks BRINKMANN MASCHINENFABRIK GMBH amp CO KG The following table shows the intervals for the various maintenance tasks Refer to the relevant maintenance cards for a list of necessary tasks Note Have the initial after sales service carried out by a Brinkmann Maschi nenfabrik GmbH amp Co After Sales service engineer or by a dealer authorised by Brinkmann Maschinenfabrik GmbH The operator respon sible for the machine should be present to obtain a better insight into how to perform maintenance work on the machine Task Check the seal on the mixing tank cover Measurement and inspec tion equipment operating and auxiliary materials Comment The seal should not be perforated Material should not be embedded in the seal Replace seal if necessa ry Check that the delivery hoses and couplings are in perfect
11. eEoe GD KDD 14 6 8 9 10 11 4 5 4 O5DF001_0608_en 5 Operation Buttons on the control panel Indicator lamps on the control panel 05DF001_0608_en 00906 Gis BRINKMANN MASCHINENFABRIK GMBH amp CO KG 1 ON button Press this button to start the machine 2 OFF button Press this button to switch the machine off 3 Mixing mechanism button ON OFF Press this button to switch the mixing mechanism on or off manually 4 Flotation air button ON OFF Press this button to switch the flotation air supply on or off manually 14 Central lubrication system button analogue control The central lubrication system is actuated manually and lubricates the lubrication points until the button is released 5 Scraper remote control indicator lamp digital control Lights up when the scraper remote control is actuated 6 Air filter indicator lamp Lights up when the air filter is clogged 7 Maintenance indicator lamp digital control Lights up every 500 operating hours 8 Charge monitor indicator lamp Lights up when the machine battery is not charging 9 Engine indicator lamp Lights up when the engine oil pressure or engine temperature are too high 10 Compressor temperature indicator lamp Lights up when the compressor overheats 11 Protective grille indicator lamp Lights up when the protective grille is open 12 Display digital control 13 Cover digital control Remove only when the covere
12. 75 Operating materials compressor Check the compressor oil level Close the filler neck 2 tightly gt Inspect for leaks 7 45 Maintenance card 09 001 Compressor Changing the compressor oil filter 3 Page 4ofs Dees BRINKMANN MASCHINENFABRIK GMBH amp CO KG Proceed as follows to change the compressor oil filter gt Shut down the machine before starting work Chapter 7 6 Shutting down the machine gt Make sure that the compressed air tank is depressurised Have a suitable container ready to collect the used oil gt Loosen the filter cartridge 4 using a suitable oil filter wrench and unscrew Collect any escaping oil in the container gt Dispose of the old filter cartridge 4 and collected oil in accordance with regulations Clean any dirt from the sealing surfaces on the filter carrier Make sure that dirt does not enter the oil system Apply a light coating of oil to the seal on the new filter cartridge 4 gt Screw on the new filter cartridge 4 by hand until the seal rests on the sealing surface gt Tighten the filter cartridge 4 another half a turn gt Check the oil level gt Inspect for leaks WKO09 001_0605en Maintenance card 09 001 Compressor BRINKMANN PageSofs jos MASCHINENFABRIK GMBH amp CO KG Check for leaks WK09 001_0605en The following checks are necessary after changing the compressor oil or compresso
13. DIN EN 590 Fill fuel up to the max mark if necessary Check that the hood is locked and secured properly before setting off Check that the tailgate bracket is attached correctly and is fully functional before setting off Replace bulbs or the cable if necessary Secure the loader with the securing chain before starting your journey Place the scraper in the holder on the loader and secure with split pins before setting off Every 40 operating hours Weekly maintenance tasks in addition to daily maintenance tasks Machine with loader scraper Task Check the tyre pressure condi tion of the tyres and the tread depth Measurement and inspec tion equipment operating and auxiliary materials Comment Check the brakes breakaway cable overrunning brake equip ment and coupling Check all power and V belts Tighten Replace if necessary Check the tapered nipple on the automatic cover Continued on next page Clean if necessary Have Brinkmann readjust or replace the nipple 07DFO01_0605_en 7 Maintenance BRINKMANN MASCHINENFABRIK GMBH amp CO KG Every 40 operating hours Weekly maintenance tasks in addition to daily maintenance tasks Task Lubricate all weekly lubrication points Measurement and inspec tion equipment operating and auxiliary materials Grease gun multipurpose grease DIN 51502 KPF 2C Comment MC 02 001
14. Disconnecting the battery is the only sure way to prevent the engine from starting and machine parts from moving Always disconnect the battery before performing maintenance work on moving parts Operating the machine after an EMERGENCY STOP gt Reconnect the battery gt Unlock the EMERGENCY STOP button by pulling and turning 7 Maintenance 7 7 Maintenance kits Maintenance kit six monthly 500 operating hours BRINKMANN MASCHINENFABRIK GMBH amp CO KG Brinkmann has prepared maintenance kits for the Trans Mix DC 260 45 The maintenance kits include all the original Brinkmann spare parts required for the respective maintenance task Maintenance kits are avai lable for six monthly 500 hrs and annual 1000 hrs maintenance tasks Brinkmann accepts no liability for the use of non original spare parts Brinkmann single part order no 200 117 4416 212 900 0687 530 318 2415 212 914 9310 414 614 2200 350 121 0194 350 121 0196 219 712 0104 Kit consists of 1 Engine oil filter 1 Fuel filter 1 Copper ring 1 Air filter cartridge 1 Power belt 2 Sealing pistons complete 2 Compression springs 1 Preliminary fuel filter Maintenance kit annual 1000 operating hours Brinkmann maintenance kit order no Overview of maintenance kit compon ents 800 010 51 Brinkmann single part order no 200 117 4416 212 900 0687 211 612 3980 530 318 2415 200 417 9846 210 661 1028 200 601 501
15. Filling hopper Mixing tank Tailgate bracket Loader Scraper O3DF001_0608_en BRINKMANN MASCHINENFABRIK GMBH amp CO KG 3 Technical description 3 5 Technical data The technical data and features listed below relate to the DC 260 45 55 B and BS DC 260 45 DC 260 45 B DC 260 55 DC 260 55 B DC 260 55 BS Dimensions Length 4470 mm 4850 mm Width 1495 mm Height 1540 mm 2120 mm Filling height 940 mm at hopper 420 mm at loader Weights Weight full tank 45 1540 kg 45 1710 kg 45 1875 kg 55 1550 kg 55 1720 kg 55 1885 kg Tyres Tyre size 185 R14C 205 R14C Wheel 5 2 Jx 14 H2 Inflation pressure 4 5 bar Tightening torque of wheel bolts Ball collar screws 90 Nm Chassis Tow hitch as ordered Trailer coupling ring as per DIN 74054 Part 1 EC test code 00 0241 or ball head coupling EC test code 00 0131 Permitted driving speed In accordance with regulations in the country of use Caution Do not exceed the statutory maximum speed in the country of use DC 260 45 DC 260 45 B DC 260 45 BS DC 260 55 DC 260 55 B DC 260 55 BS Operating materials Engine oil Fluid volume BP Vanellus E6 15W 40 with filter change 6 5 Transmission fluid Fluid volume Texaco Meropa 680 ISO VG 680 31 Compressor oil Fluid volume BP Energol HLP HM 46 SHELL Corona AS 46 at 10 6 5 Fuel Fluid volume Diesel fuel DIN EN 590 55 Hydraulic fluid Flui
16. O5DF001_0608_en 5 Operation Automatic mixing tank cleaner optional 05DF001_0608_en BRINKMANN MASCHINENFABRIK GMBH amp CO KG The purpose of the automatic mixing tank cleaner is to clean the inside of the mixing tank at the end of the delivery cycle or when work is com pleted This helps to prevent the formation of material deposits in the mixing tank especially when mixing quick setting material gt Connect the water supply hose to the quick release coupler 1 on the mixing tank cleaner and establish the water supply gt Move the mixing tank cleaning high pressure cleaner valve 2 to the left position mixing tank cleaning At the end of the delivery cycle after the mixing tank is depressurised leave the cover on the mixing tank closed The mixing shaft must be switched on gt Wear protective goggles Caution Do not run the water pump dry as it will become damaged Make sure the water supply is established before switching on the water pump Always switch off the water pump at the ball valve 3 before cutting off the water supply gt Move the ball valve 3 to the lower position to switch on the water pump and start mixing tank cleaning Allow the tank cleaning cycle to run for a few minutes depending on the amount of deposits Danger Never open the mixing tank cover while the automatic mixing tank clea ning cycle is in progress Water and material spraying out under pressu re may c
17. Open the compressor oil filler neck 2 on the compressed air tank one turn This will allow any residual pressure to escape safely Then open the filler neck 2 completely 1 WKO09 001_0605en Maintenance card 09 001 Compressor Changing the compressor oil WK09 001_0605en Be Page30f5 jos BRINKMANN MASCHINENFABRIK GMBH amp CO KG gt Fill compressor oil up to the top green area on the inspection glass 7 5 Operating materials compressor As a precaution use the same compressor oil that you are already using in the machine Note down the exact oil grade Check the compressor oil level Do not fill above the green area Excessive oil increases oil consumption Close the filler neck 2 tightly Proceed as follows to change the compressor oil Start the engine and allow the compressor to heat to operating tem perature Shut down the machine before starting work Chapter 7 6 Shutting down the machine gt Make sure that the compressed air tank is depressurised Place a suitable container under the oil drain plug 3 on the com pressor and the compressor oil cooler gt Unscrew the oil drain plug 3 The old compressor oil drains out Open the oil filler 2 to accelerate the draining process gt Once the oil has drained completely screw in the oil drain plug 3 with a new sealing washer and tighten torque 55 Nm gt Fill fresh compressor oil into the filler neck 2
18. Scraper remote control with battery Charger Radio receiver 05DF001_0608_en 5 13 BRINKMANN 5 Operation MASCHINENFABRIK GMBH amp CO KG 5 7 Closing the coveron Use a hand brush to clean the edge of the filling dome and cover the mixing tank Close the cover on the dome of the mixing tank Fig A Danger Replace the rubber seal on the cover immediately if larger cracks appear or if material is embedded in the seal There is the danger that the cover will not close properly and be thrown open violently by the pressure in the mixing tank Pull the locking latch over the sliding gate Fig B Push the lever on the locking latch downwards as far as it will go Fig C The cover on the mixing tank is closed Fig D Pressure required to pump the material has not yet started to build up in the mixing tank 5 14 O5DF001_0608_en 5 Operation 5 8 Opening the cover on the mixing tank 5 9 Manual depressurisation automatic cover BRINKMANN MASCHINENFABRIK GMBH amp CO KG Should you need to open the cover on the mixing tank you must first establish that the mixing tank is depressurised The mixing tank depres surises automatically at the end of a delivery cycle However the mixing tank can be depressurised manually at any time see 5 9 Manual de pressurisation The procedure for opening the cover is the sa
19. Unscrew the top cover 3 on the fan 2 to make both cooling ele ments 1 accessible 2 screws gt Wear protective goggles Dust or dirt particles may get in your eyes when cleaning with compressed air high pressure cleaners or steam jets Clean the oil cooler 1 as follows gt Blow any light dirt from the fins on the cooling elements 1 with compressed air low pressure gt Wash larger amounts of dirt off the fins on the oil cooler 1 with wa ter You may also use pressure washer and steam jets low pressure Clean the fan 2 and fan housing with a slightly moist lint free cloth After cleaning with the moist cloth blow the oil cooler 1 with com pressed air low pressure gt Fit the cover 3 back on the fan 2 WKO7 001_0605en Maintenance card 08 001 Engine Engine oil Engine oil filter WK08 001_0605en BRINKMANN MASCHINENFABRIK GMBH amp CO KG Page 1 of5 This maintenance card describes how to check the engine oil level and change the engine oil and the engine oil filter Refer to the maintenance tables in Chapter 7 2 Maintenance intervals for details of the maintenance intervals The intervals specified apply for normal machine use When operating the machine at high ambi ent temperatures in very dusty or humid conditions more frequent oil changes are recommended Use only engine oils specified in Chapter 7 5 Operating materials engine No further mai
20. condition Replace at the first sign of damage Replace the delivery hoses after using for a maximum of 3 months Check all safety devices Check whether all safety devices are installed and are functioning correctly Visual check of the whole machine for obvious defects MC 01 001 Visual check Pay special attention to cabling lines seals and corrosion Lubricate all daily lubrication points Grease gun multipurpose grease DIN 51502 KPF 2C MC 02 001 Lubrication diagrams Check the compressor oil level BP Energol HLP HM 46 at 10 C SHELL Corona AS 46 MC 09 001 Compressor Fill up to the max mark if neces Sary Check the engine oil level Fill up to the max mark if necessary 15W40 for diesel engine 10W40 for turbo engine MC 08 001 Engine If an automatic central lubrica tion system is fitted check the fluid level Continued on next page 07DF001_0605_en Multipurpose grease DIN 51502 KPF 2C MC 03 001 Central lubrication system Check whether the container is sufficiently full Fill grease up to the max mark if necessary 7 Maintenance Daily maintenance tasks BRINKMANN MASCHINENFABRIK GMBH amp CO KG Task Check the air filter Measurement and inspec tion equipment operating and auxiliary materials Comment MC 05 001 Air filter Clean Replace if necessary Check the fuel level Level indicator on the fuel tank Diesel
21. on the overrunning brake equipment are seated securely Measurement and inspec tion equipment operating and auxiliary materials Comment Chapter 7 4 Tightening torques Use a torque wrench Tighten the wheel nuts evenly at diagonals adjust the tyre pressure Specialist workshop Chapter 7 4 Tightening torques Use a torque wrench Retighten if necessary Every 10 000 15 000 km check the shock absorbers on the overrunning brake equip ment for oil loss power loss and air leaks Specialist workshop Have repaired Every 10 000 15 000 km check the pneumatic springs fitted to the adjusting aid on the overrunning brake equipment Specialist workshop Have repaired Every 10 000 15 000 km check the play around the tension bar on the overrunning brake equipment Specialist workshop Maximum play 1 5 mm Have repaired Every 10 000 15 000 km check the brake system settings and the wear on the brake pads Specialist workshop Have adjusted replaced if necessary Every 10 000 15 000 km check that the handbrake functions correctly and the handbrake seals are tight Continued on next page 07DF001_0605_en Specialist workshop Have repaired 7 Maintenance BRINKMANN MASCHINENFABRIK GMBH amp CO KG Maintenance work on the chassis Task Every 10 000 15 000 km check that the guide for the bre akaway cable is secure and that the breakaway cable func
22. the screed in the mixing tank may harden and will no longer discharge If you intend to stop work for longer periods empty the mixing tank and the delivery hoses to prevent the screed from hardening there Pro ceed as described in Chapter 5 16 Stopping material delivery or Chapter 5 17 Finishing work Binding agent in the Binder Cement is aggressive and may damage your eyesight If binder or eyes sprayed material get in your eyes proceed as follows immediately Press the EMERGENCY STOP button on the machine Chapter 5 7 Shutting down the machine in an emergency gt Rinse them thoroughly with cold flowing water Do not rub your eyes gt Then consult a doctor immediately bene fhe Pressing the EMERGENCY STOP button does not automatically depres surise the mixing tank Carefully depressurise the mixing tank if still pressurised after an EMERGENCY STOP automatic lever air relief cock Before opening the cover or releasing a hose coupling check the pres sure gauge to see whether the mixing tank is depressurised Even if the tank is depressurised the delivery hoses may still be pressurised O5DF001_0608_en 5 3 5 Operation BRINKMANN MASCHINENFABRIK GMBH amp CO KG 5 3 Control panel The control panel is used to control and monitor the most important on the machine machine functions Digital control panel M 316 060 0141 w IN Analogue control panel 0 7 IK
23. BRINKMANN MASCHINENFABRIK GMBH amp CO KG The header air and flotation air must be set in accordance with the de livery hose diameter and length the type of delivery upwards down wards or along level surfaces and composition of the material The air flow is adjusted via the flotation and header air valves The following applies for both valves Upright position Valve fully open Horizontal position Valve closed Basic setting for new delivery situation gt Open the header air valve 1 and flotation air valve 2 half way to start off with Adjust in accordance with delivery type If the delivery cycle does not start close the flotation air valve briefly until sufficient pressure builds up in the mixing tank and then open again This prevents compressed air from escaping directly via the empty delivery hoses Note The sticker 4 will give you a more accurate indication The pictograms on the sticker illustrate more clearly how to operate the air valves O5DF001_0608_en 5 Operation Delivery types Correct delivery pressure Adjusting the air valves in line with the delivery type 5 13 Adjusting the ventilation pressure BRINKMANN MASCHINENFABRIK GMBH amp CO KG The delivery pressure is indicated on the pressure gauge 3 and must be set and adjusted in accordance with the delivery type Pumping upwards If you need to pump material to upper floors the ideal d
24. Make sure you can deform the whole hose slightly before releasing the hose coupling Continued on next page O5DF001_0608_en 5 Operation Most frequent causes of blockages O5DF001_0608_en BRINKMANN MASCHINENFABRIK GMBH amp CO KG gt Once the delivery hoses can be deformed slightly carefully release the couplings on the delivery hose containing the blockage and re move the delivery hose gt Eliminate the blockage by massaging bending and shaking the delivery hose If necessary wash out the blockage with a water hose If the blockage occurred as a direct result of a defect on the delivery hose or hose coupling replace the faulty part or the delivery hose Attach the delivery hose again Start up the machine again To do this unlock the EMERGENCY STOP button switch on the control and start the engine The materi al should begin to flow once again Incorrect nominal width of delivery hoses The width of the delivery hoses is too narrow for the material you are pumping Use delivery hoses with a larger nominal width Insufficient water in the material The material is too dry and does not flow or flows sluggishly Add more water to the material Defective Dirty hose couplings Water is forced out of the material because of defective seals or leaking hose couplings The material then becomes too stiff to be pumped any further Replace defective seals or hose couplings Make sure t
25. The handbrake must be released to its zero point before the machine can be towed Applying the handbrake gt Grasp the handle 1 on the handbrake and pull firmly over its dead centre position Releasing the handbrake gt Press the button on the handbrake handle 1 and release the handbrake to its zero point Caution ________ Do not secure the machine from rolling exclusively using the handbrake Always use wheel chocks on both sides The chocks prevent the machine from rolling at the set up site and are part of the basic machine equipment Place the chocks directly under the wheels on the machine Before the machine is towed insert the chocks in their holders and secure 04DF001_0605_en 4 Transport and connection Setting the parallel adjuster O4DF001_0605_en BRINKMANN MASCHINENFABRIK GMBH amp CO KG The drawbar on the machine must be parallel with the ground The parallel adjuster is always parallel with the drawbar and must be adjusted to the same height as your trailer coupling so that the overrunning brake can function correctly Adjust the parallel adjuster as follows gt Adjust the height of the support wheel so that the drawbar on the machine and therefore the parallel adjuster are parallel with the ground Pull the split pin 1 from the locking toggle 3 and turn the locking toggle 3 anticlockwise gt Grasp the parallel adju
26. applications and increasing or reducing operating data such as pressure range speed temperature etc outside of the factory settings constitutes improper use All protective devices must be installed and in perfect working order during operation Never operate the machine without the safety devices installed Specified inspection work should be carried out Never make any modifications or conversions to the machine without first obtaining the manufacturer s permission Any work on the machine s electric or hydraulic circuits should be carried out only by qualified hydraulic and electrotechnical specialists that have trained to work on the machine 2 3 Safety regulations Use contrary to the designated use Liability Exclusion of liability Modifications BRINKMANN MASCHINENFABRIK GMBH amp CO KG Use of the machine other than that described above or which goes beyond such use is considered contrary to the designated use Brinkmann Maschinenfabrik GmbH accepts no liability for damage resulting from such use The machine operator bears full responsibility The operator is obliged to act in accordance with the operating manual The safety and accident prevention regulations issued by the following institutions must be observed Industrial Employers Liability Insurance Association Commercial liability insurance company responsible National legal authorities The following persons are liable by law for
27. be operated from the control panel if necessary e g after repairs or after inserting a new grease cartridge Check the quantity of grease in the distributor on a daily basis Top up the distributor when the grease reaches the min mark The grease in one cartridge should be sufficient for approx one year of normal operation Maintenance card 03 001 Central lubrication system e Note 7 2 d __ _ 4 The front mixing shaft bearing must be lubricated every three months The lubricating point is located next to the grease distributor for the central lubricating system MC Central lubrication system Automatic pressure The compressor is switched off via a pressure monitor before the mixing cut out tank is depressurised The standard setting for the automatic pressure cut out is 2 bar Chapter 5 13 Setting the ventilation pressure Advantages The operator can leave the machine once the delivery cycle has started The delivery lines are not emptied which prevents the mixture from segregating The delivery cycle finishes in good time The speed of the turbo engine on the DC 260 55 decreases by 30 which reduces noise emissions fuel consumption and tank wear 3 12 O3DF001_0608_en 3 Technical description Operating elements 03DFO01_0608_en BRINKMANN MASCHINENFABRIK GMBH amp CO KG Analogue control Digital control 1 2 3 4 5 6 7 8 9 Control panel E
28. cleaning preserving agent or solvent Hearing damage when personnel work near the machine for long periods without ear defenders Electrical contact potentially dangerous electric shocks with electrical equipment on the machine If connections or electrical components are faulty Risk of burns from hot machine components These include engine engine oil system engine oil cooler compressor compressor oil system compressor oil cooler compressed air tank exhaust system Risk of scalding from hot engine or compressor oil Injuries caused by starting or operating the machine inadvertently or without authorisation Injuries caused as a result of becoming caught pulled in by the winch cable on the scraper Injuries caused by tripping over hoses operating equipment or other objects lying around 02DF001_0605_de 2 Safety regulations 2 14 Blockages 02DF001_0605_de ale D gt D D Q oe BRINKMANN MASCHINENFABRIK GMBH amp CO KG Blockages increase the risk of accidents so it is best to try and avoid them The most effective measures for preventing blockages include cleaning delivery hoses and hose couplings properly and replacing worn delivery hoses and hose couplings Note Selecting delivery hoses with a nominal diameter suitable for the delivered material and connecting clean delivery hoses that are not worn contributes greatly to the prevention of blockages Risk of injury from bursting
29. components All lines cables must be laid unobstructed Lines Cables resting on ma chine components may be damaged during operation Replace perfo rated kinked or damaged lines cable immediately Pay attention to any dark moist areas on the hoses and always check for escaping oil Make sure that the hose connections or couplings are not leaking Mainte nance card 13 001 Hoses Pay close attention to the seals on the filter engine and compressor Rectify any leaks immediately The fan must be running to ensure that the machine is cooled suffi ciently Clean the cooler if dirty An overheating machine will switch off automatically See also Maintenance card 07 001 Oil cooler All covers must be attached in the correct place including filler caps fan covers dirt trap on the air filter guards over moving machine parts e g V belt on the dynamo The machine must be cleaned thoroughly Crusts of dirt place operating personnel at risk and can damage the machine Clean the machine after each use before the screed residues set and deposits begin to form Make sure the area under the hood is clean Look out for signs of rust Repair rust damage as quickly as possible before the spread of rust affects the function and safety of the machine Pay close attention to rust on the brake system because this may affect the function of the brake Use a suitable machine preservative agent 7 5 Operating materials machine preservative agent after cl
30. correctly Remove dirt replace faulty parts Maintenance card 07 001 Oil cooler Continued on next page O6DF001_0605_en 6 3 6 Troubleshooting guide BRINKMANN MASCHINENFABRIK GMBH amp CO KG Engine starts but then switches off by itself Cause Sensors measuring incorrectly faulty Cause Check that both sensors are attached and functioning correctly and check the wiring Replace sensors if necessary Engine faulty Engine indicator lamp amp lights up and compressor temperature lamp flashes Repair the engine The compressor is monitored by a temperature sensor If this sensor sends critical values to the control the control switches off the engine to protect the compressor Fault during compressor temperature test Inspect the compressor oil level compressor oil filter compressor oil lines and oil trap Replace faulty lines clogged filter or oil trap top up the compressor oil if necessary Maintenance card 09 001 Compressor Inspect compressor cooler for dirt defects Check that the fan is functioning correctly Remove dirt replace faulty parts Maintenance card 07 001 Oil cooler Sensor measuring incorrectly faulty Air filter indicator lamp amp lights up Faulty control Check that the sensor is attached and functioning correctly and check the wiring Replace sensor if necessary The air filter is clogged Clean the air filter and replace if necessary Maint
31. delivery hoses or material spraying from delivery hoses hose couplings the discharge stand and the mixing tank Danger When clearing blockages always proceed as described in Chapter 5 14 Material not delivered Blockages Danger Never attempt to blow out blockages from the delivery hoses using compressed air Bursting delivery hoses pose a risk of fatal injury Danger __________ _ __ ___ ______ _ __________ _____ Never release the hose couplings while the mixing tank is still operating and pressurised Material could escape under pressure and cause serious injury in particular to the eyes Check that the ventilation lever is in the top position Also check the pressure gauge to see whether the mixing tank is actually depressurised Even if the mixing tank is depressurised the delivery hoses may still be pressurised and material could spray out when the hose coupling is released Always wear protective goggles face mask and protective gloves cover the coupling before releasing and avert your eyes while disconnecting the hose coupling Make sure that other personnel are not at risk If material gets in your eyes in spite of all precautionary measures rinse them immediately under a tap and then consult a doctor 2 2 15 Safety regulations Hydraulic and pneumatic system Inspection BRINKMANN MASCHINENFABRIK GMBH amp CO KG Work on the machine s hydraulic circuit may be carried out only b
32. distributor on machines with automatic lubrication Maintenance card 03 001 Central lubrication system and maintenance card 02 001 Lubrication diagrams Check whether all safety devices are attached and are functioning correctly Check that all fasteners on the machine are closed properly including oil filler air filter cover battery cells Check delivery hoses hose couplings and seals for damage contamination and wear Observe the warning and information plates on the machine O4DF001_0605_en 4 Transport and connection Checking oil levels Checking the air filter O4DF001_0605_en BRINKMANN MASCHINENFABRIK GMBH amp CO KG Inspect the engine oil level and the compressor oil level Check the hydraulic fluid level on machines fitted with a loader Top up oil or fluid as necessary Engine maintenance card Compressor maintenance card and Maintenance card 10 001 Hydraulic system Danger Oils and other fluids and lubricants can be hazardous to health Therefore always wear personal protective clothing and equipment when handling toxic caustic materials or other operating materials that are hazardous to health Read and take note of the manufacturer s information Never mix oils or fluids with different characteristics as they may not be chemically compatible when mixed and the fluid mixture may e g harden Danger Never open the compressor oil filler neck before the compressed air tank has been depressuris
33. eyes while disconnecting the hose coupling Make sure that other personnel are not at risk If material gets in your eyes in spite of all precautionary measures rinse them immediately under a tap and then consult a doctor Danger Do not reach into moving machine parts e g the mixing mechanism unless the machine has been shut down and the battery is disconnec ted Ignoring this instruction may result in serious or fatal injuries ben gh Only suitably trained technicians may work on the hydraulic and electri cal systems Note If in any doubt consult your local Brinkmann After Sales partner BRINKMANN MASCHINENFABRIK GMBH amp CO KG 6 Troubleshooting guide 6 1 Machine general Control does not function Cause Main switch on the control is off Switch on the control at the main switch located on the back of the control EMERGENCY STOP button Unlock the EMERGENCY STOP button Pull and turn the button pressed display indicates OFF Safety switch active If the control is switched on and the machine is not operated within an hour Decimal point appears on the display the safety switch is activated and the control no longer allows input Switch the main switch on the back of the control off and on again Faulty fuse in the control Replace the fuse for the control If the fuse blows again locate and remedy the fault Faulty control Replace the c
34. loader DC 260 45 55 B amp BS 05DF001_0608_en A A mo BRINKMANN MASCHINENFABRIK GMBH amp CO KG The loader is a hydraulic loading device for the mixing tank that assists with the loading process and allows the operator to prepare the next screed mixture during the current delivery cycle The cover must be open when you swivel up the loader Danger Make sure that there are no persons or objects in range of the loader There is a risk of injury Caution The cover on the mixing tank must be open when you swivel up the loader otherwise the cover and loader may collide and be damaged Chapter 5 8 Opening the cover on the mixing tank Note _ __ _ _ The loader can only be operated when the mixing mechanism is swit ched on The sticker 1 shows you how to operate the loader Push the lever 2 to the left The loader swivels upwards Push the lever 2 to the right The loader swivels downwards 5 5 6 Operation Operating the scraper DC 260 45 55 BS BRINKMANN MASCHINENFABRIK GMBH amp CO KG The scraper is operated via a radio remote control system The transmit ter attached to the scraper shovel is impact and water resistant The receiver is located in the control unit under the hood In the event of radio interference the scraper can also be operated via a cable Switch on the remote control at the toggle switch
35. on the control at the main switch before you can start the engine To do this proceed as follows gt Unlock the hood and lift up gt Actuate the main switch 1 Close the hood and lock On digital controls the version of the control appears on the display e g 63 for version number 6 3 followed by the operating hours Analogue control Digital control Note If OFF appears on the display when the digital control is switched on this means the EMERGENCY STOP button has been pressed Unlock the EMERGENCY STOP button Switch the main switch on and off ENDEN _ Noise can cause illness and seriously damage your hearing and nervous system Personnel required to stand in the vicinity of the machine must wear ear defenders while the machine is operating 5 Operation Starting the diesel engine on Switching off the diesel engine BRINKMANN MASCHINENFABRIK GMBH amp CO KG The machine should only be operated with the hood closed so that the cooling system functions more effectively You can start the diesel engi ne once the control is switched on Proceed as follows Press the ON button on the control panel and hold down until the engine starts The engine starts Pressure builds up The starter switches off automatically once the engine is running The ON button is fitted with an anti repeat device that prevents the starter from being actu
36. optional 5 27 High pressure cleaner optional 5 28 Cleaning the delivery hoses ne 5 29 Cleaning the header and flotation air hoses 5 30 Connection for air tapping eeenenen 5 31 Shutting down the machine for long periods 5 32 Final machine decommissioning eenne 5 33 Troubleshooting guide DE 260 General en aan 6 1 Machine general seennnnnnnn 6 1 Troubleshooting at the chassis 6 2 Table of contents VI 7 1 7 2 1 3 7 4 7 5 7 6 7 7 BRINKMANN MASCHINENFABRIK GMBH amp CO KG Maintenance Safety INS rUCTIONS ch caste craic eieeeeeeaies 7 1 Maintenance intervals asesenne 7 3 Set screw tightening torques enmnnnenne 7 11 Welding WOLK sense ee 7 12 Tightening TONGUES aan 7 12 Operating Mater alas en 7 13 Shutting down the machine nenne 7 15 Maintenance KIS 2 arcacsonteieaaceacreuesnnersiedursnspientensiets 7 16 Maintenance cards 01 001 Visual INSpection sanieren 7 17 02 001 Lubrication diagrams ne 7 19 03 001 Central lubrication system 7 23 04 001 BAT anna 7 25 05 001 Air filter so texcntcsensiivuteredovaspotubicnientsedecunicsenatelelenuss 7 29 06 001 Fuel filter are 7 33 07 001 OL COO EN aan 7 35 08 001 Eigenen 7 37 VIII TERMARSIL re
37. passage If necessary clean the filter casing 6 and dust trap 2 with a slightly moist lint free cloth Make sure that the sealing surfaces are clean Caution Never use flammable liquids or solvents to clean When cleaning the filter casing make sure that dirt does not enter the air intake opening Dirt could be drawn in enter the compressor oil and engine oil system and cause damage gt Remove the cover over the air intake opening Insert the filter ele ment 4 again Insert the dust trap 2 and secure with the spring clips 5 The dust discharge valve 1 must point downwards Replace the air filter element 4 and the safety cartridge 3 if the safety cartridge becomes dirty or during scheduled maintenance at the latest Proceed as follows gt Release the three spring clips 5 on the filter casing 6 Continued on next page Maintenance card 05 001 Air filter B page 4ot4 Des BRINKMANN MASCHINENFABRIK GMBH amp CO KG gt Remove the dust trap 2 gt Remove the filter element 4 and the safety cartridge 3 and cover the air intake opening to prevent dust from entering If necessary clean the filter casing 6 and dust trap 2 with a slightly moist lint free cloth Make sure that the sealing surfaces are clean Caution Never use flammable liquids or solvents to clean When cleaning the filter casing make sure that dirt does not enter the air intake openin
38. prevents material from setting and deposits from for ming in the mixing tank The mixing shaft is fitted with two cleaning nozzles 1 Compressed air keeps the nozzles free of deposits during a delivery cycle During the cleaning cycle pressurised water is injected through the nozzles while the mixing shaft rotates and cleans the inside of the mixing tank with the same efficiency as a high pressure cleaner Wear resistant material a series connected water filter and stabilising pressure valves ensure maximum safety Simply connect the automatic mixing tank cleaner to the mains water supply and switch on the water pump The machine operator can now quickly clean the mixing tank even between 2 delivery cycles This facility is extremely useful especially when mixing quick setting material because it prevents deposits from forming inside the mixing tank which you would otherwise have to laboriously scrape off to ensure correct functioning of the machine A cleaning lance can also be connected to clean the outside of the machine Water injected to clean the mixing tank can be used for subsequent material mixtures pumped through the delivery hoses for cleaning or drained via the mixing tank outlet Advantages Increased safety for the machine operator because machine downti mes e g caused by deposits blocking the mixing shaft and manual cleaning of the mixing tank interior are largely eliminated Simplified cleaning
39. suitable oil drip tray ready and put on all necessary protective equipment gt Open the filler neck 1 Pull the hydraulic fluid filter out of the hydraulic fluid tank Collect the escaping fluid in the container Dispose of the fluid and used fluid filter in accordance with regulations Insert the new hydraulic fluid filter into the hydraulic fluid tank Close the filler neck 1 again gt Perform a function check Maintenance card 10 001 Hydraulic system Function check BRINKMANN MASCHINENFABRIK GMBH amp CO KG Page 4 of 4 Proceed as follows to perform a function check Switch on the machine and start the engine Wait until the mixing mechanism begins to operate Push the loader lever carefully to the right to swivel the loader up slowly If you do not encounter any problems when doing this swivel the loader up and down several times to ensure it will function correctly during normal operation When the loader is down pull the scraper out a few metres and wind up the cable again by actuating the scraper remote control scraper winch is operated hydraulically Check the hydraulic fluid level and top up the hydraulic fluid as re quired WK10 001_0605en Maintenance card 11 001 Check valves Check valves BSR Preparation Position of the check valves WK11 001_0605en B BRINKMANN MASCHINENFABRIK GMBH amp CO KG Page 1 of 2 This mainten
40. the air filter Remove this dust as follows Press in the dust discharge valve 1 on the dust trap 2 several times The accumulated dust pours out Massage the valve 1 slightly to dislodge any remaining dust A dirty safety cartridge 3 indicates that the air filter element is not functioning correctly In this case change the air filter element 4 and safety cartridge 3 The air filter element 4 safety cartridge clean can be cleaned with compressed air if only slightly dirty The pressure should not exceed 5 bar Keep the nozzle at a reasonable distance from the filter element 4 so as not to damage the element during cleaning gt Release the three spring clips 5 on the filter casing 6 gt Remove the dust trap 2 gt Remove the air filter element 4 and cover the air intake opening to prevent dust from entering Continued on next page WKO5 001_0605en Maintenance card 05 001 Air filter Changing the air filter element WKO5 001_0605en 5 Page 3of4 ku BRINKMANN MASCHINENFABRIK GMBH amp CO KG gt Use compressed air to blow the dust against the normal air flow di rection and out of the filter element 4 Inspect the air filter element 4 for damage Replace damaged filter elements immediately Caution Wear respiratory protection and a face mask to protect against dust particles Dust particles could get in your eyes or enter your respiratory
41. the hose couplings while the mixing tank is pressurised Even if the tank is depressurised the delivery hoses may still be pressurised Always proceed as described in Chapter 5 14 Releasing hose couplings after a delivery cycle or in the event of blockages as described in Chapter 5 15 Material not delivered Blockages The machine must not be operated without a discharge stand attached correctly at the delivery hose end The end of the hose will thrash around posing a risk of fatal injury The mixing tank must be depressurised before the cover is opened Inspect the ventilation lever and tank pressure gauge to see whether the mixing tank is actually depressurised Check the mixing tank at the intervals specified in accordance with Chapter 2 7 Operating pressure reservoirs The operator must make sure that other personnel are not standing within the slewing circle of the loader during operation 2 2 5 2 6 Safety regulations Safety equipment Safety information for the pressure reservoir BRINKMANN MASCHINENFABRIK GMBH amp CO KG Never remove or modify safety devices on the machine Safety devices that are removed for maintenance work machine set up or repair must be refitted directly after the work is complete and checked to make sure they are fully functional Safety devices may only be checked repaired or replaced by qualified personnel All signs that have a safety or accident prevention function must
42. towing vehicle to move the machine once the lever 1 is open Never reach into the open spherical cap on the machine coupling The closing mechanism is pretensioned by a spring and may trigger at the slightest touch causing injuries gt Detach the machine from the ball head on the vehicle coupling Use the handle on the parallel adjuster gt Detach the breakaway cable O4DF001_0605_en 4 11 4 Transport and connection 4 3 Transportation and towing BRINKMANN MASCHINENFABRIK GMBH amp CO KG Brinkmann trailer mounted machines may only use public roads if properly approved When being towed in road traffic they are subject to Road Traffic laws applicable in the respective country These also stipulate the maximum permissible road speed for trailer mounted machines Trailer mounted machines must not be used for the transport of goods The machine should be empty of material Observe regulations governing the operation of trailers in particular the permitted towed and drawbar load of the towing vehicle Never move a machine with a negative drawbar load The General Operating Licence GOL is delivered with the machine and should accompany the machine during transportation You may have to obtain an additional licence depending on the country of use and the relevant regulations The registration regulations applicable in the country of use shall always apply The trailer mounted machine
43. was printed The contents of this document may not be reproduced in part or in full without our written permission All technical data drawings etc are protected by copyright law Copyright by BRINKMANN MASCHINENFABRIK GmbH amp Co KG 01DF001_0607_en BRINKMANN MASCHINENFABRIK GMBH amp CO KG 1 Introduction 1 2 Signs and symbols The following signs and symbols are used in these operating instructions Action symbols Text following this symbol describes tasks that you are required to work through generally in the sequence shown from top to bottom Text after this icon describes the result or the effect of an action Reference to maintenance cards This symbol is used to refer to required maintenance cards possibly as a supplement to the maintenance cards you are currently reading The following special tools are required This icon identifies the special tools required to carry out the work Normal tools i e standard tools or tools carried in the vehicle are not listed additionally Environmental protection This symbol is used to identify tasks where particular attention must be paid to environmental protection Accompanying text appears in italics and is underlined OO SSS ae rare i Important specifications regarding economical use of the machine are highlighted with the word Note in bold and the pictogram illustrated Accompanying text appears in italic
44. 0 200 118 0149 200 117 9240 212 914 9310 414 614 2200 212 914 9311 411611 1200 422 210 3200 212 911 0068 350 121 0194 350 121 0196 219 712 0104 Kit consists of 1 Engine oil filter 1 Fuel filter 1 Compressor oil filter 1 Copper ring 1 Valve cover seal 1 Sealing washer oil trap 1 Fuel hose 1 5 metres 1 Cross adapter 1 T connector 1 Air filter cartridge 1 Power belt 1 Safety cartridge 1 Toothed V belt 1 Rubber O ring for cover 1 Air oil separator complete 2 Sealing pistons complete 2 Compression springs 1 Preliminary fuel filter Brinkmann maintenance kit order no Overview of maintenance kit compon ents 800 010 52 Brinkmann Maschinenfabrik GmbH amp Co KG Ersatzteilservice An der Heller 4 12 33758 Schlo Holte Fax 05207 914790 Use our fax order form at the end of this operation manual to place an order 7 16 07DFO01_0605_en Maintenance card 01 001 Visual inspection Page 1 of 2 BRINKMANN MASCHINENFABRIK GMBH amp CO KG Visual inspection This maintenance card describes particular aspects that should be of the machine observed closely during a visual inspection of the machine Perform a visual inspection on a daily basis before starting work and immediately rectify obvious defects damage or imminent damage from e g faulty oil lines Also carry out brief visual inspections while the machine is operat ing Have a brief look at the most important parts of the machin
45. 1 Safety of machinery Electrical equipment of machines Part 1 General requirements The technical documentation is available in full The operating manual for the machine is available Schloss Holte Kh BA f a Germany 29 08 2005 2 O Qualified engineer Stefan Brinkmann Managing Director BRINKMANN MASCHINENFABRIK GMBH amp CO KG 8 Conformity 8 60 08BMO04_0605_en BRINKMANN Order MASCHINENFABRIK GMBH amp CO KG BRINKMANN Maschinenfabrik GmbH amp Co KG Fax 49 0 52 07 91 47 90 Ersatzteilservice E mail ersatzteile estrichboy de An der Heller 4 12 33758 Schlo Holte Invoicing address Delivery address only fill in if different from invoicing address Name Customer no Company Street POB ZIP code city Telephone Fax Shipping mode UPS NVS Delivery type Complete delivery only Part deliveries possible Place a cross as applicable Machine type Chassis no We order in line with the Brinkmann conditions of sale and payment available to us Date Signature Brinkmann Maschinenbau GmbH amp Co KG An der Heller 4 12 D 33758 Schlo Holte Telefon 49 0 52 07 91 47 0 Telefax 49 0 52 07 91 47 10 Internet www estrichboy de E Mail info estrichboy de
46. 1_0608_en BRINKMANN MASCHINENFABRIK GMBH amp CO KG 5 Operation 5 15 Delivery stops There may be several reasons behind the formation of blockages in the Blockages delivery hoses i e the material remains in the delivery hoses and cannot be delivered as far as the discharge stand A list of the most frequent causes of blockages and instructions on how to eliminate the blockages are included in the following section Danger Never release the hose couplings while the mixing tank is still operating and pressurised Material could escape under pressure and cause serious injury in particular to the eyes Check that the ventilation lever is in the top position Also check the pressure gauge to see whether the mixing tank is actually depressurised Even if the mixing tank is depressurised the delivery hoses may still be pressurised and material could spray out when the hose coupling is released Always wear protective goggles face mask and protective gloves cover the coupling before releasing and avert your eyes while disconnecting the hose coupling Make sure that other personnel are not at risk If material gets in your eyes in spite of all precautionary measures rinse them immediately under a tap and then consult a doctor A Danger Never attempt to blow out blockages from hoses using compressed air The delivery hoses may burst Ignoring this instruction may cause serious or fatal injuries Locati
47. 6 Shutting down the machine WK13 001_0605en Maintenance card 13 001 Hoses Checking the hoses Changing the hoses Check for leaks BRINKMANN Page 2 of 2 MASCHINENFABRIK GMBH amp CO KG Dark or moist areas on the hoses are the first sign of impending damage to oil system hoses Watch out for oil escaping from the hoses or hose connections Never check hoses on the air system with your hands Air could escape suddenly under pressure and cause serious injury use a leak tester spray gt Inspect all hose lines and their connections Check for the following Escaping oil air hoses and connections Moist or dark areas oil systems hoses Kinks cracks or perforated surface hoses Hoses must not rest against other components Hoses resting against other components could become damaged while the machine is running gt Do not operate the machine with the hood open for longer than necessary Close the hood or switch off the machine after the inspec tion Shut down and depressurise the machine before performing any work on it gt Make sure that the compressed air tank is depressurised If necessary drain oil from the affected system Replace faulty hoses Collect any residual oil in the line in a suitable container gt Install a new line When installing new oil lines check the oil level and top up with oil if necessary gt Inspect for leaks The following checks are necessar
48. CHINENFABRIK GMBH amp CO KG You can correct the longitudinal tilting angle using the support wheel gt Use the crank 2 to wind the support wheel 1 up or down Chapter 4 2 Chassis support wheel until the machine is in a horizontal position Selecting the best route for the delivery line and using the discharge stand is important in ensuring problem free safe machine operation Always attach the line to a discharge stand Danger Check whether the delivery line is laid correctly and attached to the discharge stand before operating the machine Never work without attaching a discharge stand securely A thrashing hose end can be extremely dangerous Secure the delivery hoses in particular on rising lines in such a way that the forces generated are absorbed by the structure or other unit components Secure rising lines with extreme care so that they do not break free as a result of the combined weight of hose and delivery material We recommend using Brinkmann fabric or leather hose clamps to secure the delivery hoses Secure the delivery hoses in the areas around the couplings to prevent the clamps from restricting the delivery hose Danger ____ __ _______ ______ ___ _ ______ __ __ Delivery lines that break free may thrash around and injure bystanders or damage property O4DF001_0605_en 4 Transport and connection Selecting delivery hoses Selecting hose cou
49. Connecting the discharge stand O4DF001_0605_en BRINKMANN MASCHINENFABRIK GMBH amp CO KG Lay the delivery hoses over a support trestle directly behind the machine Position support trestles under longer delivery lines that run along a level surface at intervals of 15 to 20 metres This should allow the material to flow through long flat delivery hoses without forming blockages Danger Always secure delivery hoses especially in rising lines Secure the delivery hoses so that the forces generated are absorbed by the structure or other unit components Bear in mind that the clamps used to secure the delivery hoses must be able to withstand the weight of the delivery hoses as well as the weight of the material There is a risk of injury from delivery hoses breaking free or thrashing around Always attach the end of compressed air conveyor hoses to a discharge stand Brinkmann discharge stands steel or aluminium are available for different hose diameters Two types of connection are available Fixed coupling connection Rotary coupling connection The rotary coupling sleeves can compensate for twisting delivery hoses Danger Never work without attaching a discharge stand securely A thrashing hose end can be extremely dangerous 4 Transport and connection 4 7 Starting up Preparing for start up BRINKMANN MASCHINENFABRIK GMBH amp CO KG This chapter contains info
50. Lubrication diagrams Check that check valves are functioning correctly MC 11 001 Check valves Clean if necessary and replace the sealing washers and springs of the valves or the entire check valve Check the header and flotation air lines Chapter 5 15 Cleaning Clean if necessary Check the condition of wear parts and the mixing mecha nism Chapter 4 7 Checking the mixing paddles wear plates mi xing shaft bearing Have Brink mann replace these components Test the function of the central lubrication system Every 500 operating hours Six monthly maintenance tasks in addition to daily and weekly maintenance tasks MC 03 001 Central lubrication system When automatic central lubrication system is fitted with additional equipment Task Have the tapered nipple replaced now at the latest Measurement and inspec tion equipment operating and auxiliary materials Comment Have Brinkmann replace this component Have the wear plates in the mixing tank and the mixing mechanism replaced now at the latest Have Brinkmann replace this component Lubricate all six monthly lubrica tion points Grease gun multipurpose grease DIN 51502 KPF 2C MC 02 001 Lubrication diagrams Replace the engine oil filter and engine oil now at the latest 15W 40 for diesel engine Filter wrench MC 08 001 Engine Replace the fuel filter and preliminary filter Continued on nex
51. MBH amp CO KG Use only high grade mineral oil for hydraulic systems with oxydation protective agent non foaming and resistant to wear in accordance with ISO VG 46 Compressor oil BP Energol HLP HM 46 at 10 C SHELL Corona AS 46 Initial filling approx 8 litres Subsequent fillings approx 6 5 litres with filter change fill to max mark Use the following for gearbox oil ISO VG 680 Gearbox oil Texaco Meropa 680 Volume approx 3 litres The hydraulic system for the loader scraper requires fluid with the fol lowing specifications SISO VG 46 DIN 51519 Hydraulic fluid Viscoclub HLP 46 Volume approx 12 litres Use the following as a machine preservative and corrosion protection agent Brinkmann BC machine preservative agent item no 605 000 0000 Use lubricating grease with the following specification Multipurpose grease according to DIN 51502 KPF 2C Lubricate all lubrication points on the machine in accordance with the maintenance tables in Chapter 72 Maintenance intervals and the ubri cation diagrams maintenance card Do not store oils and greases outdoors Water could seep into the sto rage container and render the oil unusable without you realising 07DFO01_0605_en 7 Maintenance 7 6 Shutting down the machine 07DFO01_0605_en BRINKMANN MASCHINENFABRIK GMBH amp CO KG The greatest risk the machine poses is from moving parts mixing shaft engine compressor V belt and power be
52. MERGENCY STOP button Pressure gauge for the mixing tank pressure Header air valve Flotation air valve Air extraction cock Lever for the hydraulic system loader only Main switch Operating hours meter with digital control shown on display 3 13 3 3 14 Technical description Loader Scraper BRINKMANN MASCHINENFABRIK GMBH amp CO KG The loader is a hydraulic loading device for the mixing tank and offers the following advantages The low filling height makes the work of the machine operator easier Anew mixture can be prepared in the loader while a delivery cycle is in progress The scraper is a shovel that is drawn towards the machine by a cable winch It is used to draw sand from flat separated piles easily and con veniently into the loader The scraper is operated via a radio remote control system The transmit ter attached to the scraper shovel is impact and water resistant The receiver is located in the engine control box under the hood In the event of radio interference or a flat battery the scraper can be operated using the remote control cable O3DF001_0608_en 3 Technical description Remote control on the scraper Working light with magnet foot BRINKMANN MASCHINENFABRIK GMBH amp CO KG The scraper is operated via a radio remote control system The transmitter attached to the scraper shovel is impact and water resistant The remote contro
53. N MASCHINENFABRIK GMBH amp CO KG 3 Technical description Rating plate The most important machine data is summarised on the rating plate BRINKMANN Maschinenfabrik GmbH amp Co KG D 33758 Schlo Holte T 49 0 5207 91470 13 4 5 2 6 1 Machine model 4 Permitted gross weight 2 Machine number 5 Permitted axle load 3 Year of manufacture 6 Permitted drawbar load 3 6 Options Consult your dealer or a local Brinkmann Maschinenfabrik GmbH amp Co KG representative as to how and whether you should upgrade your machines Please refer to the current Brinkmann Maschinenfabrik GmbH amp Co KG catalogue to view a list of optional extras and additional equipment or visit our website at www estrichboy de 03DFO01_0608_en 3 5 3 7 BRINKMANN MASCHINENFABRIK GMBH amp CO KG Technical description Safety equipment The following is a list of safety devices installed on the machine EMERGENCY STOP The EMERGENCY STOP button is located in the hood beside the control button panel Caution n nn Familiarise yourself with the location of the EMERGENCY STOP button on your machine When the EMERGENCY STOP button is pressed the following activities are triggered Diesel engine and compressor are switched off Compressed air tank is depressurised Mixing mechanism is switched off OEM Bh 3 Ze Pressing the EMERGENCY STOP button does not automatically depres surise the mixing tank Carefully depress
54. NFABRIK GMBH amp CO KG Proceed as follows to change the engine oil filter Have a suitable container ready to collect the used oil gt Loosen the filter cartridge 4 using a suitable oil filter wrench and unscrew Collect the escaping oil in the container gt Dispose of the old filter cartridge 4 and collected oil in accordance with regulations Clean any dirt from the sealing surface on the filter carrier Make sure that dirt does not enter the oil system Apply a light coating of oil to the seal on the new filter cartridge 4 gt Screw on the new filter cartridge 4 by hand until the seal rests on the sealing surface gt Tighten the filter cartridge 4 another half a turn Check the engine oil level top up if necessary gt Inspect for leaks WK08 001_0605en Maintenance card 08 001 Engine Check for leaks WK08 001_0605en BRINKMANN MASCHINENFABRIK GMBH amp CO KG Page 5 of5 The following checks are necessary after changing the engine oil or engine oil filter Start the machine and allow to run for approx 2 minutes gt Inspect the oil drain plugs and oil filter seal for leaks gt Shut down the machine again Chapter 7 6 Shutting down the ma chine Seal up any leaks that may occur Check the engine oil level and top up if necessary Maintenance card 08 001 Engine BRINKMANN MASCHINENFABRIK GMBH amp CO KG WK08 001_0605en Mainte
55. Noise level ooo eeeecceeeeeccceeceeeeeceeeeeeeceeeeeeetteeeeeneeeeeeas 3 4 Rating platei aaia aa 3 5 3 6 IN e EE REN ER E 3 5 3 7 Safety EAUIPMEeNE nee 3 6 EMERGENCY STOP B ttan u aueeisn ann 3 6 Protective grille asus 3 7 GUIO Ane ne See ene me eet ER eee nea ent eee ren 3 8 Maintenance flap eennenennnnen 3 8 3 8 Function description eneenennnnennennnnen 3 9 SUNN DES Sc de esate vlc ea eps Siete sees 3 9 Unit description a 3 10 COMPIESSON cranra nania ra EE A 3 10 Mixing ae re 3 11 Automatic central lubrication system 3 12 Automatic pressure cUt OUt nnnnnen 3 12 Operating elements nennen 3 13 ee ia a a sense cee 3 14 SQA 8 gan ean EEE SN EEE Py ere eres sree 3 14 Radio remote control for the scraper 3 15 Working light with magnet foot 3 15 Automatic mixing tank cleaner 3 16 II OODFO01_0608_en Table of contents OODFO001_0608_en 4 4 1 4 2 4 3 4 5 4 6 4 7 BRINKMANN MASCHINENFABRIK GMBH amp CO KG Transport installation and connection Re ru 4 1 Chassis ONE a IRRE RI OBERE U AEE E 4 2 Breakaway cable neneennnnnnnn 4 3 Tailgate Dackel ee 4 4 Support WIBe lee 4 5 PPP AWE FEN een een 4 6 Wheel choc teens 4 6 Setting the parallel adjuster 4 7 Ball head coupling nennen 4 8
56. Note The scraper can only be operated when the mixing mechanism is swit ched on Create a ramp of material in front of the loader so that the scraper can draw it directly into the loader see illustration The scraper cannot lift the material into the loader from the front The pile of sand behind the loader should be as central as possible Use the scraper to draw the sand directly into the loader as close behind the machine as possible in the direction that the winch is pulling The further the scraper deviates from the normal pulling direction of the cable the more the winching mechanism is put under stress which can cause increased wear or damage the winching mechanism and the scraper cable Caution lt Een Do not use the scraper to draw in material at the side of the loader as this will place the winching mechanism under excessive inappropriate stress and could cause damage Unwinding the scraper cable The cable reel is fitted with a free wheel that can be used when the remote control switch is not activated Pull the scraper to the required position Winding up the scraper cable gt Actuate the remote control switch The cable reel winds up the cable and pulls the scraper towards the loader On digital controls the reception lamp lights up O5DF001_0608_en BRINKMANN 5 Operation MASCHINENFABRIK GMBH amp CO KG Cable operation gt Disconnect the plug from the
57. Operating Manual BRINKMANN MASCHINENFABRIK GMBH amp CO KG Compressed air conveyors DC 260 45 DC 260 45 B DC 260 45 BS DC 260 55 DC 260 55 B DC 260 55 BS 2006 08 300 001 1001_en BRINKMANN e Maschinenfabrik GmbH amp Co KG An der Heller 4 12 D 33758 Schlo Holte Telefon 052 07 91 47 0 Telefax 05207 914710 E Mail brinkmann estrichboy de Internet www estrichboy de Table of contents OODFO001_0608_en 22 2 3 2 4 2 9 2 10 2 11 2 12 2 13 BRINKMANN MASCHINENFABRIK GMBH amp CO KG Introduction DAAC TVS IAA PORNERSSABINERENEESERN EEE EENREEENNEEE FREIEN REINER 1 1 FOTEWOTO dees anaren ae ae a aa a a En 1 2 Signs and SYM Satis cvsaiverennnraccreedyerrecrandiancioniiabayeusaden 1 3 Safety Regulations PARGID ee en nee ee 2 2 ONWardsSsale nanen een 2 2 Designated Use ua une era 2 3 Use contrary to the designated use n 2 4 Hab eei amatecnsesasl ae E 2 4 Exclusion of liabiliy n ennen nenn 2 4 MOON On ee re 2 4 Sources of danger essnenssnnnsnenennennnnennennnnena nn 25 Det VC OTIS as Sesesestny ch saienssceneieemesetsnedeasawneinnentetaaesd sajna 2 5 Hot machine components nennen 2 5 Delivery hoses and hose couplings 2 5 Discharge Stand 2 5 Mixing tank een tieren 2 5 era 2 5 Safety SOUNDS UE au een 2 6 Safety information for pressure reservoirs cnneeeee 2 6 Operating pressure reServoi
58. Permitted slewing Circle nennen 4 9 Permitted drawbar load eene 4 9 Connecting the machine een 4 10 Disconnecting the machine ne 4 11 Transportation and UN an 4 12 Before driving Off eneeneennennnennennnen 4 13 SN En ae ea tna Slates 4 14 Set up site requirements 222nssnnenneennennnnennnnnnnn 4 14 Locat ON iaaa E aE ARE EEEE EE nat coins 4 14 Setting ONG ee aa een 4 15 Angle of inelnallon een al 4 15 2 OWEN nenne re 4 16 Laying the delivery line nn 4 16 Selecting the delivery hoses ne 4 17 Selecting the hose couplings e 4 17 Selecting the connector for the mixing tank Outlet 4 18 Laying the delivery hoses ne 4 18 Connecting the discharge stand 4 19 TE ee een 4 20 Preparing for star up uenanenen 4 20 Checking oil levels 2 neennnnnnnen 4 21 Checking the air filter nenne 4 21 Inspecting the mixing paddles 4 22 Inspecting the wear plates nn 4 22 Inspecting the mixing shaft bearing 4 22 III Table of contents 4 8 5 3 5 4 5 5 5 6 5 7 5 8 5 9 5 10 BRINKMANN MASCHINENFABRIK GMBH amp CO KG Refuelling the machine
59. W _ _ _ I All tightening torques x 1 1 apply for bolts with cement in the thread 07DF001_0605_en 7 11 7 7 3 7 4 Maintenance Welding work Tightening torques BRINKMANN MASCHINENFABRIK GMBH amp CO KG During electrical welding work e g arc welding the external voltage may destroy electronic components on the machine Therefore always observe the following points before welding Disconnect both battery cables Detach the connector plug on the control Danger MMM Welding work on fuel and oil systems may only be carried out by trained welders observing the relevant safety regulations Danger of explosion Danger Never perform welding work on pressure reservoirs or make modifications Tightening torques depend on bolt grade thread friction and bolt head bearing area The values specified in the following tables are guide values These values are only valid if no other values are specified in this operating manual Caution Bolts must always be replaced with bolts of the same size and grade Bolts with adhesive in the locking threads and self locking nuts must always be replaced after removal Continued on next page 07DF001_0605_en 7 7 5 Maintenance Operating materials Drive motor 07DF001_0605_en i BRINKMANN MASCHINENFABRIK GMBH amp CO KG This chapter lists all the operating materials used in your mac
60. Wear plates twisted bent Inspect the mixing shaft bearings as follows gt Inspect the mixing shaft bearings for damage or wear Have Brinkmann Maschinenbau GmbH replace worn or damaged mixing shaft bearings Damaged mixing shaft bearings are identified as follows Cracked sealing washers visible in the mixing tank Radial play caused by reduced diameter of mixing shaft pin Cement deposits escaping from the bearings at the gearbox end during delivery When the bearings are lubricated cement deposits escape with the grease into the tank from the bearing at the gearbox end or between the gearbox and mixer tank Compressed air escapes from the bearings The mixing shaft is difficult to turn by hand when mixing tank is empty DENDIEI Never reach into moving machine components unless the machine has been shut down and secured against unauthorised inadvertent starting Always disconnect the battery before reaching into the mixing tank See Chapter 7 6 Shutting down the machine O4DF001_0605_en 4 Transport and connection Refuelling the machine O4DF001_0605_en BRINKMANN MASCHINENFABRIK GMBH amp CO KG The Trans Mix is powered by a diesel engine The filler neck 2 is located under the hood at the same height as the control The level indicator 1 for the fuel tank is located next to the filler neck 2 Only fill up to the maximum mark Stop the engine before filling the mach
61. __ __ __ Do not operate the machine while the maintenance flap is open Do not open the maintenance flap without first disconnecting the battery on the machine See Chapter 7 6 Shutting down the machine Ignoring this instruction may cause serious injuries The maintenance flap may be opened only for maintenance cleaning or repair work and must be closed immediately after the work is complete O3DF001_0608_en BRINKMANN MASCHINENFABRIK GMBH amp CO KG 3 Technical description 3 8 Description of function This chapter is designed to help you understand the functions of the machine so that you can limit the field of the machine s applications to suitable areas and avoid errors in operation General Compressed air conveyors belong to the discontinuous flow conveyor category The pumping medium is initially mixed in a mixing and pumping tank as in an enforced mixer Once the mixing process is complete the mixing tank designed as a pressure reservoir is connected to a compressed air supply The compressed air is typically produced using a screw compressor and partly enters the mixing tank as header air or tank air The compressed air also enters the pressure line as flotation air or hose air which breaks the material up into plugs and pushes these through the hose like in a pneumatic tube conveyor Mixing tank Mixing shaft Mixing paddle Cover Tank outlet Header air line Flotation
62. above 5 bar Delivery is extremely slow or stops completely Cause Remedy The delivery hoses are blocked by Clean the delivery hoses and remove the material deposits material deposits Delivery is not Replace the delivery hoses if necessary possible or only to a limited extent Restart the delivery process with a large quantity of header air and without flotation air Then adjust the header and flotation air correspondingly Mixing tank pressure above 6 bar Delivery stops Blockages Cause Remedy Blockages in the mixing tank outlet When clearing blockages proceed as described in Chapter 5 15 Delivery stops The delivery hoses are soft Blockages Locate and eliminate the cause of frequently occurring blockages as these can Blockages in the delivery line Delivery pose a serious risk to operating personnel There are many possible causes for hoses are hard up to the point of the blockages occurring e g composition of the material nominal width of the blockage after which they are soft delivery hoses faulty coupling seals etc Read also Chapter 5 15 Common causes of blockages 06DFO01_0605_en 6 9 BRINKMANN MASCHINENFABRIK GMBH amp CO KG 6 Troubleshooting guide 6 2 Troubleshooting at the chassis Overrunning brake ineffective Cause Brake pads have not been worn in The brake pads may not have been worn in before the machine was delivered The problem disappears after the brakes are appl
63. accidents resulting from the failure to comply with safety regulations and accident prevention regulations or the inadequate supervision of operating personnel the operating personnel or if deemed not responsible due to lack of training or basic knowledge in handling the machine his supervisors Therefore always make sure that the necessary care is taken We state here expressly that Brinkmann Maschinenfabrik accepts no liability for damage arising from incorrect or negligent operation servicing or maintenance or as a result of use contrary to the designated use This statement also applies to machine modifications additions and conversions that may compromise safety The guarantee will no longer be valid in such cases Never make any modifications additions or conversions to the machine which may affect safety without first obtaining permission from the manufacturer This also applies to the installation and adjustment of safety equipment and valves as well as to welding work on load bearing elements and pressure reservoirs In particular this includes adjustment of safety and control pressures power outputs speeds of rotation and other settings to values other than those set in the works deactivation or modification of safety equipment Operating the machine with faulty safety equipment Cautin 8 Safety equipment should be repaired adjusted or replaced by technically qualified experts only All safety releva
64. achine from moving If the chassis rolls back the handbrake tightens automatically Danger The machine may roll until the braking force takes full effect The drawbar must always be parallel with the ground during the journey see Chapter 4 3 Before moving off ground clearance The support wheel moves the machine into a horizontal position at the place of work Wind up fold up and secure the support wheel in this position before driving off The frame is made from a special torsion resistant high grade steel that gives the machine stable roadholding O4DF001_0605_en 4 Transport and connection Breakaway cable O4DF001_0605_en BRINKMANN MASCHINENFABRIK GMBH amp CO KG The breakaway cable actuates the handbrake emergency brake if the trailer detaches itself from the towing vehicle by accident 1 Breakaway cable 4 Eye trucks 2 Breakaway cable guide 5 Ball neck passenger vehicles 3 Snap hook Attaching the breakaway cable DIN trailer coupling ring Thread the breakaway cable 1 through the cable guide welded on the side 2 insert the snap hook 3 through the eye provided 4 and clip the snap hook 3 onto the cable 1 Attaching the breakaway cable ball head coupling Thread the breakaway cable 1 through the cable guide welded on the side 2 wind around the ball neck 5 and clip the snap hook 3 onto the cable 1 Caution Make sure that the breakawa
65. ad Stop The engine switches off and the compressed air tank is de pressurised via a relief valve 03DF001_0608_en BRINKMANN MASCHINENFABRIK GMBH amp CO KG 3 Technical description Mixing tank The mixing shaft in the mixing tank is powered by the diesel engine via a gearbox and automatically tensioned V belt Mixing paddles fitted to the mixing shaft mix the material in the mixing tank m it K E og I R 1 Mixing shaft 2 Mixing paddle To make it easier to start the engine at low temperatures or when the mixing tank is full the mixing shaft mechanism can be disengaged by pressing a button See also Chapter 5 11 Delivering material mixing mechanism button Danger Do not reach into the mixing tank unless the machine has been shut down and secured against unauthorised inadvertent start up Disconnect both battery terminals as well See Chapter 7 6 Shutting down the machine Ignoring this instruction may cause serious or fatal injuries 03DF001_0608_en 3 11 BRINKMANN MASCHINENFABRIK GMBH amp CO KG 3 Technical description Automatic central A piston pump assembly lubricates the following important mixing shaft lubricating system components automatically Front and rear mixing shaft seals Rear mixing shaft bearing The central lubrication system can
66. air line Discharge stand ONAUBRWN 03DF001_0608_en 3 9 3 3 10 Technical description Description of the unit Compressor BRINKMANN MASCHINENFABRIK GMBH amp CO KG The DC 260 consists of a diesel engine compressor unit a chassis and a mixing tank The compressor and mixing tank are mounted to a frame The frame is protected underneath from water and dirt and together with the axle and the overrunning brake equipment forms the chassis Diesel engine Compressor unit Drawbar chassis Axle chassis Mixing tank Frame UAWN The compressor is powered by an oil cooled diesel engine via a high performance coupling and supplies a steady flow of compressed air The diesel engine DC 260 45 operates at a constant speed The speed of the turbo engine DC 260 55 increases automatically to maximum while the compressor is generating pressure and decreases to minimum when pressure is not being generated The compressor uses a full load control system with 5 operating modes Start Pressure begins to build up in the compressed air tank when the engine starts The compressor runs at idling speed when the pressure in the compressed air tank reaches 2 bar Loading Maximum pressure generated in the compressed air tank Unloading The system controls the air consumption according to the air flow 100 or 0 Idling The compressed air tank keeps the air pressure at 2 bar The compressor runs under no lo
67. ance card describes how to clean the check valves in the air system on the machine Refer to the maintenance tables in Chapter 7 2 Maintenance intervals for details of the maintenance intervals No further maintenance cards are required No special tools required Caution a Shut down the machine and depressurise the compressed air tank be fore starting work on the air system Complete the following tasks before starting maintenance work on the check valves gt Shut down the machine before starting work Chapter 7 6 Shutting down the machine The check valves are located under the maintenance flap on top of the mixing tank and prevent the material from reaching the shut off valves on the header and flotation air lines Maintenance card 11 001 Check valves page2of2 A BRINKMANN MASCHINENFABRIK GMBH amp CO KG Cleaning the check valves Proceed as follows to clean the check valves gt Unscrew the cover connection 1 on the check valves 2 and remove the cover Remove the sealing pistons and compression springs if necessary gt Rub off soft dirt with a cloth gt Scrape out any hard solidified dirt Insert the sealing pistons and compression springs again and screw the covers 1 back onto the check valves Replacing the sealing Proceed as follows to change the sealing pistons and compression pistons and compression springs springs gt Unscrew the cover connection 1 on the
68. at other personnel are not at risk If material gets in your eyes in spite of all precautionary measures rinse them immediately under a tap and then consult a doctor 7 A D CG Preparation Complete the following tasks before changing the tank outlet gt Shut down the machine before starting work Chapter 7 6 Shutting down the machine gt Make sure that the mixing tank is depressurised Always observe the danger warnings before disconnecting hose couplings Clean the mixing tank WK12 001_0605en 7 55 Maintenance card 12 001 Tank outlet page2of2 S BRINKMANN MASCHINENFABRIK GMBH amp CO KG Changing the tank outlet Proceed as follows to change the tank outlet gt Unscrew the connecting piece 1 and check for wear You can keep the connecting piece 1 for future use gt Detach the bottom air hose 2 from the tank outlet gt Unscrew the screws 3 and remove the old tank outlet Check the seal Faulty perforated seals must be replaced gt Insert the new tank outlet and secure with the screws 3 The flota tion air connection must face upwards gt Connect the bottom air hose 2 back to the tank outlet gt Screw a connecting piece 1 to the tank outlet gt When operating for the first time after the change inspect the tank outlet the flotation connection and the connection piece for leaks If you identify a leak shut down the machine and repair the leak
69. atch Mixer depressuriser lever only automatic covers prior to 1997 6 monthly lubrication points Detail Designation Mixing shaft bearing lubricating nipples located next to battery Overrunning brake equipment 4 lubrication points on the tension bar Handbrake on the tension bar WK02 001_0605en MASCHINENFABRIK GMBH amp CO KG Be Page30f3 m BRINKMANN Maintenance card 02 001 Lubrication diagrams X A Nie WK02 001_0605en Maintenance card 02 001 Lubrication diagrams BRINKMANN MASCHINENFABRIK GMBH amp CO KG WKO2 001_0605en Maintenance card 03 001 Central lubricating system Page 1 of 2 8 BRINKMANN Central lubricating system Preparation WKO03 001_0605en MASCHINENFABRIK GMBH amp CO KG This maintenance chart describes how to refill the central lubrication system Fill up the distributor when the level approaches the min mark One grease filling is sufficient for approx one year Use only the grease specified in Chapter 7 5 Operating materials lubricating grease No further maintenance cards are required No special tools required Caution Cleanliness is of utmost importance when filling the central lubrication system Prevent dirt or other impurities from entering the centra
70. ated while the engine is running The starter should not run for longer than 30 seconds The oil pressure indicator lamp and charge indicator lamp light up briefly and go out if the self test does not detect any faults Caution __ _ _ If the engine oil pressure and temperature indicator lamps do not light up briefly when the engine is started one of the engine sensors or sen sor cables is defective The engine will function normally but the cut out protecting against excessive engine temperature or insufficient engine oil pressure is rendered inoperative The engine could be damaged Mate If you release the ON button before the engine starts the anti repeat device prevents you from pressing the ON button again immediately The LED on the start button flashes You can attempt to start the engine again once the LED stops flashing Danger All covers protecting personnel from moving parts must be in place be fore the engine is started Make sure that the running machine does not pose a risk to personnel To switch off the diesel engine proceed as follows Press the OFF button on the control panel This will switch off the engine The LED on the OFF button flashes the button pad is blocked for 30 seconds You can start the engine again once the LED stops flashing O5DF001_0608_en 5 Operation 5 5 Operating the
71. ause serious injuries in particular to the eyes Wear protective goggles gt Move the ball valve 3 to the upper position to switch off the water pump again Always switch off the water pump before cutting off the water supply and disconnecting the supply hose 5 Operation High pressure cleaner optional BRINKMANN MASCHINENFABRIK GMBH amp CO KG The automatic mixing tank cleaner has a connector for attaching the cleaning lance from a high pressure cleaner This makes cleaning the outside of the machine much easier gt Connect the water supply hose to the quick release coupler 1 on the mixing tank cleaner and establish the water supply gt Connect the hose on the cleaning lance to the connector 4 and tighten securely gt Move the mixing tank cleaning high pressure cleaner valve 2 to the right position high pressure cleaner gt Wear protective goggles Caution Do not run the water pump dry as it will become damaged Make sure the water supply is established before switching on the water pump Always switch off the water pump at the ball valve 3 before cutting off the water supply gt Move the ball valve 3 to the lower position to switch on the water pump again You can now use the cleaning lance Danger Never direct the cleaning lance towards people Water and material escaping under pressure may cause serious injuries in particular to the eyes Always wear prote
72. be attached to the machine These signs must not be modified removed or damaged Illegible signs must be replaced Pressure reservoirs are subject to pressure reservoir regulations 8 Group IV for this particular reservoir Brinkmann Maschinenfabrik GmbH amp Co KG has already performed a pressure and product acceptance test Regular checks are also necessary after initial operation Before making any checks you must possess a type approval and pressure test certificate These are provided by Brinkmann Maschinenfabrik GmbH amp Co KG when the machine is delivered Danger Welding work on pressure reservoirs or reservoir outlets is not permitted Do not make any structural modifications 02DF001_0605_de BRINKMANN MASCHINENFABRIK GMBH amp CO KG 2 Safety regulations 2 7 Operating pressure The pressure reservoir operator is responsible for carrying out repeat reservoirs checks at the intervals specified and documenting these checks Checks must be carried out in Germany by a technical expert pressure reservoir regulations 32 e g at an approved T V or DEKRA centre Your Trans Mix is subject to the following inspection intervals in accordance with pressure reservoir regulations 10 Internal Every Specialist inspection inside the reser inspection 5 years voir performed at a certified testing centre Pressure test Every Pressure test on tank by an autho 10 years rised inspector at a ceti
73. be repaired immediately If necessary inform the supervisor Stop work if you find any defects that may jeopardise operational safety Danger Operate the machine only when all safety equipment is present and functioning correctly There is a risk of serious injury Use only delivery lines hoses couplings etc that are suitable for the delivery job provided by the machine manufacturer and in perfect condition Delivery lines are subject to wear which varies according to the pressure and composition of the medium the material from which the delivery line is made etc Observe the following when selling the machine Pass all the accompanying documentation operating manual maintenance instructions diagrams machine charts inspection certificates etc you received with your machine on to the new operator If necessary you may have to order the documents from us quoting the machine number The machine should never be sold without the accompanying documentation Report an onwards sale or acquisition to Brinkmann to receive information relating to modifications or innovations relevant to safety and qualify for technical consultancy from our works Instruct the new operator and his operating personnel in the operation of the machine just as you were instructed by us and have them confirm that they have received instruction from you Should you so require we will be happy to instruct the new operator and the new operating personne
74. by instructed persons under the supervision and guidance of a qualified electrician and in accordance with the electrical engineering rules and regulations Only personnel having special knowledge and experience in hydraulic systems may work on hydraulic equipment The workplace refers to the area in which authorised personnel remain in order to carry out work While the machine is operating the workplace of the operator is at the operating panel on the side of the machine The operator must make sure that the machine poses no risk to other personnel and must cease operation if an unauthorised person approaches the machine While the machine is operating the workplace of the floor layer is in the vicinity of the discharge stand The working area is the area where work is carried out with and at the machine including delivery lines and the discharge stand The working area may be classed as a danger zone depending on the work performed The working area must be secured against unauthorised access while work is in progress If necessary erect warning plates and barriers The operator is responsible for safety in the working area when the machine is in use Proceed as described in Chapter 5 1 Shutting down in an emergency Caution AMAR amp o amp o AM In the event of malfunctions stop the machine immediately and secure it Have any faults rectified immediately Pressing the EMERGENCY STOP button does not automatically depressur
75. centration of batteries that are not maintenance free Maintenance card 04 001 Battery Caution 2 H_ gt As electrolyte batteries contain a sulphuric acid solution that may cause irritation when brought into contact with the eyes or skin Always observe all safety regulations when handling batteries Wear the necessary protective clothing If acid comes into contact with the skin rinse off immediately with plenty of water If acid gets in your eyes rinse immediately with clean water and then consult a doctor O4DF001_0605_en 5 Operation 5 Operation 5 1 Shutdown in an emergency 05DF001_0608_en BRINKMANN MASCHINENFABRIK GMBH amp CO KG This chapter contains information and specific steps for operating and cleaning the machine properly Make sure you are familiar with the procedures for shutting down the machine in an emergency situation before you start operating the machine See also Chapter 3 7 Safety equipment EMERGENCY STOP button Caution m e ee e a o Familiarise yourself with the location of the EMERGENCY STOP button so that you can press it quickly in an emergency or if the machine starts to make unusual noises Danger Proceed immediately as described below if an emergency occurs while you are operating the machine Press the EMERGENCY STOP button gt Perform first aid call the emergency services if necessary gt Note the incident and report in accordance
76. check valves 2 and remove the cover gt Remove the old sealing pistons and compression springs Insert the new sealing pistons and compression springs gt Screw the cover 1 back on 7 54 WK11 001_0605en Maintenance card 12 001 Tank outlet Page 1 of 2 BRINKMANN MASCHINENFABRIK GMBH amp CO KG Tank outlet The tank outlet is subject to natural wear In a state of advanced wear a blind hole will open up on the tank outlet and allow air to escape The tank outlet must be replaced as soon as air starts to escape from a blind hole Refer to the maintenance tables in Chapter 72 Maintenance intervals for details of the maintenance intervals No further maintenance cards are required No special tools required Danger Never release the hose couplings while the mixing tank is still operating and pressurised Material could escape under pressure and cause serious injury in particular to the eyes Make sure that the mixing tank is depressurised automatic lever in top position or air vent cock open Check the pressure gauge to see wheth er the mixing tank is actually depressurised Even if the tank is depressurised the delivery line may still be pressurised and material could spray out when the hose coupling is released There fore always wear protective goggles cover the coupling before releas ing and avert your eyes while disconnecting the hose coupling Make sure th
77. ctive goggles gt Move the ball valve 3 to the upper position to switch off the water pump again Always switch off the water pump before cutting off the water supply and disconnecting the supply hose Detach the cleaning lance from the connector 4 O5DF001_0608_en BRINKMANN 5 Operation MASCHINENFABRIK GMBH amp CO KG Cleaning the delivery Most of the coarse dirt is cleaned from the delivery hoses when the mi hoses xing tank is cleaned You can remove any residual dirt from the delivery hoses using a sponge ball Proceed as follows gt The mixing tank must be depressurised Danger Never release the hose couplings while the mixing tank is still operating and pressurised Material could escape under pressure and cause serious injury in particular to the eyes Check that the ventilation lever is in the top position Also check the pressure gauge to see whether the mixing tank is actually depressurised gt Detach the hose coupling at the tank outlet gt Insert a soaking wet sponge ball into the delivery hose gt Secure the hose coupling back on the tank outlet Push the ventilation lever downwards and hold Pressure builds in the mixing tank The sponge ball is blown through the delivery hoses cleaning them as it goes Clean the sponge ball with water gt Repeat the procedure until all the delivery hoses are clean gt Detach all the delivery hoses a
78. d buttons are required for maintenance work See also Chapter 5 3 Control panel on the machine covered buttons on digital control special functions of digital control and fault display on digital control 5 Operation Covered buttons 13 digital control BRINKMANN MASCHINENFABRIK GMBH amp CO KG Do not operate the machine without the cover The cover should only be removed for maintenance purposes by authorised personnel During normal operation the buttons have the following functions Protective grille button The protective grille button activates or deactivates the circuit breaker for the protective grille Error appears on the display when it is deactiva ted The machine should only be started with the protective grille open by qualified personnel for maintenance purposes Make sure that the cir cuit breaker is activated again once the maintenance work is complete Danger Never reach into moving machine parts Never operate the machine without a protective grille or with the protective grille circuit breaker deactivated There is a risk of serious injury Mixing time preset button The mixing time preset button allows you to preset a delay interval in seconds which specifies the time the machine continues to mix after the automatic lever is actuated and before delivery begins The facto ry default setting is O seconds The maximum setting is 120 seconds The mixing time preset increases by 10 seconds ev
79. d closed Before operating the machine perform the following function checks while the engine is running Check the function of the safety equipment Check whether all safety devices are attached and are functioning correctly Do not modify the safety devices Check whether the protective grille in the filling dome is attached correctly whether the guard covering the V belt is installed the functional reliability of the protective grille cut out on the machine the functional reliability of the EMERGENCY STOP button Danger Defective safety devices could appear to be safe but in reality pose a danger The machine may continue to operate in an emergency or dangerous situation and cause serious injury to personnel If a safety device does not respond during the function check it must be replaced or repaired by a qualified person Never operate the machine if a safety device is defective Therefore check the functional capability of all safety devices before starting work Continued on next page O4DF001_0605_en BRINKMANN MASCHINENFABRIK GMBH amp CO KG 4 Transport and connection Check the functional capability of the EMERGENCY STOP button gt Start the machine Chapter 5 4 Starting the machine Press the EMERGENCY STOP button The motor switches off The compressed air tank depressurises The mixing mechanism stops Danger Pressing the EMERGENCY STOP button does not automa
80. d volume HLP 46 ISO VG 46 DIN 51519 121 Caution n The fluid capacities are only approximate values These may vary accor ding to the design and depend on the quantity of oil remaining Do not fill oil tanks beyond the max mark on the level indicator 03DF001_0608_en 3 3 3 Technical description Compressor Engine Engine type BRINKMANN MASCHINENFABRIK GMBH amp CO KG DC 260 45 B BS Diesel engine DEUTZ F3M2011 The compressor can be operated with two different types of engine Refer to the following table for the data DC 260 55 B BS Turbo diesel engine DEUTZ BF3M2011 Power output 30 5 kW at 2200 rpm 46 kW at 2600 rpm Compressor type ATLAS COPCO Airtec C111 Flow rate in accordance with ISO 1217 Delivery rate Storeys 55 30 Note 4 2 m3 min at delivery pressure 5 m3 min at delivery pressure of 6 bar of 6 bar 45 55 I m i Nominal hose diameter I 200 NW65 160 NW 53 gt NW 60 120 80 NW 50 40 2 3 4 5 Flow rate m min The flow rates stated are guide values only The actual rates depend on the properties and consistency of the material being delivered Noise level Pressure level in accordance with ISO 2151 over 7m DC 260 45 B BS 70 dB A DC 260 55 B BS 72 dB A Power level in accordance with EU RL 2000 14 EC 98 dB 100 dB O3DF001_0608_en BRINKMAN
81. e for example if you open the hood briefly to switch off the control This will help you to identify imminent damage earlier reduce downtimes and increase safety at work To rectify faults read the corresponding mainte nance chapter or consult a suitable authorised workshop No further maintenance cards are required No special tools required Note _______________ Safety at the workplace is paramount Visual inspections are supposed to help identify obvious defects so you can rectify them before they cause any real damage Visual inspections are not a substitute for the prescribed maintenance tasks me N Preparation Complete the following tasks before performing a visual inspection Switch on the machine and start the engine to check that all lines connections and seals are leak light Allow the machine to run for approx 2 minutes Open the hood WK01 001_0605en 7 17 Maintenance card 01 001 Visual inspection 7 18 Safety equipment Lines oil fluids air fuel and cabling Seals Fan cooler Covers Cleanliness Rust Operating pressures Unusual machine noises BRINKMANN MASCHINENFABRIK GMBH amp CO KG Page 2 of 2 Pay particular attention to the following points when performing a visual inspection The protective grille must be attached to the filling dome and fully func tional The EMERGENCY STOP button must be functional Guards must cover moving machine
82. e delivery line Danger Engine exhaust gases contain constituents which can be fatal or pose a serious health hazard Always set up the machine at a well ventilated site Do not operate the machine in enclosed spaces 04DF001_0605_en 4 Transport and connection Set up Angle of inclination O4DF001_0605_en BRINKMANN MASCHINENFABRIK GMBH amp CO KG Set up the machine so that it is absolutely stable and cannot roll gt Detach the towing vehicle and secure the machine against rolling Apply the handbrake and position both chocks under the wheels on the machine Chapter 4 2 Chassis handbrake and wheel chocks gt Remove the tailgate bracket and attach to the front holder on the support wheel Chapter 4 2 Chassis tailgate bracket gt Release the safety chain on the loader and swivel the loader downwards DC 260 B and BS only Chapter 5 5 Operating the loader Set up the machine in a horizontal position before operating aN T a Remain within the following inclination angles to guarantee continual problem free operation Horizontal Inclination angle in direction of travel 6 Lateral inclination angle both directions 5 6 5 4 Transport and connection Alignment 4 6 Laying the delivery line and setting up the discharge stand en on BRINKMANN MAS
83. e will damage the mixing shaft seals Danger Before cleaning the mixing tank switch off the engine and the main switch press the EMERGENCY STOP button and secure the machine against unauthorised inadvertent starting Do not reach into the mixing tank Serious or fatal injuries may be the consequence if the mixing me chanism starts up unexpectedly Disconnecting the battery is the only sure way of preventing the engine and mixing mechanism from starting If you cannot avo id reaching into the mixing tank always disconnect the battery first Position the discharge stand in a location where dirty water can drain out without causing any damage Make sure that the delivery hoses do not become kinked Swivel the protective grille back onto the dome Start up the machine again To do this unlock the EMERGENCY STOP button switch on the control at the main switch and start the engine gt Close the cover on the mixing tank A second person should hold the discharge stand firmly while the waste water is pumped out Push the ventilation lever downwards and hold Pressure builds in the mixing tank and the dirty water is pumped out Danger __ MMMM If a second person does not hold the discharge stand firmly pressurised water escaping from the hose may cause the stand to thrash around violently This poses a risk of serious injury gt Repeat the process The mixing tank should be filled with water half way
84. eaning to prevent rust from forming Never use diesel fuel for machine mainte nance Always keep an eye on the operating pressure gauges on the machine If the any of the gauges shows an unusual reading excessive insuf ficient pressure find out the cause Stop machine operation until the cause has been identified and the problem solved On hearing unusual machine noises switch off the machine immediately and find out the cause of the noises Repair any damage before continu ing machine operation WKO1 001_0605en Maintenance card 02 001 a B Lubrication diagrams pageiof3 Dee BRINKMANN MASCHINENFABRIK GMBH amp CO KG Lubrication diagrams This maintenance card shows you the location of the lubrication nipples for lubricating with a grease gun Refer to the maintenance tables in Chapter 7 2 Maintenance intervals for details of the maintenance inter vals The mixing shaft seals on machines fitted with a central grease lubrica tion system are lubricated automatically If necessary you can lubricate these manually by pressing the central lubrication system button under the cover on the control panel All moving machine components that are not listed separately should be lubricated every six months e g toothed discs on the parallel adjuster No further maintenance cards are required The following special tools are required Grease gun Ne LX Caution ______________ _ All lubrication nippl
85. ed The compressed air tank depressurises automatically when the engine is switched off Check the pressure gauge to see whether the compressed air tank is actually depressurised Check the compressor and engine air filter Clean the filter if slightly dirty or dusty otherwise replace with a new one Maintenance card 05 001 Air filter Caution a a Always replace the filter before starting the engine because dirt could enter the oil systems and damage the compressor or engine Inspecting the mixing paddles Inspecting the wear plates Inspecting the mixing shaft bearings Transport and connection BRINKMANN MASCHINENFABRIK GMBH amp CO KG Inspect the mixing paddles on the mixing shaft as follows gt Inspect the mixing paddles for damage or wear Have Brinkmann Maschinenbau GmbH replace worn or damaged mixing paddles gt Measure the gap between the mixing paddles and the wear plates and adjust if necessary The distance should be 15 2 mm Damaged mixing paddles are identified as follows Sections of the mixing paddles bent or broken off Surface of the mixing paddles worn by 50 or more Inspect the wear plates in the mixing tank as follows gt Inspect the wear plates for damage or wear Have Brinkmann Maschinenbau GmbH replace worn or damaged wear plates Damaged wear plates are identified as follows Holes in the wear plates Chunks missing from the edges of the wear plates
86. el engine by pressing the OFF button Switch off the control at the main switch The battery may go flat if the control remains switched on Close the flap on the control panel and attach a padlock to secure the machine against inadvertent unauthorised starting O5DF001_0608_en 5 Operation 5 18 Cleaning General 05DF001_0608_en BRINKMANN MASCHINENFABRIK GMBH amp CO KG Empty and clean the machine and the delivery hoses after completing work or when stopping operation for longer periods Only a properly cleaned and maintained machine guarantees durable problem free safe operation Environmental protection When cleaning always observe the waste disposal and environmental protection regulations applicable in your country or region Observe the following points when cleaning the machine For reasons relating to safety and proper functioning of the machine cover or seal all openings where water cleaning agent must not enter before cleaning with water especially using a steam jet or high pres sure cleaner or other cleaning agents The machine is splash proof but not waterproof Caution Do not clean electrical components on the machine with water high pressure cleaners or steam jets These components may become da maged when electricity passes through them Control cabinets electric motors and electrical plug connectors are especially at ri
87. elivery pressure is 4 5 5 bar Pumping downwards If you need to pump material e g into a cellar the ideal delivery pressure is 2 3 bar Pumping along a level surface If you need to pump material along level surfaces the ideal delivery pressure is 3 4 bar If the pressure 3 exceeds the ideal delivery pressure gt Close the header air valve 1 further and open the flotation air val ve 2 more If the pressure 3 falls below the ideal delivery pressure gt Open the header air valve 1 more and close the flotation air val ve 2 further The tank pressure decreases when the mixing tank is empty The venti lation lever unlocks the compressed air supply to the tank is interrup ted and the tank depressurises automatically You can set the residual pressure at which the tank is automatically depressurised by adjusting the peg on the ventilation lever Bear in mind that you can only adjust the ventilation pressure when the tank is empty ventilation lever in top position Position A Tank depressurisation begins at a pressure of approx 2 5 bar Position B Tank depressurisation begins at a pressure of approx 1 3 bar Proceed as follows to adjust the ventilation pressure Pull the adjusting peg 5 from the detent Slide the adjusting peg 5 along to the desired detent in accordance with the preset delivery pressure O5DF001_0608_en 5 14 Operation Detaching hose couplings after a deli
88. enance card 05 001 Air filter Control performs emergency shutdown even though the oil pressure engine temperature and compressor oil temperature are correct Replace the control Machine does not respond to the scraper remote control Cause The reception indicator lamp does not light up Remedy If the reception indicator lamp does not light up when you actuate the scraper remote control the receiver cannot receive signals from the remote control Remote control switched off Switch on the remote control at the toggle switch Battery flat Charge the battery via the control Use the spare battery or the remote control cable Chapter 5 6 Operating the scraper cable operation and charging the battery Serial number setting for remote control incorrect Check the serial number and change if necessary Chapter 5 6 Calibrating the scraper remote control control unit No radio reception A strong source of interference is blocking the signals from the remote control or the antenna is faulty Check the antenna and replace if necessary Use the remote control cable Chapter 5 6 Operating the scraper cable operation Remote control faulty If operation is not possible via the cable the remote control is faulty Consult your local Brinkmann After Sales partner O6DFO001_0605_en 6 Troubleshooting guide BRINKMANN MASCHINENFABRIK GMBH amp CO KG Machine does not respond to the scrap
89. equirements Set up site BRINKMANN MASCHINENFABRIK GMBH amp CO KG The operator bears responsibility for setting up the machine safely Inspect the proposed site carefully and reject the set up site if you have any doubts in respect of safety The supporting ground must be such that the machine cannot sink under its own weight Provide sufficient lighting at the set up site The set up site must be large enough to ensure that there is sufficient clearance around the whole machine Keep away from walls accessible from all sides for servicing and repairs on the machine positioned on level firm preferably horizontal supporting ground Caution e e ao m The machine must be positioned outside the danger zone of elevated work sites or protective roofing must be provided for the machine at the operating site Select a machine set up site where explosive flammable or toxic gases or steam cannot be drawn into the machine dust cannot be drawn in or blown towards the machine by the wind the machine does not draw in its own exhaust gases there is no need for any sharp delivery hose bends hoses do not have to be laid across one another or rest against other objects e g corner of walls Risk of chafing the delivery line is as short as possible Note Output depends on the delivery characteristics of the material as well as the thickness the length and routing of th
90. er remote control Cause The reception indicator lamp lights up Remedy If the reception indicator lamp lights up when you actuate the scraper remote control the receiver is able to receive signals from the remote control If the lamp flashes irregularly there is a source of interference Machine cannot carry out remote control commands reception indicator lamp lights up The mixing mechanism must be switched on If the mechanism is switched on the LED on the mixing mechanism button 88 lights up If necessary press the mixing mechanism button to switch on the mixing mechanism Check the wiring at the control output and the limit switch on the winch cable Low battery power Reception indicator lamp flashes irregularly The battery is almost flat and the transmitter is issuing irregular signals or the signal strength is too weak The scraper jerks during operation Charge the battery via the control Use the spare battery or the remote control cable Chapter 5 6 Operating the scraper cable operation charging the battery Interrupted radio reception Reception indicator lamp flashes irregularly A source of interference is blocking the signals from the remote control or the antenna is faulty The scraper jerks during operation or delays in stopping Check the antenna and wiring replace if necessary Use the remote control cable Chapter 5 6 Operating the scraper cable operation Charging ind
91. ery time the button is pressed When the setting reaches 120 seconds and the button is pressed again the display returns to O Central lubrication system button If the machine is fitted with a central lubrication system this lubricates the mixing shaft seals and the front mixing shaft bearing automatically after each delivery cycle It may be necessary to lubricate these seals af ter maintenance work Press and hold the central lubrication system but ton until lubricating grease clearly escapes from the mixing shaft seals Continued on next page O5DF001_0608_en BRINKMANN MASCHINENFABRIK GMBH amp CO KG 5 Operation Special functions of Some buttons activate a special control function if pressed and held the digital control while the control is switched on These buttons and their functions are described in the following section The maintenance indicator lamp lights up every 500 operating hours to indicate the imminent need for maintenance work The indicator lamp remains lit until switched off by the operator The machine control must be switched off and the cover on the control panel removed Press and hold the central lubrication system button and actuate the 0 main switch The maintenance indicator lamp switches off and the control then returns to normal operating mode Fault display of The control saves a list of all faults that occur even momentary faults the digital control that do not cause the machine to s
92. es are covered by a red protective cap Clean all lu bricating nipples carefully before using the grease gun so that dirt does not enter the lubricating system and cause premature wear or damage the machine Before placing the grease gun on the lubricating nipple actuate the gun until grease escapes from the adapter This will prevent air bubbles from entering the lubricating system Lubricate all lubricat ing nipples until grease visibly escapes from the lubrication point Make sure the red plastic caps are clean and replace them on the lubricating nipples to stop dirt from entering the lubricating system WK02 001_0605en 7 19 Maintenance card 02 001 Lubrication diagrams rage2o3 SA BRINKMANN MASCHINENFABRIK GMBH amp CO KG Daily lubrication points Detail Designation Mixing shaft seal lubricate at least twice a day lubricating nipple located next to the battery does not apply if central lubrication system fitted no pipe connected to the nipple Cover bolt joint lubricate once a day only steel cover Ventilation ball valve lubricate once a day only steel cover with manual ventilation Weekly lubrication points Detail Designation Loader unit additional equipment 4 lubrication points Lever bearing 2 lubrication points only steel cover Cover bearing only automatic covers prior to 1997 Cover sliding gate lightly lubricate contact surface on cover locking l
93. es the max mark on the compressor oil level gauge Maintenance card 09 001 Compressor Incorrect compressor oil grade Replace the compressor oil with the correct grade Chapter 7 5 Operating materials compressor oil Oil return line blocked Check valve faulty Clean the oil return line replace the check valve if necessary Air oil separator faulty Have Brinkmann check replace the separator Intake control valve faulty internally Compressor overheating Have Brinkmann check replace the valve Cause Inadequate compressor cooling Set up the machine in a well ventilated location Oil filter clogged externally Clean the oil cooler Maintenance card 07 001 Oil cooler Compressor oil level too low Check the compressor oil level Maintenance card 09 001 Compressor Cooling fan faulty Replace the cooling fan Fine oil trap blocked Have Brinkmann check replace the trap Compressor oil filter clogged Replace the compressor oil filter Maintenance card 09 001 Compressor Air and oil escape from the air filter after the machine is stopped Cause Dump valve faulty Remedy Repair the dump valve replace if necessary Incorrect oil grade no additives to prevent foam formation Contact Brinkmann Chapter 7 5 Operating materials O6DFO001_0605_en BRINKMANN MASCHINENFABRIK GMBH amp CO KG 6 Troubleshooting guide Mixing tank pressure
94. ety regulations Injury risks Other risks BRINKMANN MASCHINENFABRIK GMBH amp CO KG The machine has been built using state of the art technology and in accordance with recognised safety regulations Nevertheless its use may constitute a serious or fatal risk to the operator or third parties or cause damage to the machine and other property The following is a list of injuries that may result from improper use of the machine Risk of crushing and bumping when moving and setting up the machine Risk of injury from falling loads in particular when loading the machine incorrectly using a crane or winch Risk of injury caused by a brake that releases itself or missing wheel chocks Risk of crushing and bumping and risk of injury when slewing the loader Risk of crushing and bumping from the discharge stand thrashing around at the delivery hose end Particularly during blockages Injuries serious or fatal caused by thrashing hose end not attached to discharge stand Injuries in particular to the eyes caused by releasing disconnecting a pressurised delivery hose Particularly when a blockage forms Risk of eye and skin injuries caused by hydraulic fluid discharging when connections on the compression system are opened and the machine is not shut down in accordance with regulations Eye and skin injuries caused by concrete spatter water glass or other chemical substances Health damaged after breathing in dust particles
95. fied testing centre Note I The operator is responsible for keeping reservoir documents safe 2 8 Personnel selection The machine may only be operated maintained or serviced and qualification independently by persons machine operators who have reached the legally required age are physically able rested and not under the influence of alcohol drugs or medication have been instructed in the operation and maintenance of the machine can be expected reliably to execute the tasks they are charged with Training The machine may be operated serviced or maintained only by persons who are trained to carry out such tasks and have been commissioned to do so Areas of responsibility must be clearly defined Do not allow persons who have not yet completed training or instruction or persons taking a general training course to operate the machine unless under the constant supervision of a person experienced in operating the machine Couplings should be fitted only by persons possessing the necessary experience and equipment required for this task Continued on next page 02DF001_0605_de 2 7 2 9 2 10 Safety regulations Qualified electrician Hydraulics engineer Workplace Operator Floor layer Working area Procedure in an emergency BRINKMANN MASCHINENFABRIK GMBH amp CO KG Work on the electrical system and equipment of the machine should be carried out by a qualified electrician or
96. g Dirt could be drawn in enter the compressor oil and engine oil system and cause damage Check the new filter element 4 and the new safety cartridge 3 for damage Never install damaged air filter elements and safety car tridges gt Remove the cover over the air intake opening Insert the new air filter element 4 and new safety cartridge 3 Insert the dust trap 2 and secure with the spring clips 5 The dust discharge valve 1 must point downwards WKO5 001_0605en Maintenance card 06 001 Fuel filter Fuel filter Preparation WK06 001_0605en BRINKMANN MASCHINENFABRIK GMBH amp CO KG Page 1 of 2 This maintenance chart describes how to change the fuel filter The fuel filter is located centrally on the right side of the machine next to the air filter Refer to the maintenance tables in Chapter 72 Maintenance inter vals for details of the maintenance intervals No further maintenance cards are required The following special tools are required Suitable wrench for the fuel filter Danger o Avoid naked flames naked light or ignitable sparks when changing the fuel filter Danger of fire Note ______________ Prevent dirt and other impurities from entering the fuel system on the machine Environmental protection Collect any escaping fuel Avoid fuel spillages Complete the following tasks before changing the fuel filter gt Shut down the mac
97. h type of delivery upwards downwards along level surfaces and composition of the material Infor mation to help you adjust the header and flotation air is included at the end of this chapter Push the ventilation lever 3 downwards Fig E and hold until the lever remains in that position by itself Fig F Pressure builds in the mixing tank The increase in pressure locks the cover Material delivery begins The material is now delivered to its destination When the mixing tank is empty the tank pressure escapes through the delivery hoses and the pressure in the tank decreases The decreasing tank pressure unlocks the ventilation lever the compressed air supply to the tank is interrupted and the tank depressurises automatically The mixing tank is ready to be loaded again Pressing the mixing mechanism button on the control panel allows you to access the automatic control and switch the mixing shaft on and off manually The LED on the mixing mechanism button lights up when the mixing shaft rotates The mixing shaft must be switched on during delivery and when the machine is being loaded Pressing the flotation air button on the control panel allows you to access the automatic control and switch the flotation air supply on and off manually The LED on the flotation air button lights up when the air supply is active 5 Operation 5 12 Adjusting the header and flotation air lt
98. h distilled water if necessary Close all the cells on the battery again Your protective equipment is no longer required gt Reconnect both battery cables WKO4 001_0605en Maintenance card 04 001 Battery Battery maintenance Longer machine downtimes WKO4 001_0605en BRINKMANN Page 3 of 3 MASCHINENFABRIK GMBH amp CO KG This section describes how to maintain the battery for a long useful life gt Keep the battery as clean and dry as possible gt Do not place tools on the battery as they may short circuit the termi nals and damage the battery Apply non acidic terminal grease to the battery contacts gt Connections and terminals must be tightened securely and lightly coated with paraffin gt Maintain the electrolyte level to approx 10 15 mm above the lead plates Observe the following points if you do not intend to operate the machine for longer periods gt Remove the battery and store in a warm dry place gt Charge the removed battery at regular intervals Maintenance card 04 001 Battery BRINKMANN MASCHINENFABRIK GMBH amp CO KG WKO4 001_0605en Maintenance card 05 001 BRINKMANN MASCHINENFABRIK GMBH amp CO KG Air filter Page 1 of 4 Air filter on This maintenance card describes how to clean and replace the collective engine compressor air filter of the engine and compressor The air filter is located centrally on the left side of the machine Refer t
99. hat hose couplings are absolutely clean before connec ting them 5 Operation 5 16 Stopping material delivery 5 17 Finishing work BRINKMANN MASCHINENFABRIK GMBH amp CO KG You can interrupt the delivery process at any time Interruptions in delivery may be necessary in the event of machine malfunctions Stop the delivery cycle for a short time only otherwise blockages may form in the delivery hoses and the material may begin to set in the mixing tank If the machine is stopped for longer periods proceed as described in Chapter 5 17 Finishing work gt Close the header and flotation air valves Press the flotation air but ton This will switch off the flotation air The LED on the flotation air button goes out gt Open the header and flotation air valves again Press the flotation air button again to resume material delivery This will switch on the flotation air again The LED on the flotation air button lights up If you wish to stop the delivery process definitively proceed as follows gt Allow the machine to run until the mixing tank is empty The tank depressurises automatically The cover must remain closed gt Activate the flotation air to empty the delivery hoses Press the flo tation air button to do this Press the button again once the delivery hoses are empty Clean the machine and delivery hoses Chapter 5 18 Cleaning Close the header and flotation air valves Switch off the dies
100. he connection on the tank outlet O5DF001_0608_en 5 Operation 5 19 Connection for air tapping 05DF001_0608_en BRINKMANN MASCHINENFABRIK GMBH amp CO KG The machine has a separate connection for tapping air You can connect compressed air consumers e g compressed air gun to this connection Proceed as follows to operate as a compressor gt Close the header air 1 and flotation air 2 valves Both valves must be in a vertical position Switch off the mixing mechanism by pressing the mixing mechanism button on the control panel The LED on the mixing mechanism but ton goes out gt Connect the consuming device to the air tapping coupling 4 gt Open the air extraction cock 3 The valve 3 must be in a vertical position You can now operate the connected consumer device Caution _ Connect compressed air consumers only The air tapping coupling does not have a check valve Connecting the lines to convey media other than air e g water may damage the com pressor ENDET Never direct compressed air towards people Compressed air can cause serious injuries Do not use compressed air from this machine as air for breathing Do not use compressed air to clean your working clothes 5 Operation 5 20 Longer machine downtimes BRINKMANN MASCHINENFABRIK GMBH amp CO KG If you do not intend to use the machine for longer periods e g over the winte
101. hine Carry out oil changes with reference to the maintenance tables in Chap ter 72 Maintenance intervals Note C When replenishing or changing oil use only oils included in the recom mended lubricants list Read the information provided by the manufac turer When hydraulic fluids of different viscosity grades are mixed the new viscosity is determined by the mix ratio of the fluids Consult the manufacturer UE ph Never mix oils with different characteristics e g biodegradable oil with mineral oil Environmental protection ___ You must carefully collect store all operating fluids e g used oil filters cleaning cloths or other auxiliary materials and dispose of them separa tely from other waste Observe the national and regional waste disposal regulations applicable to your area Store different used oils separately Contact the relevant authorities or waste disposal companies The engine requires a year round high pressure multigrade oil Viscosity SAE 15W40 for diesel engine 10W40 for turbo engine Initial filling approx 8 litres Subsequent fillings approx 6 5 litres with filter change fill to max mark Fuel Use summer diesel or winter diesel only DIN EN 590 Continued on next page 7 Maintenance Compressor Gearbox Hydraulic system Machine preservative agent Corrosion protection Lubricating grease Storing lubricants BRINKMANN MASCHINENFABRIK G
102. hine before starting work Chapter 7 6 Shutting down the machine Maintenance card 06 001 Fuel filter Changing the fuel filter Check for leaks B Page 2of2 En BRINKMANN MASCHINENFABRIK GMBH amp CO KG Proceed as follows to change the fuel filter Have a suitable container ready gt Unscrew the fuel filter 1 using the filter wrench and remove gt Allow the fuel in the fuel filter 1 to collect in the container Dispose of used fuel filters 1 in accordance with regulations gt If required clean the sealing surface on the filter seat with a clean lint free cloth Apply a light coating of oil to the sealing surface and the seal on the new fuel filter 1 and fill the filter 1 with some diesel fuel gt Screw on the fuel filter 1 by hand until the seal touches the filter seat Then tighten the fuel filter 1 read the information on the filter car tridge The following checks are necessary after changing the fuel filter gt Start the machine and the engine and allow to run for approx 2 minutes gt Inspect the fuel filter seal for leaks gt Shut down the machine before starting work Chapter 7 6 Shutting down the machine Seal up any leaks that may occur WK06 001_0605en Maintenance card 07 001 Oil cooler Oil cooler E gt S WK07 001_0605en B BRINKMANN MASCHINENFABRIK GMBH amp CO KG Page 1 of 2 This maintenance card describes h
103. hut down You can view the fault type and how many of them occur on the control Switch off the control at the main switch to close the fault display Activating the fault display The machine control must be switched off and the control panel cover removed Press and hold the OFF button and actuate the main switch The con trol activates the fault display The first fault indicator lamp air filter lights up and the display shows the number of air filter faults Selecting the fault type and viewing the number of faults The fault display must be active You can identify the fault type from the lit indicator lamp and view the number of faults on the display SOCee Press the OFF button again to switch to the next fault type The num ber of faults appears on the display Continued on next page O5DF001_0608_en 5 7 5 Operation ESC OK ESC OK BRINKMANN MASCHINENFABRIK GMBH amp CO KG Resetting the fault counter Adjusting the number of operating hours Reset the fault counter by entering a special code in the Setting serial numbers screen The number of operating hours can then be adjusted to match the actual operating hours You can enter a value smaller than the current value but the system will not accept this value The machine control must be switched off and the cover on the control panel removed Press and hold the ON button and actuate the control The contro
104. icator on the battery flashes when inserted in the charging socket Cause Rapid charging switched off Battery temperature too high or too low Battery faulty Temperature of the battery normal Remedy Rapid charge mode is only active when the battery temperature is between 10 C and 40 C The battery is charged as normal speed outside of this temperature range If the engine is running while the battery is charging it is normal for the charging indicator on the battery to flash because of the heat dissipated by the engine Connect the spare battery to the charging socket If the spare battery is charged in rapid charge mode the other battery is faulty Charging connection faulty Temperature of the battery normal O6DF001_0605_en Connect the spare battery to the charging socket If the charging indicator on the spare battery also flashes the charging connection is faulty 6 Troubleshooting guide BRINKMANN MASCHINENFABRIK GMBH amp CO KG Mixing shaft stops does not start Cause Mixing tank too full Remedy Empty the mixing tank Fill the mixing tank to no more than 15 mm below the lower edge of the dome Power belt faulty Check power belt and replace if necessary Mixture too dry Remove the material from the mixing tank and clean the tank if necessary Use the correct mixing ratio for the new mixture Material e g stone blocks the mixing shaft Remove
105. ied a few times Carefully run in the brakes Wear on the brake pads tension bar Have an authorised specialist workshop check adjust replace the brake system retracts fully during braking Brake pads damaged Have an authorised specialist workshop check adjust replace the brake system Sluggish brake mechanism Corrosion Have a specialist workshop overhaul the brake mechanism to ensure ease of on the tension bar movement Unsettled driving behaviour or jerky braking Cause Remedy Shock absorbers defective Have a specialist workshop check repair change the brakes Machine brakes when vehicle accelerates Too much play in the brake system Have an authorised specialist workshop check adjust replace the brake system Reversing sluggish or not possible Cause Remedy Handbrake not released completely Release handbrake completely released Brake system adjusted too tightly Have an authorised specialist workshop check adjust the brake system 6 10 O6DFO001_0605_en BRINKMANN MASCHINENFABRIK GMBH amp CO KG 6 Troubleshooting guide Brakes overheat Cause Handbrake not released completely Release handbrake completely released Brake system set incorrectly defective Have an authorised specialist workshop check adjust replace the brake system Handbrake ineffective Cause Handbrake not applied fully Apply handbrake fully Handbrake set incorrectly Ha
106. ine with diesel fuel 7 5 Operating materials fuel Note Fill the machine with fuel before the level becomes too low fill the tank up to the max mark directly after finishing work preferably in the evening If you operate the machine until the diesel tank is empty you may need to bleed the fuel line and fuel filter Fill the fuel tank only with commercial diesel fuel to avoid damaging the engine Use summer or winter diesel depending on the outside temperature Danger Do not smoke when you are filling the tank Stop the motor before filling the machine with fuel Never fill the machine near naked flames or ignitable sparks Clean the area around the filler neck before refuelling Do not spill fuel onto hot machine parts There is a risk of the fuel igniting 4 Transport and connection Test run Function checks BRINKMANN MASCHINENFABRIK GMBH amp CO KG After completing all inspection work and rectifying any defects you will need to start the engine and perform a series of function checks while the machine is running Danger Any defects identified during these inspections must be rectified immediately A fresh inspection is necessary after each repair The machine may only be put into operation once all the inspections described below have been concluded satisfactorily gt Start the machine Chapter 5 4 Starting the machine Danger The machine should only be operated with the hoo
107. ing and overturning during transport Suspended loads Attach a crane hook or shackle to the lifting eye Never lift the machine with a cable threaded directly through the lifting eye because the cable could fray and break Suspended loads may fall if they are not attached properly or if the auxiliary loading device is damaged You should therefore never walk under suspended loads 4 Transport and connection 4 2 Chassis Trailer coupling 1 Overrunning brake equipment 2 Parallel adjuster 3 Handbrake 4 Drawbar 5 Support wheel 6 Frame 7 BRINKMANN MASCHINENFABRIK GMBH amp CO KG The chassis consists of the following components 1 2 3 6 7 1 Trailer coupling 5 Support whee 2 Overrunning brake equipment 6 Drawbar 3 Parallel adjuster 7 Frame 4 Handbrake The trailer coupling can be fitted either with a trailer coupling ring as per DIN 74054 or a ball head coupling When the towing vehicle brakes or travels downhill the tension bar on the overrunning brake equipment retracts depending on the magnitude of the drawbar force and the machine brakes accordingly The parallel adjuster makes sure that the overrunning brake equipment and the drawbar always remain parallel to one another As a result the trailer coupling on the machine can be adapted to the height of the towing vehicle The handbrake prevents the m
108. ise the mixing tank Carefully depressurise the mixing tank if still pressurised after an EMERGENCY STOP automatic lever air relief cock Before opening the cover or releasing a hose coupling check the mixing tank pressure gauge to see whether the mixing tank is depressurised Even if the tank is depressurised the delivery lines may still be pressurised 02DF001_0605_de 2 Safety regulations 2 12 Protective equipment 02DF001_0605_de 8000 2 G BRINKMANN MASCHINENFABRIK GMBH amp CO KG If necessary or when specified use the following protective equipment to limit the risk of injury to personnel Protective helmet A protective helmet protects your head e g from falling objects Safety boots Safety boots protect your feet e g from falling objects crushing or protruding nails Protective gloves Protective gloves protect your hands e g from burning aggressive or toxic materials and cutting injuries Protective goggles Protective goggles protect your eyes e g from sprayed material and other particles Respiratory protection and face mask A face mask protects your face and respiratory protection prevents building material particles from entering your respiratory passage Ear defenders Ear defenders protect your hearing against noise produced in the direct vicinity of the machine Safety harness A safety harness prevents you from falling when working e g on scaffolding 2 2 13 Saf
109. l displays the Setting serial numbers screen initially and the preset serial numbers appear on the display While the serial numbers are displayed press the protective grille or mixing time preset button These buttons increase or decrease the preset value gt Press the protective grille and mixing time preset buttons to enter the value 33333 This value is the special code for clearing the fault memory and adjusting the number of operating hours Press the mixing mechanism button to cancel code entry The fault memory is not cleared and the control returns to normal operating mode Press the central lubrication system button to confirm the entry The fault memory is cleared The number of operating hours is displayed and can now be modified Press the protective grille and mixing time preset buttons to set the new number of operating hours Press the mixing mechanism button to cancel operating hour entry The control returns to normal operating mode Press the central lubrication system button to confirm the operating hours entry The new operating hours entry is accepted and the control returns to normal operating mode O5DF001_0608_en 5 Operation 5 4 Starting the machine Main switch O5DF001_0608_en BRINKMANN MASCHINENFABRIK GMBH amp CO KG Before starting the machine check that the machine is safe for operati on and no one can be injured when the machine starts You must switch
110. l is switched on off at the main switch 1 Press the pushbutton 2 to actuate the scraper The transmitter must be removed during transportation The receiver and the battery charging socket are located on the engine control under the hood Two batteries are included in the scope of supply While operating with one battery you can the charge the other by connecting it to the charging socket on the control Only charge the batteries when they are completely flat Chapter 5 6 Operating the scraper charging batteries In the event of radio interference or a flat battery 3 the scraper can be operated using the remote control cable Proceed as described in Chapter 5 6 Operating the scraper cable operation amp S n The working light 4 has a magnet foot and can be fixed to magnetic metal surfaces e g the hood of the machine to illuminate the work place when the light is poor The lamp can be swivelled and turned on and off via a switch 5 on the back The connector socket 6 is located on the right side of the machine Before driving off secure the light to the support plate 7 on the fuel tank Do not leave the lamp attached to the hood while driving 03DF001_0608_en 3 15 3 Technical description Automatic mixing tank cleaner 3 16 BRINKMANN MASCHINENFABRIK GMBH amp CO KG The automatic mixing tank cleaner makes the daily task of cleaning the tank easier and
111. l lubrica tion system Even small particles could damage the mixing shaft bearing Try to avoid air pockets in the central grease distributor as this could have a negative influence on lubrication Complete the following tasks before filling the central lubrication sys tem gt Shut down the machine before starting work Chapter 7 6 Shutting down the machine Maintenance card 03 001 Central lubricating system Page 2 of 2 B BRINKMANN Filling the grease distributor Function check MASCHINENFABRIK GMBH amp CO KG Proceed as follows to fill the distributor on the central lubrication sys tem Open the fastening latch 1 on the distributor cover 2 Lift up the cover 2 on the distributor gt Open the lid on the grease cartridge 3 and position upside down with the opening over the distributor Pull the opening lug on the grease cartridge 3 Press the grease into the distributor using the handle on the grease cartridge 3 gt Remove the empty grease cartridge 3 Close the cover 2 on the distributor again gt Lock the cover 2 with the fastening latch 1 gt Perform a function check Proceed as follows to perform a function check on the central lubrica tion system gt Remove the cover on the machine control panel to make the central lubrication system accessible digital control Switch on the machine and start the engine The mixing mechanism should s
112. l on your behalf 02DF001_0605_de 2 2 2 Safety regulations Designated use 02DF001_0605_de BRINKMANN MASCHINENFABRIK GMBH amp CO KG The machine has been built using state of the art technology and in accordance with recognised safety regulations Nevertheless its use may constitute a serious or fatal risk to the operator or third parties or cause damage to the machine and other property You must also observe the operating manual and comply with the conditions and intervals for maintenance and inspection to operate the machine within the limits of its designated use The machine is designed for mixing and delivering screed mortar and concrete mixes with a maximum grain size of 16 mm Other materials should only be processed after consultation with Brinkmann Maschinenfabrik GmbH amp Co KG The machine must be inspected for operational reliability by a technical expert once a year in accordance with BetrSichV 10 of 27 09 2002 The operator is responsible for commissioning the inspection The maximum permissible gross weight must not be exceeded The definition specified outlines the designated use of the machine The machine generates compressed air for industrial use It compresses atmospheric air to operating overpressure and supplies a defined quantity of this air at this pressure Using this machine for other tasks conveying suction media other than air operating the compressed air in non industrial
113. lace and charge regularly MC 04 001 Battery Store the machine in a clean dry location O5DF001_0608_en 5 Operation 5 21 Final machine decommissioning disposal 05DF001_0608_en BRINKMANN MASCHINENFABRIK GMBH amp CO KG Final decommissioning and disposal require complete disassembly of the machine into its individual components When dismantling and disposing of the machine make sure that there is no possibility of damaging the health of personnel or the environment Environmental protection Final disposal of the machine should be carried out by a specialist com pany Danger ___ _____ _____ ___________ When the machine is dismantled operating materials e g compressor oil or hydraulic fluid may escape and pose a risk They may be harmful to health or burn the skin Read the information provided by the opera ting material manufacturer and wear appropriate protective clothing Risk of injury on sharp edged machine components Continued on next page 5 Operation BRINKMANN MASCHINENFABRIK GMBH amp CO KG Materials used The following materials are mainly used in the machine Material Copper Plastic rubber PVC Polyester used for in Cable Machine frame Hood Mixing tank components Compressor components Seals Hoses Air cowls on the hood Cable
114. lts loader and material or oil that escapes under pressure Switch off the machine engine by pressing the OFF button The com pressed air tank depressurises automatically Also check the pressure gauge on the compressed air tank to see whether the compressed air tank is actually depressurised The mixing tank must be depressurised before the cover is opened The ventilation lever on the cover must be in the top position or the air vent cock open Also check the pressure gauge on the tank to see whether the mixing tank is actually depressurised Close the cover on the control panel and secure with a padlock gt Close the header air valve and the flotation air valve Switch off the control at the main switch Press the EMERGENCY STOP button Always disconnect the battery so that the machine cannot start or be Started unintentionally in particular when working on moving parts e g working at or inside the mixing tank changing V belts or power belts Danger Make sure that both the compressed air tank and the mixing tank are depressurised automatic lever ventilation lever compressed air tank mi xing tank pressure gauge displays Before maintenance work can be performed the engine and the main switch must be switched off the EMERGENCY STOP button pressed and the machine secured against unauthorised inadvertent starting Serious or fatal injuries may be the consequence if the machine starts up unex pectedly
115. me as the procedure for closing the cover but in reverse Banger MMMM Never open the cover while the mixing tank is still pressurised Always make sure that the mixing tank is depressurised before opening the cover The automatic lever must be in the top position Check the pressure gauge to see whether the mixing tank is actually depressurised Check the pressure gauge to see whether the mixing tank is depres surised gt If the mixing tank is still pressurised proceed as described in Chapter 5 9 Manual depressurisation Pull the lever on the locking latch upwards Pull the locking latch from the sliding gate and swivel downwards gt Lift up the cover on the mixing tank The automatic cover depressurises automatically at the end of delivery You can also depressurise the mixing tank manually at any time but current unfinished delivery cycles will be stopped prematurely The noise of manual depressurisation is significantly louder because there is no pressure cut out at the end of delivery Pull the ventilation lever 1 on the automatic cover upwards The air supply to the mixing tank stops The mixing tank is depressurised Fig F G Always check the pressure gauge to see whether the mixing tank is actually depressurised before opening the cover O5DF001_0608_en 5 5 10 Loading the mixing Operation tank BRINKMANN MASCHINENFABRIK GMBH am
116. must display its own official licence plate and is therefore subject to a roadworthiness test The plate can be obtained on production of the operating licence at the licensing office responsible O4DF001_0605_en 4 Transport and connection 4 4 Before moving off O4DF001_0605_en BRINKMANN MASCHINENFABRIK GMBH amp CO KG Check the following points before towing the machine on the open road The brake system overrunning brake equipment has been checked The tyre pressure has been checked The breakaway cable is attached correctly to the towing vehicle The tailgate bracket is attached in travel position secured connected and fully functional The towing gear is fully functional and coupled correctly After the machine is attached the support wheel is wound to the top position folded away and secured The chocks have been removed and secured in the holder The handbrake is released The mixing tank is depressurised empty and clean The air extraction cock is closed The hood has been closed properly and the clasp locks secured The loader if available has been raised and secured with the chain The scraper if available has been positioned in the holder on the loader and secured with the split pins Stow away the working light with magnet foot if available before starting your journey 4 Transport and connection 4 5 Set up site Set up site r
117. n Always collect the old compressor oil Avoid oil spillages Dispose of the collected oil and used oil filter in accordance with regulations Maintenance card 09 001 Compressor Preparation EN Checking the compressor oil level Topping up compressor oil B Page 205 Dees BRINKMANN MASCHINENFABRIK GMBH amp CO KG Complete the following tasks before changing the compressor oil filter or compressor oil Align the machine horizontally gt Measure the compressor oil level preferably when the machine is warm approx 40 C Start the machine and allow the engine to run for 20 30 minutes gt Shut down the machine before starting work Chapter 7 6 Shutting down the machine gt Always wear a face mask and protective gloves when working with compressor oil Compressor oil is toxic and can penetrate the skin This section describes how to check the compressor oil level The inspec tion glass with float should indicate an oil level in the top green area Do not allow the oil level to fall into the bot tom red area Proceed as follows to check the oil level gt Check the compressor oil level at the inspection glass 1 on the compressed air tank The inspection glass should indicate an oil level in the top green area This section describes how to top up the compressor oil Proceed as fol lows gt Make sure that the compressed air tank is depressurised gt
118. nance SA BRINKMANN MASCHINENFABRIK GMBH amp CO KG Make sure your working environment is scrupulously clean during maintenance work Dirt that e g enters the oil systems can damage the machine Cover components and vacant openings with a clean cloth or paper or mask off with adhesive tape Never perform welding work or work that generates heat in the vici nity of fuel or oil systems If this kind of work is absolutely necessary empty the fuel or oil system completely and clean e g using a steam jet All fuel and oil must be removed completely Disconnect the battery when arc welding Never perform welding work on pressure reservoirs or make modifi cations If you need to work under the machine or remove a wheel always support the tension bar and axle securely Do not rely solelyon a vehicle jack Under no circumstances should the soundproofing material be re moved from the hood or modified Soundproofing material should not come into contact with oil fuel or cleaning agent as it may be damaged Make sure that you do not leave tools loose components or cleaning cloths in the machine Make sure that covers or adhesive tape attached for maintenance work are removed Check that the machine is functioning correctly before releasing for general use Check all operating pressures temperatures and speed settings Test all control devices All safety devices must be fitted and fully functional Danger _____________
119. nance card 09 001 Compressor Compressor oil Compressor oil filter WK09 001_0605en SR B BRINKMANN MASCHINENFABRIK GMBH amp CO KG Page 1 of5 This maintenance card describes how to check the compressor oil level and change the compressor oil and the compressor oil filter The com pressed air tank and the compressor oil tank on the machine are one and the same Refer to the maintenance tables in Chapter 72 Mainte nance intervals for details of the maintenance intervals The intervals specified apply for normal machine use When operating at high ambi ent temperatures in very dusty or humid conditions more frequent oil changes are recommended Use only compressor oils specified in Chap ter 7 5 Operating materials compressor No further maintenance cards are required The following special tools are required Oil filter wrench suitable for compressor oil filters Danger Take care when draining the oil or changing the oil filter Drained oil may be extremely hot Risk of scalding Use the drain hose Never open the compressed air tank while still pressurised Never work on the compressor or the compressor oil system before the compressed air tank has been depressurised Note Prevent dirt and other impurities from entering the oil system on the compressor Change the oil once the compressor has warmed up It is appropriate to change the oil and oil filter at the same time Environmental protectio
120. nd clean the hose couplings thoroughly with water Residual mortar easily collects around the hose couplings Dirty hose couplings increase delivery hose wear and cause blockages gt Inspect the delivery hoses and hose couplings for damage Damaged hoses hose couplings or seals should be replaced immediately O5DF001_0608_en 5 29 5 Operation Cleaning the header and flotation air hoses BRINKMANN MASCHINENFABRIK GMBH amp CO KG The header air and flotation air hoses are located under the mainte nance flap on the mixing tank The machine must be shut down before cleaning can begin Shut down the machine and secure against unauthorised inadvertent starting See Chapter 7 6 Shutting down the machine gt Close the header and flotation air valves Danger Make sure that the machine has been shut down and the mixing tank is depressurised Check whether the ventilation lever is in the top position Also check the pressure gauge to see whether the mixing tank is actually depressurised Open the maintenance flap gt Release the hose couplings and remove the hoses gt Rinse the hoses thoroughly with water Clean the check valves if necessary MC 11 001 Check valves gt Connect the hoses again Then close the maintenance flap Caution Do not cross over the hoses when reconnecting Secure the header air valve to the connection on the mixing tank and the flotation air valve to t
121. nd service life of the machine The operating manual must be supplemented by the relevant national rules and regulations for accident prevention and environmental protection Always keep the operating manual with the machine The machine owner must make the location of this operating manual known to all personnel charged with performing jobs on the machine and ensure it is accessible at all times This operating manual must be read and applied by any person who carries out work with or on the machine e g Operation including set up fault rectification in the course of work removal of production waste maintenance and disposal of fuels and consumables Service maintenance inspection repair and or Transportation Generally recognised rules of technology for safe and proper working must be observed in addition to the operating manual and mandatory rules and regulations for accident prevention and environmental protection in the country and place of use of the machine You will make it much easier for us to answer any questions or respond to orders if you can give us the details of the machine model and the machine number vehicle ID no Send your questions to your local Brinkmann customer service partner or directly to Brinkmann Maschinenfabrik GmbH amp Co KG Modifications are made from time to time in the interests of constant improvement and may not have been taken into consideration when this operating manual
122. ne start up BRINKMANN MASCHINENFABRIK GMBH amp CO KG Always secure the machine against unauthorised or inadvertent operation by non authorised personnel before leaving the working area This means Press the OFF button on the machine control panel gt This will switch off the engine gt Open the hood and actuate the main switch on the control gt This will switch off the control Close the hood and secure the clasp locks Close the flap on the control panel and secure with a padlock Make sure that the mixing tank is depressurised Check the tank pressure gauge and open the ventilation lever air relief cock If you intend to stop machine operation for long periods proceed as described in Chapter 5 16 Finishing work Prevent material from hardening in the mixing tank or the delivery hoses The operator must always supervise machine operation or appoint a qualified person to monitor the machine in his absence If unauthorised persons approach the machine the operator must stop work immediately The operator is responsible for safety of all persons present in the working area Chapter 2 10 Working area 02DF001_0605_de 3 Technical description BRINKMANN MASCHINENFABRIK GMBH amp CO KG 3 Technical description 3 1 Designation 3 2 Equipment 3 3 Scope of supply This chapter describes the components and assemblies on this machine and how they function Please note that all possible option
123. ng and If the mixing tank is pressurised the delivery hoses will also be pressu eliminating blockages rised up to the blockage The hoses become hard and are difficult to deform Downstream of the blockage the delivery hoses are almost completely free of pressure and are easy to deform If there is a blocka ge at the tank outlet the entire delivery line is easy to deform gt Once all protective measures have been taken detach the delivery hoses and tread on them lightly until they deform The blockage is located at this point gt Move or shake the hose vigourously back and forth at that point to eliminate the blockage Sometimes you only need to ventilate the mixing tank and start the delivery cycle again to loosen the blockage The material should begin to flow once again O5DF001_0608_en 5 21 5 Operation Stubborn blockages A BRINKMANN MASCHINENFABRIK GMBH amp CO KG Sometimes blockages cannot be removed just by moving the delivery hoses back and forth Eliminating stubborn blockages poses a serious risk to operating personnel gt Shut down the machine before starting work See Chapter 7 6 Shut ting down the machine gt Make sure that the mixing tank is depressurised The ventilation lever must be in the top position Also check the pressure gauge to see whether the mixing tank is actually depressurised Danger _ _ ___________________ ___________ __________ ___ Never release the hose couplings
124. nmental Spare parts Storing the machine 02DF001_0605_de BRINKMANN MASCHINENFABRIK GMBH amp CO KG High sound levels can cause permanent hearing damage However noise levels in the vicinity of the machine may exceed 85 dB A depending on operating conditions A distance of less than 5 m from the machine is considered the vicinity Wear the prescribed ear defenders Instruct your personnel to wear their personal ear defenders at all times As the operating company you are responsible for ensuring that your personnel comply with this regulation Dispose of old materials such as oils filters batteries replaced parts etc in line with regulations Used cleaning rags should also be disposed of properly Spare parts must comply with the technical requirements specified by the manufacturer Spare parts from original equipment manufacturers guarantee this Use only original spare parts Brinkmann Maschinenfabrik GmbH amp Co KG accepts no liability for damage caused as a result of using non Original spare parts The machine should only be stored in a dry clean and well ventilated area If the machine is stopped for longer periods see Chapter 5 20 Shutting down the machine for long periods Danger There is a risk of fuel vapours accumulating and igniting if the machine is stored in a poorly ventilated area 2 2 20 Safety regulations Unauthorised Inadvertent machi
125. nnen 7 43 10 001 Hydraulic system ana 7 49 11 001 Check valves ee are 7 53 12 001 Tank outlet na 7 55 BOOT HOSES er eee ener ae eer erat terre errr 7 57 Conformity Declaration OF COMMOr MY ran 8 1 Fax order form OODFO01_0608_en 1 Introduction 1 Introduction Machine data 01DF001_0607_en BRINKMANN MASCHINENFABRIK GMBH amp CO KG This chapter contains instructions and information to help you use this operating manual If you have any queries please contact Brinkmann Maschinenbau GmbH amp Co KG An der Heller 4 12 D 33758 SchloB Holte Germany Tel 49 0 52 07 91 47 0 Fax 49 0 5207 91 47 10 Internet www estrichboy de E mail info estrichboy de or your local branch or works agency Before operating the machine please enter the following data from the rating plate here 1 Machine model 2 Vehicle ID no 3 Year of manufacture BRINKMANN Maschinenfabrik GmbH amp Co KG D 33758 Schics Holt 49 0 5207 91470 1 1 1 Introduction Foreword BRINKMANN MASCHINENFABRIK GMBH amp CO KG This operating manual is designed to familiarise the user with the machine and assist him in using the machine properly in all possible applications The operating manual contains important information on how to operate the machine safely properly and economically Observing these instructions helps to avoid danger to reduce repair costs and downtimes and to increase the reliability a
126. nt devices must be in place and fully functional 02DF001_0605_de 2 Safety regulations 2 4 Sources of danger Malfunctions Hot machine components Delivery hoses and hose couplings Discharge stand Mixing tank Loader 02DF001_0605_de BRINKMANN MASCHINENFABRIK GMBH amp CO KG During work never reach into the moving parts of the machine whether the machine is running or switched off Always stop and secure the machine prior to maintenance work as described in Chapter 76 Shutting down the machine Always place chocks under the wheels and apply the handbrake to prevent the machine from rolling at the set up site Before starting up the machine make sure that nobody is placed at risk by the running machine Do not loosen or tighten threaded unions on hoses or delivery lines when these are pressurised In the event of malfunctions stop and secure the machine as described in Chapter 7 6 Shutting down the machine Have any faults rectified immediately There is a risk of burns from hot machine components during and after machine operation mainly on the engine compressor oil systems including oil cooler and oil storage tank The delivery hoses and hose couplings are designed for a maximum pressure of 10 bar The maximum pressure of 10 bar must not be exceeded Material discharged from split delivery hoses or cracked hose couplings can cause serious injuries in particular to the eyes Never release
127. ntenance cards are required The following special tools are required Oil filter wrench suitable for engine oil filters Danger Take care when draining the oil or changing the oil filter Drained oil may be extremely hot Risk of scalding Use the drain hose Note Prevent dirt and other impurities from entering the oil system on the engine Change the oil once the engine has warmed up It is appropri ate to change the oil and oil filter at the same time Environmental protection Always collect the old engine oil Avoid oil spillages Dispose of the col lected oil and used oil filter in accordance with regulations Maintenance card 08 001 Engine Preparation Checking the engine oil level 8 Page2of5 Des BRINKMANN MASCHINENFABRIK GMBH amp CO KG Complete the following tasks before changing the engine oil filter or engine oil Align the machine horizontally Start the machine and allow the engine to warm up to operating temperature gt Shut down the machine before starting work Chapter 7 6 Shutting down the machine This section describes how to check the engine oil level The oil level should be close to the maximum mark and should not be lower than the mark on the dipstick Proceed as follows to check the oil level Pull out the engine oil dipstick 1 and wipe with a clean lint free cloth Insert the dipstick 1 push in as far as possible and pull ou
128. nvironmental protection Always collect the old hydraulic fluid Avoid fluid spillages Dispose of the collected fluid in accordance with regulations Always wear protective gloves and protective goggles when performing work that may involve coming into contact with hydraulic fluid Hydrau lic fluid is toxic and can penetrate the skin Complete the following tasks before changing the hydraulic fluid gt Align the machine horizontally If the machine is cold start the engine and allow to run for a short time so that the hydraulic fluid warms up and becomes less viscous gt Swivel down the loader on the machine so that all the hydraulic fluid flows back into the hydraulic fluid tank Chapter 5 5 Operating the loader gt Shut down the machine before starting work Chapter 7 6 Shutting down the machine WK10 001_0605en Maintenance card 10 001 B Hydraulic system Page 204 S BRINKMANN MASCHINENFABRIK GMBH amp CO KG Checking the This section describes how to check the hydraulic fluid level The fluid hydraulic fluid level level should be close to the maximum mark and should not be lower than the mark on the dipstick Proceed as follows to check the fluid level Pull the dipstick 1 from the hydraulic fluid tank 3 and clean with a clean lint free cloth gt Reinsert the dipstick 1 pull out again and check the oil level The oil level should be close to the maximum mark on
129. o the maintenance tables in Chapter 7 2 Maintenance intervals for details of the maintenance inter vals The change intervals specified apply for normal machine use When using the machine in an extremely dusty environment we recommend performing changes more frequently pay close attention to the air filter indicator lamp Inspect new filter elements for damage cracks Never use damaged air filter elements No further maintenance cards are required No special tools required SR Caution Never use the engine without an air filter If you discover that the air filter is damaged stop machine operation immediately Prevent dirt and other impurities from entering the oil system on the engine or compressor Cover the air intake opening when the air filter is removed The compressor or engine could be damaged Environmental protection Dispose of old air filters and safety cartridges in accordance with regula tions Preparation Complete the following tasks before changing the air filter gt Align the machine horizontally gt Shut down the machine before starting work Chapter 7 6 Shutting down the machine WK05 001_0605en 7 29 Maintenance card 05 001 Air filter Cleaning the dust trap Safety cartridges Cleaning the air filter element B Page2 Dees BRINKMANN MASCHINENFABRIK GMBH amp CO KG Larger dust particles collect in the dust trap and do not therefore clog
130. on to daily weekly and six monthly maintenance tasks Task Industrial safety inspection Accident Prevention Regulati ons by a qualified person Measurement and inspec tion equipment operating and auxiliary materials Comment Have Brinkmann perform this inspection Have the safety valve on the compressed air tank checked Authorised specialist workshop Have adjusted replaced if necessary Change the hydraulic fluid filter and hydraulic fluid Viscoclub HLP 46 MC 10 001 Hydraulic system Replace the compressor oil filter and compressor oil now at the latest BP Energol HLP HM 46 at 10 C SHELL Corona AS 46 MC 09 001 Compressor Have the hydraulic system loader scraper checked Have Brinkmann check this compo nent Have the air oil separator on the oil trap replaced Have Brinkmann replace this component Replace all V belts now at the latest Specialist workshop Check engine valve play and have adjusted if necessary Specialist workshop See also Deutz operating manual Have the toothed belt with tension roller for controlling the engine valves checked 07DF001_0605_en Specialist workshop Have replaced if necessary BRINKMANN MASCHINENFABRIK GMBH amp CO KG 7 Maintenance More than 1000 operating hours Maintenance intervals over several years in addition to daily weekly six monthly and annual maintenance tasks Measu
131. ontrol Charge monitor indicator lamp does not light up when the control is switched on On digital controls nothing appears on the display Cannot start motor Cause Remedy Flat or faulty battery Check electrolyte level and charge battery Replace faulty battery Maintenance card 04 001 Battery Loose battery connection or oxidised Check and repair Maintenance card 04 001 Battery battery maintenance battery terminals Loose cable connection or damaged Check the cable connections and wiring and repair if necessary wiring Dynamo or V belt faulty Replace the dynamo or the V belt Engine indicator lamp does not light up briefly when the engine starts CAUTION Engine can be operated the sensors for the oil pressure and engine temperature are inoperative however Engine is not protected in the event of a fault Faulty sensors or wiring Check the engine temperature sensor engine oil pressure sensor and wiring replace if necessary 6 2 O6DFO001_0605_en BRINKMANN MASCHINENFABRIK GMBH amp CO KG 6 Troubleshooting guide Charge monitor indicator lamp lights up when the engine is running The battery on the machine does not charge The machine can be operated until the battery is flat Cause Remedy Faulty V belt on dynamo Check the V belt and replace if faulty Faulty dynamo Check dynamo and replace if necessary The starter does not turn the engine when the ON button is pressed
132. oupling indicator 2 must change from red to green gt Push down the lever 1 Inspect the wear indicator 3 after driving approx 500m It must turn green gt Connect the tailgate bracket cable to the towing vehicle Caution Only tow the machine when the trailer coupling is attached and secured correctly The breakaway cable Chapter 4 2 Breakaway cable must be attached correctly Release the handbrake remove the wheels chocks and wind up fold in and secure the support wheel before towing the machine Never move a machine with a negative drawbar load Do not load the machine O04DF001_0605_en BRINKMANN 4 Transport and connection MASCHINENFABRIK GMBH amp CO KG Disconnecting the Tow the machine as close as possible to the set up site Pushing the machine machine increases the risk of accident so take extra care in such cases Disconnect machines with a DIN trailer coupling ring in accordance with the specifications provided by the manufacturer of the towing vehicle or the coupling At the set up site detach machines with a ball head coupling from the towing vehicle as follows gt Detach the tailgate bracket cable from the towing vehicle gt Wind down the support wheel until the ball head coupling on the towing vehicle is no longer under load Pull the lever 1 upwards The coupling indicator 2 must change from green to red Caution Do not use the
133. out is activated O4DF001_0605_en 4 25 4 8 Transport and connection Shutting down the machine after operation Instructions for winter operation BRINKMANN MASCHINENFABRIK GMBH amp CO KG You can shut down the machine once all inspection work is complete Always secure the machine against unauthorised inadvertent starting Switch off the engine by pressing the OFF button The compressed air tank depressurises automatically Switch off the control by pressing the main switch under the hood Close the hood and secure Close the flap on the control panel and secure with a padlock During the cold winter months work is hampered by low temperatures Perform any maintenance and repair work during this period if possible bring the machine to an authorised specialist workshop for an annual check The machine can only function correctly above temperatures of 0 C Observe the following points Never use frozen material Use winter diesel Additives keep winter diesel fluid at low temperatures whereas summer diesel may thicken and block the fuel lines Chapter 75 Operating materials Use a compressor oil whose viscosity is adapted to the temperature Chapter 7 5 Operating materials compressor oil In extremely low temperatures remove the battery after completing work and store in a warm place Only reinstall shortly before starting the machine Check the acid level and acid con
134. ow to clean the engine oil cooler and the compressor oil cooler Refer to the maintenance tables in Chapter 7 2 Maintenance intervals for details of the maintenance intervals Both cooling elements are fitted at the front of the machine next to one an other and supplied with cooling air by the fan No further maintenance cards are required No special tools required Danger The oil cooler may be extremely hot if the machine has just stopped operating Risk of burning Clean the oil cooler only when the machine is cold Caution c m mc If you decide to clean the oil cooler using water make sure that water does not enter the oil systems the air system or the electronics Cover or seal off all relevant openings and components on the machine before hand to protect them from damage Do not set the air or water pressure too high and keep the nozzle on the cleaning equipment at a reasonable distance from the cooling ele ments Do not spray the cooling fins on the oil cooler at an angle only in the direction of air flow The cooling fins may bend and the cooling elements will then be damaged Maintenance card 07 001 Oil cooler Preparation Cleaning the oil cooler external Page 2of2 BRINKMANN MASCHINENFABRIK GMBH amp CO KG Complete the following tasks before cleaning the oil cooler gt Shut down the machine before starting work Chapter 7 6 Shutting down the machine gt
135. p CO KG Aggregate water and binder are mixed together in the mixing tank Caution m en nn Load the mixing tank only when the mixing mechanism is switched on Fill the mixing tank to no more than 15 mm below the lower edge of the filling dome 15 mm N U SN Swivel the hopper 1 onto the filling dome on the mixing tank gt Fill the mixing tank approx 100 l with aggregate Z up to half way Fill binder B directly into the mixing tank via the hopper 1 in accor dance with the manufacturer s instructions Fill the necessary quantity of water W into the mixing tank gt Fill the mixing tank with aggregate Z Check whether sufficient water has been added Top up with water if necessary Swivel back the hopper 1 clean the edge of the dome and close the cover 2 on the mixing tank Allow the machine to continue mi xing with the cover closed for at least 2 minutes before starting the material delivery cycle O5DF001_0608_en 5 Operation 5 11 Delivering material Generating tank pressure Mixing mechanism button Flotation air button 05DF001_0608_en BRINKMANN MASCHINENFABRIK GMBH amp CO KG The cover on the mixing tank must be closed before material is deliver ed The header air and flotation air must be set and readjusted in ac cordance with the line thickness line lengt
136. plings O4DF001_0605_en BRINKMANN MASCHINENFABRIK GMBH amp CO KG Delivery hoses are available with different inner diameters e g nominal width 50 60 65 Selecting a suitable delivery hose depends on the material you wish to pump A decisive factor in hose selection is the size of the aggregate grains The larger the aggregate grains are e g gravel the larger the nominal width of the delivery hoses must be Delivery hoses and their couplings are subject to natural wear caused by abrasion and material ageing Therefore have a qualified specialist check the operational reliability of the delivery hoses every 3 months and record this inspection on the safety inspection sheet Never use damaged delivery hoses Always use original Brinkmann delivery hoses and couplings or hoses and couplings approved by Brinkmann Consult your Brinkmann After Sales partner in this regard You will require different types of coupling connection that correspond with the nominal width of the delivery hose Secure all connected hose couplings Nominal width 50 Nominal width 53 Nominal width 60 various types Note Always connect delivery hoses with the same nominal width otherwise the output of the machine will decrease and minor blockages may form in the delivery line Connect only clean hose couplings together The seals on the hose couplings should not be damaged or dirty Dirty couplings will no
137. priate points in the operating manual Note Special safety regulations may be necessary for some tasks These special safety regulations are only found in the description of the particular task The following is a list of regulations and safety standards for further reference Machinery Directive 98 37 EC pr EN 12001 Delivery spraying and distributing machines for concrete and mortar EN 292 Safety of machinery pr EN 12151 EN 60204 1 Electrical equipment of machines EN 50081 1 EN 50082 1 EMC Directives 89 336 EEC Low voltage Directives 73 23 EEC Safety regulations for mortar delivery and spraying machines issued by the German Industrial Employers Liability Insurance Association ZH 1 575 02DF001_0605_de 2 2 1 Safety regulations Principle Onwards sale BRINKMANN MASCHINENFABRIK GMBH amp CO KG Use the machine only as specified and when in technically perfect condition be aware of safety factors and dangers and observe the operating manual Any faults especially those affecting machine safety should be rectified immediately Make sure that safety equipment is not removed rendered inoperable or modified protective grille on the filling dome etc safety equipment removed for the purposes of maintenance work is refitted immediately after the work is completed Check operational safety every time you start work Any defects identified or suspected must
138. r you should grease or preserve the machine as required Do not store the machine for longer than three months If in any doubt consult your local Brinkmann service partner Proceed as follows Note Preservation and greasing protect the machine against corrosion and premature ageing and are deemed necessary if the machine is not used for longer periods is exposed to a corrosive atmosphere during transportation or storage gt Empty the machine as described in Chapter 5 17 Finishing work clean thoroughly and switch off gt Lubricate all lubrication points on the machine Maintenance card 02 001 Lubrication diagrams Run the engine until warm and then shut down the machine Drain the oil from the engine and fill with corrosion protection oil Maintenance card 08 001 Engine Drain the fuel tank and fill with a mixture of 90 diesel fuel and 10 corrosion protection oil Start the engine and allow to run for approx 10 minutes Switch off the engine and shut down the machine Then crank the engine by hand to preserve the cylinders and combustion chambers Close Seal off the intake and exhaust openings gt Remove the V belt pack and place in storage Spray the grooves on the V belt pulleys with anti corrosion agent Preserve the machine with a suitable anti corrosion agent Brinkmann BC machine preservative agent item no 605 000 0000 gt Remove the battery store in a dry well ventilated p
139. r oil filter Start the machine and allow the compressor to run for approx 2 minutes under no load gt Inspect the oil drain plugs and oil filter seal for leaks gt Shut down the machine again Chapter 7 6 Shutting down the ma chine gt Make sure that the compressed air tank is depressurised Seal up any leaks that may occur Check the compressor oil level and top up if necessary Maintenance card 09 001 Compressor BRINKMANN MASCHINENFABRIK GMBH amp CO KG WKO09 001_0605en Maintenance card 10 001 Hydraulic system Loader Scraper hydraulic system Protective equipment Preparation BRINKMANN Page 1 of 4 MASCHINENFABRIK GMBH amp CO KG This maintenance chart describes how to change the hydraulic fluid Refer to the maintenance tables in Chapter 72 Maintenance intervals for details of the maintenance intervals Use only hydraulic fluids speci fied in Chapter 7 5 Operating materials hydraulic system The hydraulic fluid tank is located centrally on the right side of the machine No further maintenance cards are required No special tools required Note When maintaining hydraulic systems cleanliness is of the utmost im portance Prevent dirt or other impurities from entering the hydraulic system Never leave the tank lid off for longer than necessary Small particles in the oil may scratch valves cause pumps to seize and clog restrictors and control bores E
140. rement and inspec Task tion equipment operating Comment and auxiliary materials Every 18 months or Texaco Meropa 680 Specialist workshop after 5000 operating hours change the gearbox oil Every 2 years have the T V Dekra etc roadworthiness of the machine checked by an officially certified test centre Every 2 years External inspec Pressure vessel regulation tion of the mixing tank by an officially certified test centre Every 3 years have the dam Specialist workshop pers on the overrunning brake equipment replaced Every 3 years or after 3000 Specialist workshop operating hours have the toothed belt with tension roller for controlling the engine valves replaced Every 3 years or after 3000 Specialist workshop operating hours have the injection valves checked and adjusted Every 5 years Internal inspec Pressure vessel regulation tion of the mixing tank by an officially certified test centre Every 10 years Strength Pressure vessel regulation test on the mixing tank by an officially certified test centre 7 8 07DFO01_0605_en 7 Maintenance BRINKMANN MASCHINENFABRIK GMBH amp CO KG Maintenance work on the chassis Task After the first 50 km and after each wheel change check the tyre pressure and make sure the wheel nuts are seated securely After the first 100 200 km have the brake system adjusted Every 10 000 15 000 km check that the fastening bolts
141. rmation on starting up the machine and includes instructions on how to check the condition of your machine and how to carry out a test run including function checks After receiving the machine the operator must familiarise himself with the machine This means He must have read and understood this operating manual In particular Chapter 2 Safety regulations Inthe event of an emergency he must take the proper measures for shutting down and securing the machine etc Chapter 5 1 Shutdown in an emergency Every time the machine is used the operator must assume full responsibility for the safety of personnel located in the working area around the machine The machine operator is therefore obliged to ensure that the area surrounding the machine is completely safe Chapter 2 10 Working area The entire system should be monitored during the first few hours of operation to identify any potential malfunctions Important inspections and checks must be performed before the machine can be started Check whether the machine has been set up correctly Chapter 4 5 Set up site Always inspect the machine thoroughly for obvious defects before starting work Inspect under the hood as well Maintenance card 01 001 Visual inspection Check the most important wear parts such as the V belt delivery line and mixing mechanism Check whether all lubrication points are lubricated sufficiently Make sure that there is sufficient grease in the
142. rs neeceeessmnennnnnnnennennnnnennn 2 7 Personnel selection and qualification 2 7 UU UMN i oe NE tease ct ba Aa AT E 2 7 Qualified electrician 2 nn 2 8 Hydraulics engineer enenennnenen 2 8 WOorkp acer 2 8 Operatore onana ee Pe ESTER AS er Ten ee rE TAA 2 8 Screed layer 200cnsssssssnennesnnnnnnennnnnennnnnennnen 2 8 Working AIO nennen nern 2 8 Procedure in an emergency nennnennnnnnen 2 8 Protective equipment uussnssssnsnnnnennnnnennennnnnnnnnnnnn 2 9 allt ca 21 WERE REINER tanga 2 10 BRINKMANN MASCHINENFABRIK GMBH amp CO KG Table of contents 2 14 TRIOCK AGES ee ee 2 11 2 15 Hydraulic and pneumatic systems 2 12 2 16 NoiSe aces scan eet ERBEN LEEUNEEENAERE RW EHER ENESEHEHNE 2 13 2 17 Environmental protection nennen 2 13 2 18 Spare Dar sees hast aaatcaysessertvaacacinaduteaaanadadactacccneedens 2 13 2 19 Storing Ihe nachlesen 2 13 2 20 Unauthorised Inadvertent machine start Up 2 14 3 Technical description 3 1 DS CMON a res nn nagrendeeereeteenn 3 1 3 2 EQUIPMENT a ee een hey detains 3 1 3 3 Scope Of SUNY ns een eher 3 1 3 4 WETS OU ore iisanteininasctutaaiad an cinandaanianader aatanedaedaantnalaaaedvnnds 3 2 3 5 Technicaldataisrr nennen 3 3 COMPPESSON EN QING cc ccietetusmtscistancuaevairaaraninonmnereuasnay 3 4 PMI ek oh ach cette sete E EEE A 3 4
143. rs respira tory protection etc Always observe the rules and specifications of trade associations especially the accident prevention regulations Only process and deliver materials that the machine was designed to process see Chapter 2 2 Designated use and Chapter 2 3 Use contra ry to the designated use If in any doubt please contact your Brinkmann service partner Safety measures during Is the machine securely positioned Is the machine secured against normal operation moving or rolling Rectify immediately any faults that may affect safety Operate the machine only when all protective devices are attached and fully functional Before switching the machine on make sure that no one can be inju red by the starting machine Inspect the machine at least once every shift for visible external dama ge and check the function of the safety devices 5 2 O5DF001_0608_en BRINKMANN 5 Operation MASCHINENFABRIK GMBH amp CO KG Checks before Before starting always check the following points starting Are all the delivery hoses correctly in place Are the delivery hoses and hose couplings undamaged and secured properly Are all rising lines secured tightly Is the end of the delivery hose attached to the discharge stand Have all lubrication points been lubricated in accordance with MC 02 001 Lubrication diagrams Interrupting work If work is interrupted for longer periods
144. s Wheels Printed circuit boards Printed circuit boards Parts requiring The following operating materials and machine components must be separate disposal separated prior to disposal Material Electronic scrap Oils and fluids used for in Switch cabinet Control unit Electric motor Scraper remote control Batteries on machines with scraper Compressor oil Hydraulic fluid on machines with loader scraper 05DF001_0608_en 6 Troubleshooting guide BRINKMANN MASCHINENFABRIK GMBH amp CO KG 6 Troubleshooting guide DC 260 general D gt N gt POG O6DF001_0605_en This chapter contains an overview of faults their possible causes and remedies for the Trans Mix DC 260 When troubleshooting always ob serve the general safety regulations Chapter 2 Safety requirements Danger Never release the hose couplings while the mixing tank is still operating and pressurised Material could escape under pressure and cause serious injury in particular to the eyes Check that the ventilation lever is in the top position Do not rely entire ly on the pressure gauge display as it may be faulty Even if the tank is depressurised the delivery hoses may still be pressu rised and material could spray out when the hose coupling is released Therefore always wear protective goggles cover the coupling before releasing and avert your
145. s and is underlined Caution Particular specifications or instructions and prohibitions relating to damage prevention are highlighted with the word Caution in bold and the pictogram illustrated Accompanying text appears in italics and is underlined Continued on next page 01DF001_0607_en 1 3 1 Introduction A A BRINKMANN MASCHINENFABRIK GMBH amp CO KG Danger Particular specifications or instructions and prohibitions relating to the prevention of personal injury or extensive damage are highlighted with the word Danger in bold the pictogram illustrated and a line Accompanying text appears in italics and is underlined If the nature of the danger is known the text is preceded by the corresponding warning pictogram Danger of crushing This symbol is used for tasks that pose a risk of crushing to personnel or body parts Suspended loads _ ___ ___________ This pictogram is used for tasks where falling loads pose a serious risk High voltage This symbol is used for tasks that pose a risk of electric shock with potential fatal consequences 01DFO01_0607_en 2 Safety regulations BRINKMANN MASCHINENFABRIK GMBH amp CO KG 2 Safety regulations This chapter summarises the most important safety regulations and is therefore particularly suitable for instructing new operators for the first time Naturally the various regulations also appear again at the appro
146. s are also described DC 260 45 B S Scraper optional Loader optional Compressor output approx Mixing tank volume total in Diesel compressor The DC 260 is fitted with the following standard equipment Automatic electrically powered central lubrication system for sealing or storing the mixing tank Central lifting eye concealed in the hood Protective grille cut out EMERGENCY STOP button Safety cover with automatic depressurisation Automatic pressure cut out at pump end The following parts are included in the scope of supply Trans Mix DC 260 Operating manual Tailgate bracket 12 V DC or 24 V DC Tank outlet with connection NW 50 or NW 60 65 Ball head trailer coupling or DIN trailer coupling ring Tool set 2 batteries charger remote control cable machine with scraper The specifications relate to the series machine The scope of supply may deviate from these specifications if special equipment is fitted 03DF001_0608_en 3 4 Technical description Overview DC 260 45 DC 260 55 Standard DC 260 45 B DC 260 55 B Loader DC 260 45 BS DC 260 55 BS Loader and scraper BRINKMANN MASCHINENFABRIK GMBH amp CO KG Below you will find an overview of the most important components these will then be described in more detail on the following pages ONDUVUPWMN Overrunning brake equipment Chassis Hood Control panel
147. sk In the first six weeks of operation clean all painted surfaces with cold water only at a maximum pressure of 5 bar Do not use any aggressive cleaning agents The paintwork should have hardened completely after six weeks you can then use e g steam jets to perform cleaning work Do not use corrosive or flammable cleaning agents in particular tetrachloromethane Use lint free cloths only After cleaning spray the machine with Brinkmann BC machine preservative agent This prevents rust from forming and protects and preserves the machine without damaging rubber components cables or seals Brinkmann accepts no liability for the use of other agents in particular diesel fuel After cleaning immediately remove any covers adhesive tape that you attached for cleaning work Forgetting to remove all the covers adhesive tape may damage the machine All lubrication points must be lubricated after cleaning 5 Operation Cleaning the mixing tank BRINKMANN MASCHINENFABRIK GMBH amp CO KG gt Shut down the machine and secure against unauthorised inadvertent starting See Chapter 7 6 Shutting down the machine gt Raise the protective grille on the filling dome and move to one side gt Thoroughly rinse the mixing tank with a liberal amount of water until all mortar residues have been removed In particular make sure that crusts of dirt do not form on the seals around the mixing shaft as thes
148. socket 4 on the radio receiver on Charging the battery You can charge flat batteries via the charger on the machine The bat tery is charged quickly 2 minutes to 1 hour providing its temperature remains between 10 C and 40 C The battery is charged at normal speed outside of this temperature range If the control is switched off the battery can be charged if the EMERGENCY STOP button is unlocked The machine must be connected to the mains power supply to charge the battery A spare battery is included in the scope of supply gt Connect the remote control to the socket 4 on the radio receiver using the remote control cable The remote control signals are now transmitted via the cable gt Disconnect the battery 2 from the scraper remote control and plug into the charging socket 3 on the charger The charging indicator lamp is lit continuously during the charging process and flashes when the battery is charged m Only recharge the battery when flat otherwise the capacity of the bat tery will decrease and the battery will become unusable Nole I If the ambient temperature is too warm for rapid charging the charging indicator lamp on the battery starts to flash when connected to the socket on the control However the battery may also be faulty Chapter 6 Troubleshooting guide charging indicator on the battery flashes when connected to the socket on the control
149. ss in the control system Remedy Have Brinkmann check and repair the control system Control valve faulty dirty set incorrectly Have Brinkmann check adjust replace the valve Safety valve faulty opens too soon Have an authorised specialist workshop check adjust replace the safety valve Capacity or pressure of compressor lower than usual Cause Air consumption exceeds the capacity of the compressor Remedy Check the consumer system downstream of the compressor air lines mixing tank tank outlet connected air consumer Air filter element clogged Clean or replace the air filter element Air filter maintenance card Dump valve not fully open Set the speed control cable correctly Air oil separator element clogged Have Brinkmann check replace the element Blow out valve releases air Have Brinkmann check adjust replace the valve Engine runs slowly Check Adjust the engine speed regulator Maintain fuel filter replace if necessary Maintenance card 06 001 Fuel filter Air flow rate from compressor minimal Pressure excessive Air oil separator element clogged Have Brinkmann check replace the air oil separator O6DF001_0605_en Troubleshooting guide BRINKMANN MASCHINENFABRIK GMBH amp CO KG Compressor oil consumption is excessive oil mist escaping from discharge valves Cause Compressor oil level too high Remedy Drain oil until it reach
150. ster by the handle only 2 and adjust to the same height as the vehicle coupling Turn the locking toggle 3 clockwise as far as possible and then strike with a rubber or plastic hammer Insert the split pin 1 again to secure the parallel adjuster Caution Only tow the machine when the drawbar is parallel with the ground This procedure guarantees maximum ground clearance during the journey and makes sure the overrunning brake can function correctly Always adjust the parallel adjuster accordingly in relation to the drawbar 4 Transport and connection Ball head coupling Coupling indicator 1 Wear indicator 2 BRINKMANN MASCHINENFABRIK GMBH amp CO KG The ball head coupling on the machine is fitted with a coupling indicator 1 and a wear indicator 2 Before towing attach the coupling on the machine correctly to the trailer coupling on the towing vehicle and lock The coupling indicator consists of a red and green cylinder on the ball head coupling When the coupling is open only the red head of the cylinder is visible If the coupling is connected correctly the cylinder pops out to reveal a green edge Danger If the cylinder does not pop out when the machine is attached and only the red head of the cylinder is visible the coupling is not connected correctly or is faulty and the machine should not be towed under any circumstances The ball head co
151. t again Check the oil level on the dipstick 1 WK08 001_0605en Maintenance card 08 001 Engine Topping up the engine oil Changing the engine oil WK08 001_0605en Be Page30f5 jos BRINKMANN MASCHINENFABRIK GMBH amp CO KG This section describes how to top up the engine oil Proceed as follows gt Open the engine oil filler neck 2 gt Fill with engine oil up to the maximum mark 7 5 Operating materi als engine As a precaution use the same engine oil that you are already using in the machine Note down the exact oil grade Check the oil level Only fill up to the maximum mark Close the filler neck 2 tightly Proceed as follows to change the engine oil Place a suitable container under the oil drain valve 3 on the engine gt Open the protective cap on the oil drain valve 3 and screw on the oil drain hose The oil will begin to flow as soon as the hose is at tached Open the oil filler 2 to accelerate the draining process gt Unscrew the oil drain hose once the oil has drained completely Screw the protective cap back onto the oil drain valve 3 gt Fill fresh engine oil into the filler neck 2 75 Operating materials engine Check the engine oil level Close the filler neck 2 tightly gt Inspect for leaks Maintenance card 08 001 Engine Changing the engine oil filter BRINKMANN Page 4 of5 MASCHINE
152. t page 07DF001_0605_en Filter wrench MC 06 001 Fuel filter 7 Maintenance BRINKMANN MASCHINENFABRIK GMBH amp CO KG Every 500 operating hours Six monthly maintenance tasks in addition to daily and weekly maintenance tasks Task Replace the air filter and safety cartridge now at the latest Measurement and inspec tion equipment operating and auxiliary materials Comment MC 05 001 Air filter Measure the pressure drop at the air oil separator If the drop in pressure exceeds 0 8 bar have Brinkmann replace the air oil separator Replace the sealing washer on the oil trap Have Brinkmann replace this component Check the axial clearance of the wheel hub bearing Specialist workshop Change the gearbox oil for the first time after 500 operating hours Texaco Meropa 680 Specialist workshop Have the power belt replaced now at the latest Specialist workshop Check the electrical system wiring Have an electrician check repair any faults damage to the electrical system wiring Replace the seal on the mixing tank cover now at the latest Replace the sealing ring and spring on the check valves now at the latest MC 11 001 Check valves Clean filter insert on the fuel tank 07DFO01_0605_en 7 Maintenance BRINKMANN MASCHINENFABRIK GMBH amp CO KG Every 1000 operating hours Annual maintenance tasks in additi
153. t seal properly and allow water to leak out under pressure which inevitably leads to blockages Transport and connection BRINKMANN MASCHINENFABRIK GMBH amp CO KG Selecting the connection The mixing tank connection fitted to the mixing tank outlet must match for the mixing tank outlet Laying delivery hoses the nominal width of the delivery hose selected see illustrated example 1 Mixing tank connection for nominal width 60 or larger 2 Mixing tank connection for nominal width 50 3 Mixing tank connection for nominal width 50 with stone trap The stone trap on the connector is a special feature that catches and retains larger stones to prevent them from blocking the delivery line If a mixing tank connection with nominal width 60 65 is fitted the stone trap can also be used for quick reduction to nominal width 50 You can connect delivery hoses with different widths more easily using the stone trap Keep the delivery hose line as short as possible Do not connect more delivery hoses than necessary and do not kink delivery hoses Lay the delivery line with a generous bending radius whereby the curve radius should be no less than six times the external hose diameter Delivery hoses must be designed to withstand the delivery pressure and should be laid and secured professionally Use faultless delivery hoses and couplings only Continued on next page O4DF001_0605_en 4 Transport and connection
154. tart to rotate shortly afterwards If not press the mixing mechanism button to activate the mixing mechanism Press and hold the central lubrication system button until grease vis ibly escapes from the mixing shaft bearings gt Switch off the machine gt Replace the cover on the machine control WKO3 001_0605en Maintenance card 04 001 Battery Battery WKO4 001_0605en 5 F A BRINKMANN MASCHINENFABRIK GMBH amp CO KG Page 1 of 3 This maintenance card describes all maintenance work required for the battery Refer to the maintenance tables in Chapter 72 Maintenance intervals for details of the maintenance intervals No further maintenance cards are required No special tools required UNS gy The gases emitted by the battery are explosive Avoid lighting naked flames or producing sparks near the battery The electrolyte used in the battery is a caustic sulphuric acid solution Do not allow acid to come into contact with your eyes skin or clothing If acid comes into contact with the skin rinse off with plenty of water If acid gets in your eyes rinse immediately with cold clear water and then consult a doctor Note The battery is located at the bottom right under the machine hood Protective equipment Always wear protective goggles and suitable protective gloves when working with sulphuric acid or an open battery These will protect you from possible burns
155. the dipstick 1 gt Reinsert the dipstick 1 Topping up This section describes how to top up the hydraulic fluid Proceed as fol hydraulic fluid lows Put on protective equipment Open the hydraulic fluid filler neck 2 gt Fill with hydraulic fluid up to the maximum mark 7 5 Operating materials hydraulic system As a precaution use the same hydraulic fluid that you are already using in the machine Note down the exact fluid grade Check the fluid level Only fill up to the maximum mark Close the filler neck 2 tightly 7 50 WK10 001_0605en Maintenance card 10 001 Hydraulic system Changing the hydraulic fluid Changing the hydraulic fluid filter WK10 001_0605en B Page 3of4 ku BRINKMANN MASCHINENFABRIK GMBH amp CO KG Proceed as follows to change the hydraulic fluid Place a suitable collecting container under the drain plug on the hy draulic tank gt Unscrew the drain plug The old hydraulic fluid drains out Open the filler neck 2 to accelerate the draining process gt Once the fluid has drained completely screw in the oil drain plugs with new sealing washers and tighten torque 55 Nm Fill fresh hydraulic fluid into the filler neck 75 Operating materials hydraulic system Only fill up to the maximum mark Check the hydraulic fluid level Close the filler neck tightly Proceed as follows to change the hydraulic fluid filter Have a
156. thout first dis connecting the battery on the machine Read also Chapter 7 6 Shutting down the machine The protective grille may be removed only for set up maintenance repair or cleaning work and must be refitted immediately after the work is complete and function correctly 3 Technical description Protective guard V belt Maintenance flap power belt BRINKMANN MASCHINENFABRIK GMBH amp CO KG The V belt on the dynamo is covered by a protective guard 1 to prevent personnel from reaching into the moving V belt while the machine is operating e g during brief visual inspections Always attach the protective guard 1 correctly before starting the machine Danger Always attach the protective guard correctly before starting the machine s engine In addition refit the protective guard correctly before starting the engine for function checks Never remove the protective guard without first disconnecting the battery on the machine See Chapter 7 6 Shutting down the machine Ignoring this instruction may cause serious injuries The protective grille may be removed only for maintenance or cleaning work and must be refitted correctly immediately after the work is com plete The automatic V belt release and the power belt 3 on the mixer drive are located behind the maintenance flap 2 above the mixing tank toge ther with the check valves 4 on the header and flotation air lines Danger __ ____
157. tically depressurise the mixing tank Carefully depressurise the mixing tank if still pressurised after an EMERGENCY STOP automatic lever air relief cock Before opening the cover or releasing a hose coupling check the pressure gauge to see whether the mixing tank is depressurised Even if the tank is depressurised the delivery lines may still be pressurised Only operate the machine when the EMERGENCY STOP button is fully functional gt Unlock the EMERGENCY STOP button by pulling and turning Switch the control on and off at the main switch to start the machine restart protection after the EMERGENCY STOP button is pressed Check the functional capability of the protective grille cut out gt Start the machine Chapter 5 4 Starting the machine gt Lift the protective grille This should trigger the circuit breaker The motor switches off The compressed air tank depressurises The mixing mechanism stops Danger Do not reach into the mixing tank unless the machine has been shut down and the battery is disconnected Chapter 7 6 Shutting down the machine Ignoring this instruction may cause serious or fatal injuries Take great care when opening the protective grille to check the function of the protective grille cut out Operate the machine only if the protective grille cut out is fully functional Switch the control on and off at the main switch to start the machine restart protection after the protective grille cut
158. tions correctly Measurement and inspec tion equipment operating and auxiliary materials Comment Specialist workshop Have repaired Every 10 000 15 000 km check that the support wheel functions correctly support wheel easy to move attached correctly locking toggle fully functional Specialist workshop Have repaired Every 10 000 15 000 km check the axial play on the wheel bearings and the play on the guide bearings Specialist workshop Have repaired Every 10 000 15 000 km check that the fastening bolts on the trailer coupling ring or ball head coupling are seated securely Chapter 7 4 Tightening torques Use a torque wrench Every 10 000 15 000 km check that the ball head coup ling is fully functional and easy to move also inspect for wear Specialist workshop Have repaired 07DF001_0605_en 7 Maintenance BRINKMANN MASCHINENFABRIK GMBH amp CO KG Tightening torques The tables below indicate the maximum tightening torques in Nm for of set screws a friction coefficient of mtotal 0 14 with the thread lightly oiled or lightly greased SW Width across flats X X Grade 8 8 10 9 12 9 Precision thread Dimensions Tightening torque Dimensions mm Tightening torque mm Nm Nm 8 8 10 9 12 9 M SW 88 10 9 12 9 e Note H H
159. trapped material Free the mixing shaft Machine does not deliver even though the ventilation lever is pressed down Cause Mixing shaft does not function Remedy The mixing shaft must function for material to be delivered normally Press the mixing mechanism button g to switch on the mixing shaft Proximity switch on the ventilation lever is faulty Check the proximity switch on the ventilation lever and wiring replace if necessary If the proximity switch is faulty flotation air can be controlled manually via the flotation air button X Blockage in the tank outlet delivery hoses Delivery pressure above 6 bar The delivery material has blocked the tank outlet or the delivery hoses Chapter 5 15 Delivery stops Blockages Solenoid operated valve faulty Flotation air cannot be switched on Check the solenoid operated valve and wiring replace if necessary Machine begins to deliver even though the ventilation lever is not pressed down Proximity switch on the ventilation lever is faulty Check the proximity switch and wiring replace if necessary If the proximity switch is faulty flotation air can be controlled manually via the flotation air button 9 O6DFO001_0605_en 6 Troubleshooting guide BRINKMANN MASCHINENFABRIK GMBH amp CO KG Compressor does not reduce power requirement engine continues to run at maximum speed relief valve opens to dump pressure Cause Air lo
160. upling could detach itself during the journey Risk of accident The wear indicator is located on the handle 3 of the ball head coupling and becomes visible when the handle is closed It indicates the wear on the machine ball head coupling or on the towing vehicle ball If the wear is within the permitted limits the wear indicator is green but if the ball head coupling or ball are worn the wear indicator is red green area is no longer visible Note Tow the machine approx 500m before inspecting the wear indicator The towing motion adjusts the coupling mechanism Danger If the wear indicator is red the machine has not been secured to the towing vehicle correctly and should not be towed The ball head coupling could detach itself during the journey Risk of accident O4DF001_0605_en BRINKMANN MASCHINENFABRIK GMBH amp CO KG 4 Transport and connection Permitted slewing circle The max slewing circle around the vehicle longitudinal axis angle of the machine in relation to the towing vehicle is 25 The max slewing circle around the vehicle transverse axis e g when driving over small dips railway lines or ramps is 20 20 20 25 25 Caution Exceeding the maximum slewing circle will overload the ball head coupling and may damage it There is then no guarantee that the ball head coupling will function correctly
161. urise the mixing tank if still pressurised after an EMER GENCY STOP automatic lever air relief cock Before opening the cover or releasing a hose coupling check the tank pressure gauge to see whe ther the mixing tank is depressurised Even if the tank is depressurised the delivery lines may still be pressurised Reset the EMERGENCY STOP button Unlock the depressed EMERGENCY STOP button by turning anticlo ckwise and then pulling out Turn the main switch on the control off and back on to operate the machine again O3DF001_0608_en 3 Technical description Protective grille 03DFO01_0608_en BRINKMANN MASCHINENFABRIK GMBH amp CO KG The mixing tank filling dome on your machine is fitted with a protective grille The mesh size allows material to fall into the tank yet guarantees protection for the operator If the protective grille is opened while the machine is operating a circuit breaker shuts off the engine This circuit breaker also prevents the engine from starting when the machine is switched off To clean the mixing tank or perform maintenance work the protective grille can be raised and swivelled to one side 1 Protective grille 2 Circuit breaker Danger _ Do not operate the machine without the protective grille Do not modify the protective grille Never reach inside the mixing tank wi
162. ve an authorised specialist workshop check adjust the brake system pneumatic spring faulty Brake pads have not been worn in The brake pads may not have been worn in before the machine was delivered The problem disappears after the brakes are applied a few times Carefully run in the brakes Significant friction losses Grease Ensure ease of movement of the handbrake including brake cable Have an authorised specialist workshop check adjust the brake system Difficult to adjust height of parallel adjuster Cause Remedy Joints seized Clean and grease Toothed discs corroded Adjustable peg seized Have a specialist workshop check repair replace the peg O6DF001_0605_en 6 11 BRINKMANN 6 Troubleshooting guide j MASCHINENFABRIK GMBH amp CO KG Ball head coupling does not engage when machine attached Cause Remedy Inner parts of the clutch are dirty or Clean Grease the ball head coupling and have repaired replaced by a specialist have seized workshop if necessary Ball on the vehicle coupling too large Replace the ball on the vehicle coupling Too much play between the ball head coupling and the ball Risk of detachment while towing Cause Remedy Ball on the vehicle coupling worn or Replace the ball on the vehicle coupling too small Ball head coupling worn slewing circle Have specialist workshop repair replace exceeded rivet bent 6 12 06DFO01_0605_en 7 Maintenance
163. very cycle BRINKMANN MASCHINENFABRIK GMBH amp CO KG If you wish to detach delivery hoses after a delivery cycle or disconnect them from the tank outlet always proceed as follows gt Shut down the machine before starting work See Chapter 7 6 Shut ting down the machine gt Make sure that the mixing tank is depressurised The ventilation lever must be in the top position Also check the pressure gauge to see whether the mixing tank is actually depressurised Danger Never release the hose couplings while the mixing tank is still operating and pressurised Material could escape under pressure and cause serious injury in particular to the eyes Check that the ventilation lever is in the top position Also check the pressure gauge to see whether the mixing tank is actually depressurised Even if the mixing tank is depressurised the delivery hoses may still be pressurised and material could spray out when the hose coupling is released Always wear protective goggles face mask and protective gloves cover the coupling before releasing and avert your eyes while disconnecting the hose coupling Make sure that other personnel are not at risk If material gets in your eyes in spite of all precautionary measures rinse them immediately under a tap and then consult a doctor gt Once all protection measures have been taken detach the hose cou plings carefully and remove the delivery hose 05DF00
164. while the mixing tank is still operating and pressurised Material could escape under pressure and cause serious injury in particular to the eyes Check that the ventilation lever is in the top position Also check the pressure gauge to see whether the mixing tank is actually depressurised Even if the mixing tank is depressurised the delivery hoses may still be pressurised and material could spray out when the hose coupling is released Always wear protective goggles face mask and protective gloves cover the coupling before releasing and avert your eyes while disconnecting the hose coupling Make sure that other personnel are not at risk If material gets in your eyes in spite of all precautionary measures rinse them immediately under a tap and then consult a doctor gt Once all protective measures have been taken putting on protective clothing coupling covered detach the delivery hoses again and tread on them lightly If another section of the delivery hose remains hard there is a second blockage This blockage pre vents the pressure in the delivery hose from escaping safely into the mixing tank Danger Never release the couplings on delivery hoses that are still pressurised The ends of the hose may thrash around unpredictably posing a risk of fatal injury Before releasing a hose coupling always eliminate the blockages at the mixing tank end by shaking bending and tapping the line
165. with company procedures gt Search for the cause of the fault on the machine and rectify completely If necessary shut down the machine and secure against unauthorised inadvertent starting ERDE Pressing the EMERGENCY STOP button does not automatically depres surise the mixing tank Carefully depressurise the mixing tank if still pressurised after an EMERGENCY STOP automatic lever air relief cock Before opening the cover or releasing a hose coupling check the pres sure gauge to see whether the mixing tank is depressurised Even if the tank is depressurised the delivery hoses may still be pressurised BRINKMANN MASCHINENFABRIK GMBH amp CO KG 5 Operation 5 2 Safety This machine has been built using state of the art technology and in line with recognised rules of safety engineering However this machine can pose a risk to personnel and property as with all machines When operating the machine always observe the general safety regulations included in this operating manual see Chapter 2 Safety regulations Only use this machine for its designated purpose and when in perfect technical condition Rectify immediately any faults that may affect safety Under certain circumstances it may be necessary to handle materials that pose a risk to your health Therefore always wear the necessary protective clothing in accordance with the information provided by the manufacturer protective goggles gloves ear defende
166. y persons with special knowledge and experience of hydraulic systems who can produce appropriate certification of competence certificates of training Couplings should be fitted only by persons with the relevant experience and tools required for this task Always wear protective gloves in addition to eye and face protection when working on the hydraulic system Escaping fluid is toxic and can penetrate the skin Hot hydraulic fluid poses a risk of scalding Check all lines hoses and threaded unions regularly for leaks wear and damage Seal up any leaks and repair any damage immediately Splashed fluid may cause injury and pose a fire hazard The hydraulic system must be inspected regularly as specified in safety related machine inspection regulations Bursting lines pose a safety risk to personnel The manufacturer shall not be held liable for damage resulting from the use of worn or faulty components Replace faulty hydraulic lines do not repair them Hydraulic hoses and lines should be replaced every 6 years including a maximum storage time of 2 years even if there are no signs of external damage See the manufacturing date printed on the hoses Danger Before starting work on the compressor compressor oil lines and compressed air tank make sure that the machine has stopped and the compressor system is depressurised 02DF001_0605_de 2 16 2 17 2 18 2 19 Safety regulations Noise Operator Enviro
167. y after changing hoses gt Start the machine and the engine and allow to run for approx 2 minutes gt Inspect the new hoses and their connections for leaks gt Shut down the machine before starting work Chapter 7 6 Shutting down the machine Seal up any leaks that may occur WK13 001_0605en 8 Conformity 08BMO004_0605_en BRINKMANN MASCHINENFABRIK GMBH amp CO KG The DC 260 45 55 B and BS fulfil 98 37 EC Machinery Directive 89 336 EEC Electromagnetic compatibility in version 93 3 1 EEC 73 23 EEC Low Voltage Directive The Brinkmann DC 260 45 55 machine models B and BS were deve loped designed and built in full compliance with the above EC directive in the sole responsibility of BRINKMANN Maschinenfabrik GmbH amp Co KG An der Heller 4 12 e D 33758 Schlo Holte Germany Tel 49 0 5207 9147 0 Fax 49 0 5207 91 47 10 E mail info estrichboy de Internet www estrichboy de The following harmonised standards were applied EN 292 1 Safety of machinery Basic concepts general principles for design Part 1 Basic terminology methodology EN 292 2 Safety of machinery Basic concepts general principles for design Part 2 Technical principles and specifications DIN EN 809 Pumps and pump units for liquids Common safety requirements DIN EN 12001 Delivery spraying and distributing machines for concrete and mortar DIN EN 13445 Unfired pressure vessels EN 60204
168. y cable is long enough so that the towing vehicle does not pull it taut when travelling around corners Otherwise the emergency brake may trigger unintentionally during the journey DENLTEL The breakaway cable 1 must be threaded through the cable guide 2 for the emergency brake to function correctly For ball head couplings attach the breakaway cable to the vehicle coupling before connecting up the machine 4 Transport and connection Tailgate bracket BRINKMANN MASCHINENFABRIK GMBH amp CO KG The lights and the vehicle licence plate are fitted to the tailgate bracket Travel position Working position Before starting off on a journey attach the tailgate bracket to the holder 4 on the end of the mixing tank and secure with spring pins 3 Remove the power cable 2 from the holder and insert in the socket 5 on the lighting bracket Before starting work attach the tailgate bracket to the holder on the support wheel Note The cabling of the tailgate bracket is designed for 12 V and 7 pin connectors as standard If the towing vehicle has a 24 V or 12 pin connector you will need to use an adapter Refer to the towing vehicle user manual for information on the operating voltage 12 V or 24 V or consult the vehicle manufacturer The order number for the adapters are shown below Connector on Adapter Connector on towing vehicle the machine 12 V gt 12 V 7 pin 7 pin gt

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