Operating instructions

Spraymobile

MEYCO® Mamba S
with MEYCO® Suprema

Issue January 2007

 MEYCO® Spraymobile Mamba S

Operating instructions
Chapter 0 Introduction

First issue of these operating instructions: April 2005

Current state of these operating instructions: Version A

(Alterations/Index: see table at end of this chapter)

Chapter Title Pages Index Date

0 Introduction 6 A Jan. 2007
1 Technical data 6 A Jan. 2007
2 Safety 10 A Jan. 2007
3 Design and function 12 A Jan. 2007
4 Controls and modes of operation 6 A Jan. 2007
5 Commissioning 8 A Jan. 2007
6 Operation 14 A Jan. 2007
7 Maintenance 20 A Jan. 2007
8 Overhaul 14 A Jan. 2007
9 Taking out of service, storage 4 A Jan. 2007
10 Packing, transportation 6 A Jan. 2007
11 Disposal 8 A Jan. 2007
12 Replacement parts catalogue and 2 A Jan. 2007
schematics
Total 116

We reserve the right to make technical alterations without previous notice.

© The reproduction of these operating instructions, even in excerpts, is forbidden. Without written approval of the company
MEYCO Equipment, Division of Degussa Construction Chemicals (Schweiz) AG, CH-8404 Winterthur, no part may be reproduced
in any form or by use of electronic systems, especially in the form of photocopies, photographs, magnetic media or other modes of
recording, may it be processed, duplicated or disseminated. All rights, especially the right of duplication and translation as well as
patent or registration rights, are reserved.

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MEYCO® Spraymobile Mamba S

Operating instructions
Chapter 0 Introduction

Use of these operating instructions

These operating instructions are an integral part of the spraymobile MEYCO Mamba S and contain
important advice and instructions for safety and operation.

For all persons undertaking work on or with this spraymobile, it is an obligation to read and to
understand beforehand the chapter relevant to the activity.

There are requirements of the operating personnel for all work on and with the spraymobile. These are
described in Chapter 2 «Safety». Read this chapter first.

The spraymobile may only be operated for the application purpose specified by the manufacturer. This
is described in Chapter 2 «Safety» as «Use in accordance with the specifications». Read this chapter
first.

First read Chapter 2 «Safety»!

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 MEYCO® Spraymobile Mamba S

Operating instructions
Chapter 0 Introduction

List of Contents Chapters 1–12

This list gives a broad overview of the 12 Chapters of these operating instructions. A
detailed list of contents prefaces each chapter.

Chapter 1: Technical data

1 Scope of delivery, dimensions, weights, performance data, mains requirements, etc.

Chapter 2: Safety
2 Important safety notes – obligatory reading for all users

Chapter 3: Design and function

3 Description of the design and mode of functioning

Chapter 4: Controls and modes of operation

4 Description of the controls (entry point for Chapters 5 and 6)

Chapter 5: Commissioning
5 Instructions for installation and first commissioning

Chapter 6: Operation
6 Instructions for operation

Chapter 7: Maintenance
7 Maintenance scheme, maintenance tasks

Chapter 8: Overhaul
8 Troubleshooting list, repair instructions, etc.

Chapter 9: Taking out of service, storage

9 Instructions which must be followed for taking out of service and storage.

Chapter 10: Packing, transportation

10 Instructions and regulations which must be observed for packing and transportation

Chapter 11: Disposal

11 Instructions and regulations which must be observed for disposal

Chapter 12: Replacement parts catalogue, schematics

12 Drawings of components with related material lists, wiring diagram, etc.

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Operating instructions
Chapter 0 Introduction

Alterations list

Index Date Visa Chapter/ Description of alteration

Page
- New First edition
A Jan. 2007 Pfo all chapters Logo changed

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 MEYCO® Spraymobile Mamba S

Operating instructions
Chapter 0 Introduction

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Operation manual
Chapter 1 Technical data

1 Technical data

List of Contents Chapter 1

Page

1 Technical data .............................................................................................................................1-1

1.1 Designation and scope of delivery ....................................................................... 1-3
1.1.1 Designation ..................................................................................... 1-3
1.1.2 Scope of delivery ............................................................................ 1-3
1.1.2.1 Spraymobile MEYCO Mamba S ..................................................... 1-3
1.1.2.2 Standard Accessories..................................................................... 1-3
1.1.2.3 Optional accessories ...................................................................... 1-3
1.2 Technical data......................................................................................................... 1-4
1.2.1 Spraymobile MEYCO Robojet Mamba S........................................ 1-4
1.2.1.1 Dimensions, weight......................................................................... 1-4
1.2.1.2 Operating Voltage ........................................................................... 1-4
1.2.1.3 Carrier chassis ................................................................................ 1-4
1.2.1.4 Hydraulic system............................................................................. 1-4
1.2.1.5 MEYCO Suprema Performance data ............................................. 1-5
1.2.1.6 MEYCO Robjet Minima performance data ..................................... 1-5
1.2.1.7 Dosing system performance data ................................................... 1-5

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Chapter 1 Technical data

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Operation manual
Chapter 1 Technical data

1.1 Designation and scope of delivery

1.1.1 Designation
The name plate of the machine is fitted to the equipment and looks like this:

MEYCO Equipment
Division of BASF CC (Schweiz) AG
CH-8404 Winterthur
Typ: MEYCO® Spraymobile Mamba
Machine no.: Year of manufacture:
Made in Switzerland

Fig. 1-1. Name plate

1.1.2 Scope of delivery

consisting of:
• Spraymobile
• Standard accessories
• Optional accessories

1.1.2.1 Spraymobile MEYCO Mamba S

consisting of:
• Chassis Semmco
• MEYCO Robojet Minima
• MEYCO Suprema with dosing system MEYCO Mixa hydraulic
• Hydraulic system
• Additive tank

1.1.2.2 Standard Accessories

When delivered the following standard accessories should be with the vehicle.
• Nozzle system inner diameter 50mm or 65mm complete.

1.1.2.3 Optional accessories

• Early strength testing devices

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Chapter 1 Technical data

1.2 Technical data

1.2.1 Spraymobile MEYCO Robojet Mamba S

1.2.1.1 Dimensions, weight

Length: approx. 6800 mm
Width: approx. 2050 mm
Height: approx. 2230 mm
Hopper height: approx. 1250 mm

Weight: additive tank empty: approx. 7'000 kg

1.2.1.2 Operating Voltage

Voltage: 24 VDC
Alternator power: max. 80 A

1.2.1.3 Carrier chassis

Type: Semmco Mamba
Motor: Deutz BF4M1013C
Performance: 104 kW at 2300 1/min.
Permitted total weight: 11'000 kg
Permitted axle load: 5’500 kg
Fuel tank volume (Diesel) 150 l

1.2.1.4 Hydraulic system

Oil tank capacity 400 l
Hydraulic oil type
Environmental temperature 5 - 40° C: HLP ISO VG 46
Environmental temperature < 5 - 15° C: HLP ISO VG 32

Pump for MEYCO Suprema : 80 cm3/rev.

Pump for MEYCO Robojet Minima
and S-tube MEYCO Suprema: 45 cm3/rev.
Max. system pressure MEYCO Suprema: 200 bar
Working pressure MEYCO Suprema: 180 bar
Max. system pressure Minima: 210 bar
Working pressure Minima: 180 bar
RPM for all pumps: 1’500 1/min.
Max. RPM for operation 1’800 1/min.
Max. RPM for driving 2’300 1/min.

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Chapter 1 Technical data

1.2.1.5 MEYCO Suprema Performance data

Max. delivery: 0 - 14 m3/h
Delivery pressure: 75 bar
Delivery distance horizontal *: 300 m
Delivery distance vertical *: 100 m

* Delivery distance horizontal and vertical are dependent upon concrete mix design, ie.
granulometry, cement content, plasticity of the concrete etc. and therefore the given values
are approx.

1.2.1.6 MEYCO Robjet Minima performance data

Reach vertical: 9m
Reach with parallel lance: 4.7 m
Reach horizontal: 8m
Lance stroke: 1,5 m
Turntable turning angle: 270 °
Nozzle system: max. 65 mm
All important functions are operated using remote-control

1.2.1.7 Dosing system performance data

WARNING
Additives can be dangerous to health - see Capital 2 Safety

Dosing amount max.: 14 l/min.

Pressure: 10 bar max.
Hydraulic drive: with variable speed gear
Flowmeter: adjustable scale 6 to 30
Additive tank: 400 l

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Chapter 2 Safety

2 Safety

List of contents chapter 2

Page
2 Safety ..........................................................................................................................................2-1
2.1 Introduction...................................................................................................................2-3
2.1.1 Who may work on and with the spraymobile? ......................................2-3
2.1.2 Use in accordance with the specifications............................................2-4
2.1.3 Inappropriate use ..................................................................................2-4
2.2 Warning notices and symbols.....................................................................................2-5
2.2.1 Instructions and symbols in the operating instructions.........................2-5
2.3 Fundamentals of safety ...............................................................................................2-6
2.3.1 Safety concept (protection of persons).................................................2-6
2.3.1.1 Electrical installations ...........................................................................2-6
2.3.1.2 Hydraulic plant and mechanisms..........................................................2-6
2.3.2 Influence on other safety concepts .......................................................2-6
2.3.3 First aid .................................................................................................2-7
2.3.3.1 Concrete ...............................................................................................2-7
2.3.3.2 Chemical additives (liquids) ..................................................................2-7
2.3.4 Safety elements and functions..............................................................2-7
2.3.5 Removal of safety devices ....................................................................2-7
2.4 General safety regulations ..........................................................................................2-8
2.4.1 Legal stipulations ..................................................................................2-8
2.4.2 Verifying the function of safety devices ................................................2-8
2.4.3 Replacement parts................................................................................2-8
2.4.4 Modifications .........................................................................................2-8
2.5 Responsibilities ............................................................................................................2-9
2.5.1 Obligations of the manufacturer............................................................2-9
2.5.2 Obligations of the operator ...................................................................2-9
2.5.2.1 Training, initial instruction .....................................................................2-9
2.5.2.2 Authority ................................................................................................2-9
2.5.2.3 Instruction in dangers ...........................................................................2-9
2.5.2.4 Obligation for maintenance and care....................................................2-9
2.5.2.5 Obligation to observe and inform..........................................................2-9
2.5.2.6 Whereabouts of the operating instructions ...........................................2-9
2.5.2.7 Personnel of other mother tongues ......................................................2-9

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Chapter 2 Safety

Definition of terms

Manufacturer
In these operating instructions the company MEYCO Equipment, Division of Degussa Construction
Chemicals (Schweiz) AG is designated as the «manufacturer».

Operator
As the superior juristic person the operator is responsible for the use of the spraymobile in
accordance with the specifications. The operator must fulfil properly the obligations described in
Chap. 2.5.2.

Life phases of the machine, product life phases

This is understood to include all state and application phases of the spraymobile from the moment of
leaving the factory until its disposal.
In these operating instructions the product life phases are addressed by the following chapters:
Installation (erection, assembly), Operation, Maintenance, Overhaul, Taking out of service/Storage,
Packing/Transportation and Disposal.

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Operation manual
Chapter 2 Safety

2.1 Introduction
This chapter presents the safety requirements which when using the MEYCO® Mamba
Spraymobile (hereafter called «spraymobile») must be respected obligatorily.

It is an obligation for all personnel who work on or with the spraymobile to read and
understand the chapter relevant to the activity. This applies particularly to this chapter
which is binding on all personnel and all activities. This also applies to those personnel who
only occasionally are active with the spraymobile, e.g. getting it ready, maintenance.

Please read this chapter carefully.

• Have you understood everything?
• Is anything unclear?

For any queries consult your superior.

The purpose of these safety regulations is to ensure the safety of the user when using and
handling the spraymobile.

2.1.1 Who may work on and with the spraymobile?

For working on and with the spraymobile varying personnel qualifications are prescribed. In
each case you will find these at the beginning of the relevant chapter of these operating
instructions.

STOP
The personnel qualifications describe Minimum requirements, which must be
offered for working on and with the spraymobile. The operator ensures their
observance.

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Chapter 2 Safety

2.1.2 Use in accordance with the specifications

The MEYCO Mamba Spraymobile is a diesel driven carrier vehicle with mounted double
piston pump and concrete spraying manipulator for the conveyance and application of
shotcrete. Wet spraying machine and spraying manipulator are diesel – hydraulic powered.
Use in accordance with the specifications comprises:
• Concrete spraying in accordance with the wet process
• Application of shotcrete and concrete with the spraying manipulator
• Concrete pump
• The conveyance of aqueous cement suspensions (slurries)
• Conveyance in accordance with the technical data (see chapter 1)

Typical applications:
An area of application is wherever qualitative sprayed concrete, in large quantities, must be
applied by the wet-spraying process. For example:
• Tunnel and cavity construction
• Securing of foundations and excavations
• Securing of banks

Use in accordance with the specifications also includes:

• compliance with the technical data
• the use of standard accessories and original replacement parts
• the observance of these operating instructions and compliance with the instructions and
rules contained therein

2.1.3 Inappropriate use

Any other use or use in excess of the specified purposes counts as inappropriate. In the
event of damage or injury the manufacturer will be accordingly exonerated from liability
claims. No examples of inappropriate application are known to the manufacturer.

WARNING
Operation of the spraymobile in any other way other than described in this
operation manual is forbidden

Examples of inappropriate operation:

• Using the Robojet Minima as lifting equipment
• Driving the spraymobile on official roads and transporting chemicals

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Chapter 2 Safety

2.2 Warning notices and symbols

Generally dangers are associated with the use of technological products. Dangers which
can neither be avoided by constructive measures nor by safety devices are called residual
dangers.

Although the spraymobile is characterised by a high standard of quality and safety and has
been constructed according to state of the art and legal technical regulations, in the event
of operating faults, improper application or misuse, injuries or property damage cannot be
excluded owing to the existence of residual dangers.

Therefore various warning notices and symbols are used in this user manual.

2.2.1 Instructions and symbols in the operating instructions

a) Danger symbols

STOP
Information about dangers which
• can lead to life-threatening bodily injuries

WARNING
Information about dangers which can lead
• to medium to serious bodily injury
• to considerable personal property damage

CAUTION
Information about dangers that could lead to
• light bodily injuries
• light danger to personal belongings

b) Information symbol

INFORMATION
Information, of a technical nature which, if ignored could lead to a break down,
innefficiency, or even loss of production.

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Chapter 2 Safety

2.3 Fundamentals of safety

2.3.1 Safety concept (protection of persons)

2.3.1.1 Electrical installations

• Control voltage 24 VDC only
• High-grade quality of all electrical cables.
• Consistent earthing of the machine parts.
• Emergency switch.
• Master switch lockable.
• Electromagnetic compatibility fulfils IEC 801-II.

2.3.1.2 Hydraulic plant and mechanisms

• In an emergency automatic accumulator alleviation via solenoid valve, so that by faulty
manipulation the S-tube can not autonomously switch (open when no current).
• Emergency activation stops all mechanical movements by immobilisation of the control
system and the hydraulic plant (except Diesel engine).
• During operation a hopper screen prevents access into the hopper.
• By means of a limit switch, opening of the hopper screen causes an emergency. The
main drive switches off and discharges the accumulator (no more movement possible
as no residual hydraulic pressure). For protection the limit switch is provided with a
cover.
• Emergency Stop activation stops all mechanical movements by immobilisation of the
control system and the hydraulic plant.

2.3.2 Influence on other safety concepts

The safety concepts of the spraymobile described here are autonomous and embrace the
wet spraying machine, the spraying manipulator, the dosing system, the conveyor pipe and
the original accessories. Other machines, auxiliary attachments, vehicles, etc., are not
influenced by them.

STOP
If the spraymobile is fitted together with other machines or vehicles into an
installation, the operator must elaborate installation-specific safety concepts.

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Chapter 2 Safety

2.3.3 First aid

In the event of accidents with chemical admixture substances of the manufacturer
Degussa Construction Chemicals (Schweiz) AG, for any queries contact:
Telephone: 41 1 438 22 11
Respons.: Mr. B. Stengele (296), Mrs. B. Lunk (221) or Mr. J. Isepponi (432)
Address: Degussa Construction Chemicals (Schweiz) AG, Vulkanstrasse 110,
CH-8048 Zürich

2.3.3.1 Concrete
On contact the substance concrete is corrosive. If sprayed concrete gets into the eyes, they
must be rinsed with clean flowing water immediately.

2.3.3.2 Chemical additives (liquids)

Chemical additives (liquids) can cause skin cauterisation and serious eye injuries. Their
vapours can irritate eyes and breathing passages. If a product or a mixture gets into the
eyes, the eyes must be rinsed immediately for at least 15 minutes with clean running water.
Remove contaminated clothing or shoes immediately and wash the affected skin with soap
and water. Medical help is necessary for symptoms which can obviously be traced back to
inhaling or effects on the skin or eyes. Inform the doctor about the type and designation of
the substance used (specifications on the barrel).

2.3.4 Safety elements and functions

• See safety concept personal protection (above)
• See safety concept machine protection (Chapter 1)
• Malfunction lamp on the display

2.3.5 Removal of safety devices

STOP
Any manipulation or removal of safety devices is fundamentally forbidden.

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Chapter 2 Safety

2.4 General safety regulations

2.4.1 Legal stipulations

As a supplement to the operating instructions the generally applicable legal and otherwise
binding regulations for accident prevention and for environmental protection are to be
observed.
For example, such regulations extend to the handling of dangerous substances or to the
making available and wearing of personal safety clothing, etc.

2.4.2 Verifying the function of safety devices

After each repair or service the proper functioning of the safety devices must be checked.

2.4.3 Replacement parts

Only the original replacement parts designated in these operating instructions may be used
for repairs.

STOP
For assembly, disassembly or repair purposes the replacement parts catalogue may
only be used in connection with the relevant chapter of the operating instructions.
This contains important safety instructions.

2.4.4 Modifications
Modifications to the spraymobile, in the sense of addition and reconstruction, which may
affect safety are only permissible after prior discussion with and written approval of the
company MEYCO Equipment, Division of Degussa Construction Chemicals (Schweiz) AG.
This also applies for the installation of control, feeding and transfer systems from other
suppliers.

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Chapter 2 Safety

2.5 Responsibilities

2.5.1 Obligations of the manufacturer

The manufacturer is responsible for product safety; yet considerable obligations pass to the
operator (see Chapter 2.5.2). The manufacturer observes his product beyond supplying it
to the operator. In particular, the manufacturer can request from the owner/user information
on safety aspects.

2.5.2 Obligations of the operator

2.5.2.1 Training, initial instruction

The owner/user ensures that only authorised personnel are active on the machine. He
provides - even for occasional users or temporary employees - thorough initial instruction
on the basis of these operating instructions..

2.5.2.2 Authority
The responsibilities for all operational work sequences, especially commissioning,
operation, cleaning and overhauling must be clearly defined and complied with, so that
responsibilities for safety aspects are always clearly regulated.

2.5.2.3 Instruction in dangers

The owner/user ensures that his personnel carry out work on and with the machine only on
the basis of these operating instructions. He ensures that he makes available all aids
relevant for safety that are mentioned in these operating instructions. Warning shields must
be maintained in a readable state,.

2.5.2.4 Obligation for maintenance and care

The machine must be maintained and operated in a faultless state; the maintenance
intervals must be complied with. For the necessary maintenance and overhaul work a
suitably equipped workshop is necessary.

2.5.2.5 Obligation to observe and inform

If in the course of operation (residual) dangers and risks become apparent which are not
described in these operating instructions, the operator is obliged to inform the company
MEYCO AG immediately.

2.5.2.6 Whereabouts of the operating instructions

These operating instructions must be continuously available at the place of work (tool box,
container, etc.) in the relevant language(s).

2.5.2.7 Personnel of other mother tongues

In extension of Chapter 2.5.2.6 certain occupational accident insurance schemes demand
that the operator provides appropriate operation instructions for the work to be carried
out for personnel with a defective knowledge of the language. In this case these safety
regulations and the safety-relevant information in the relevant chapters must be translated.

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Chapter 3 Design and function

3 Design and function

List of contents Chapter 3

Page
3 Design and function.....................................................................................................................3-1
3.1 Design............................................................................................................................3-3
3.1.1 Overview of the Spraymobile Mamba...................................................3-3
3.2 Technical Description ..................................................................................................3-4
3.2.1 Technical Description - Spraymobile Mamba .......................................3-4
3.2.2 Technical description - hydraulic drive unit...........................................3-5
3.2.2.1 Layout and function...............................................................................3-5
3.2.3 Technical description of MEYCO Robojet Minima................................3-6
3.2.3.1 Design and construction .......................................................................3-6
3.2.3.2 Functions ..............................................................................................3-7
3.2.4 Technical description wet spraying machine Meyco
SUPREMA 3-9
3.2.4.1 Hydraulic system...................................................................................3-9
3.2.4.2 Pump circuit for concrete cylinders.......................................................3-9
3.2.4.3 S-tube , remixer and Robojet circuit .....................................................3-9
3.2.4.4 S-tube....................................................................................................3-9
3.2.4.5 Mechanical system, flow chart............................................................3-10
3.2.5 Safety concept (machine protection) ..................................................3-11
3.2.6 Dosing system operation ....................................................................3-11
3.2.6.1 Dosing pump.......................................................................................3-11
3.2.7 Technical description and functions of the carrier vehicle..................3-12

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Chapter 3 Design and function

3.1 Design

3.1.1 Overview of the Spraymobile Mamba

The Spraymobile consists of the following main components:

1 Carrier vehicle
2 Diesel engine compartement
3 Hydraulic tank
4 Additive tank
5 Suprema pump
6 Electric control box
7 Robojet Minima
8 Dosing pump Mixa hydraulic

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3.2 Technical Description

3.2.1 Technical Description - Spraymobile Mamba

The Spraymobile is a complete and compact, mobile spraying unit; mounted on a diesel
driven, robust ,manoeuvrable carrier vehicle. The Spraymobile consists of all necessary
components incl. drive unit, so that the spraying of concrete can be carried out in an
efficient and safe manner. The Spraymobile consists of a carrier vehicle on which is
mounted equipment such as spraying manipulator, wet spraying machine, dosing pump for
fluid additive and tank for additive.

It has a hydraulic drive unit flanged to the diesel engine as well as for the control, the
necessary switch box and remote control for the manipulator and pump functions.

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3.2.2 Technical description - hydraulic drive unit

3.2.2.1 Layout and function

The hydraulic drive unit serves as energy source for the wet spray machine MEYCO
SUPREMA and the Manipulator MEYCO Robojet Minima.

1 Diesel engine
2 Hydraulic pump for MEYCO SUPREMA
3 Hydraulic pump for chassis drive
4 Hydraulic pump for Robojet Minima and loading of accumulator
5 Hydraulic oil tank

The hydraulic drive unit has two modes of operation:

1. Driving of vehicle
Here only pump 3 for the chassis drive is working in closed loop together with the
chassis drive motor.

2. Operational equipment
Here the chassis drive pump 3 is not operating (bypassed). Pump 2 supplies the
concrete spraying pump Suprema. Pump 4 suppplies the manipulator Robojet Minima
and the accumulator and remixer circuit.

To cool the hydraulic system the cooler mounted and belonging to the diesel engine is
used.

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3.2.3 Technical description of MEYCO Robojet Minima

3.2.3.1 Design and construction

The manipulator MEYCO Robojet Minima is a electro-hydraulic driven spraying arm with
cable remote control, so as to control the spraying nozzle in an effective and simple way.
The operator therefore can stand out of the danger zone and is relieved of the heavy work
of spraying by hand.
The manipulator also serves to enable the holding of the correct distance and angle to the
spraying surface, thereby assisting the production of quality shotcrete. The operation of the
manipulator is simple and requires minimal learning time.

Construction
Manipulator with 6 fields of movements consists of:
Carrier boom, Lance carrier and a lance in rollers. The boom is mounted on a slewing ring
(turntable) with a horizontal axis (roll-over-principle).
On the end of the lance there is a spraying head, hose/nozzle mounting

The complete manipulator is controlled using the cable remote-control with 10 metres of
cable.

The supply of hydraulic power is achieved with the same hydraulic pump as used for the
Suprema S-tube and remixer (see chap. 3.2.4.3).

1 Turntable on robust frame 6 Valve block, spraying head

2 Carrier boom 7 Valve block, boom
3 Lance holder 8 Cable remote-control
4 Spraying lance 9 Outriggers
5 Spraying head

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3.2.3.2 Functions

WARNING
Before any movements of the MEYCO Robojet Minima are made, ensure that
the outriggers are in working position (on the floor) to avoid any tipping of
the chassis during operation.

Outriggers
The operation of the outriggers is described in the operation manual belonging to the
carrier vehicle.

Functions of the spraying-arm

• Function D, swivelling of the spraying arm along the longitudinal axis of the vehicle.
• Function F, lifting and lowering of the spraying arm

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• Function E, equalisation of lance position

This function can be used automatically if required. So that a chosen position/angle can
be held automatically when using the F function. This can for example be used so that
whatever angle of the F movement, the lance can be held parallel to the wall.
• Function L, Lance advance

Functions of the spraying head

• Function K, swivelling of the spraying head 360° about the longitudinal axis.

• Function J, tipping the nozzle forwards and backwards

• Function N automatic oscillation movement of the nozzle

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Operation Manual
Chapter 3 Design and function

3.2.4 Technical description wet spraying machine Meyco SUPREMA

3.2.4.1 Hydraulic system

The hydraulic plant is divided into two open circuits independent of each other.

1. Pump circuit for concrete cylinders

2. Pump circuit for S-tube and remixer (this pump is also used to drive the manipulator
Robojet Minima)

3.2.4.2 Pump circuit for concrete cylinders

An axial piston variable-displacement pump with pressure – and load sensing system
serves for driving the main cylinder. This ensures a theoretically always constant heat
production, is reduced without difficulty by the powerful cooling. The maximum pressure is
set at 200 bar. An electro-magnetic 4/3-way valve, in connection with a proportional flow
control valve, serves as control unit of the main cylinder, and this supplies main cylinders A
and B alternately with the required quantity of oil. This design of the control unit guarantees
a continuous conveying stream. The return oil stream from this circuit is used to drive the
dosing system. This guarantees proportionality between concrete and accelerator flow.

3.2.4.3 S-tube , remixer and Robojet circuit

A pressure controlled variable displacement pump has the task of supplying the
downstream accumulator. This circuit is also protected by a pressure relief valve.
Owing to the S-tube switching impulse of the two transducers (front end positions of the
hydraulic cylinder) the 4/2-way solenoid valve is deflected. In this way a «lightning-fast»
accumulator discharge is enabled; i.e. a fast forwards stroke of the addressed plunger
cylinder takes place and thus a fast S-tube switching. The loading of the accumulator
recommences.
For safety reasons this system (accumulator) is discharged on switching off the installation.
This is achieved by the switching position «current-free open» of the relevant valve.

The remixer circuit which is restricted to 140 bar is also supplied by this pump. The slowly
running hydraulic motor drives the agitator. On one hand this has the task of keeping the
feed material in movement and on the other hand ensures that the same is brought to the
suction conveying-cylinder. In this way optimal filling is achieved.

The same hydraulic pump also supplies with separate line the Manipulator Robojet Minima.
This circuit operates at a max. pressure of 180 bar. See also hydraulic schematics.

3.2.4.4 S-tube
The high-pressure resistant S-tube distinguishes itself by self-adjusting sealing. Within the
S-tube the diameter is continuously reduced from 150 to 125 mm. For this reason long,
uneconomic reductions in the pressure connection or in the conveying pipe are
unnecessary.

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Chapter 3 Design and function

3.2.4.5 Mechanical system, flow chart

The concrete spraying pump MEYCO Suprema is designed as twin cylinder piston pump
for low pulsation pumping.

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Chapter 3 Design and function

3.2.5 Safety concept (machine protection)

• Temperature and level monitoring of the oil tank.
- Temperature too high – machine off.
- Level too low – machine off.
• Low voltage of 24 VD serves as control voltage.
• Protection of the electrical circuits with circuit brakers.
• Maximum pressure restriction hydraulic pumps and hydraulic system.

3.2.6 Dosing system operation

The dosing system is used to add liquid additives to shotcrete.

3.2.6.1 Dosing pump

The heart of the dosing system is a peristaltic pump with hydraulic drive and manually
adjustable variable speed gear.

1 Peristaltic pump
SP25
2 Oil level
indicator
3 Inlet flange
4 Outlet flange
5 Handwheel for
adjustment of
dosing
percentage
6 Variable speed
gear
7 Worm gear
8 Tooth belt drive
9 Hydraulic motor
10 Mixing bloc
11 Manometer
12 Outlet of dosing
liquid

Fig. 3-8 Dosing pump

The return oil flow of the concrete pumping system passes through the hydraulic motor.

This causes the motor to turn with a speed proportional to the concrete flow. Thus keeping
the dosing at constant percentage independent on the oil flow. The percentage is adjusted
with the handwheel 05 at the variable speed gear. The flow in litres/min. can be read at the
display of the control box.

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Chapter 3 Design and function

3.2.7 Technical description and functions of the carrier vehicle

Please read the handbook from the chassis manufacturer.

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Operating instructions
Chapter 4 Controls and modes of operation

4 Controls and modes of operation

List of Contents Chapter 4

Page

4 Controls and modes of operation ............................................................................................ 4-1

4.1 Controls ..................................................................................................................... 4-3
4.1.1 Controls of the main switch box........................................................ 4-3
4.1.2 Controls of control panel................................................................... 4-4
4.1.3 Remote control.................................................................................. 4-5

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Operating instructions
Chapter 4 Controls and modes of operation

4.1 Controls

4.1.1 Controls of the main switch box

1 Main switch
2 Socket for remote control
3 Opration panel
4 Emergency stop button
5 Display for concrete flow
6 Display for accelerator flow

The electric control box must always be kept close to prevent dirt coming in and causing
problems with the switch gear.

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Chapter 4 Controls and modes of operation

4.1.2 Controls of control panel

7 Hydraulic pressure ON
8 Hydraulic pressure OFF
9 Remixer ON
10 Remixer OFF
11 Pumping forward ON
12 Pumping forward OFF
13 Dosing ON
14 Dosing OFF
15 Switch pumping reverse ON/OFF
16 Adjustment concrete flow
17 Vibrator ON
18 Vibrator OFF
19 Working lights front
20 Working light hopper

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Operating instructions
Chapter 4 Controls and modes of operation

4.1.3 Remote control

25. Joystick 1 Function D: Arm swivel left/right

26. Joystick 1 Function F: Arm lifting/lowering
27. Joystick 2 Function E: Equalisation lance up/down
28. Joystick 2 Function L: Lance forwards/backwards
29. Joystick 3 Function K: Nozzle swivel left/right
30. Joystick 3 Function J: Nozzle tipping forwards/backwards
31. Concrete pumping ON
32. Concrete pumping OFF
33. Accelerator dosing ON
34. Accelerator dosing OFF
35. Reverse pumping ON/OFF
36. EMERGENCY STOP
37. Oscillation nozzle ON/OFF
38. Not used
40. Remote control plug

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Operation manual
Chapter 5 Commissioning

5 Commissioning

List of Contents Chapter 5

Page

5 Commissioning ............................................................................................................................5-1
5.1 Qualification of personnel ...........................................................................................5-3
5.1.1 Safety regulations ..............................................................................................5-3
5.1.2 Environmental protection ...................................................................................5-3
5.2 Setting up ......................................................................................................................5-3
5.2.1 Preconditions......................................................................................................5-3
5.2.2 Unpacking ..........................................................................................................5-3
5.2.3 Setting up the Spraymobile ................................................................................5-3
5.2.4 Setting up the MEYCO Robojet Minima.............................................................5-5
5.2.5 Preparation MEYCO SUPREMA........................................................................5-5
5.3 Connections ..................................................................................................................5-6
5.3.1 Delivery/conveying line ......................................................................................5-6
5.3.2 Operating media.................................................................................................5-6
5.4 First commissioning ....................................................................................................5-7
5.4.1 Making ready the raw products to be processed ...............................................5-7
5.4.2 Function test according to check list ..................................................................5-7
5.4.3 First starting........................................................................................................5-7
5.5 Final inspection ............................................................................................................5-8
5.5.1 Hydraulic system ................................................................................................5-8
5.5.2 Electrical system ................................................................................................5-8

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Chapter 5 Commissioning

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Operation manual
Chapter 5 Commissioning

5.1 Qualification of personnel

The machine may only be operated by persons who have sufficient experience with
concrete spraying machinery and heavy equipment driving, or by persons who have
completed an apprenticeship approved by the manufacturer, and have been prepared and
initiated.

5.1.1 Safety regulations

STOP - Take note of the residual dangers:

First read Chapter 2 «Safety» and take note of the information on dangers
contained therein.

5.1.2 Environmental protection

Chemical additives and or hydraulic oil: seal leaks. Avoid penetration of the liquids into the
sewerage, excavations and cellars. Soak them up or dam them with earth, sand or other
suitable substances. Do not rinse the road with water. If the product gets into the water
table, the sewerage or the earth inform the police and fire brigade about it. Inform these
offices about the type and designation of the substance used (specifications on the barrel).

5.2 Setting up

5.2.1 Preconditions
In all circumstances the condition of the ground at the installation site must enable a
durable and stable standing position for the heavy Spraymobile (for weight: see Chapter 1).
In the event of prolonged use at the same site the construction of an auxiliary foundation
and a mounting system is recommended.

5.2.2 Unpacking
• Remove any accessories which could have been packed in the hopper of the wet
spraying machine.

5.2.3 Setting up the Spraymobile

• Set up the Spraymobile in such a way that a firm standing position is ensured. First
stabilize the vehicle with it’s brakes and extending and lowering the hydraulic stabilizers.

WARNING
The heavy machine is to be set up so that a safe and firm standing position is
ensured as well as safe operation. Do not use the MEYCO Robojet Minima before
having stabilized the vehicle with the hydraulic stabilizers. In tight conditions a way
of escape must always be left open for the operator.

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Chapter 5 Commissioning

WARNING
When closing the heavy hopper screen of the shotcrete machine MEYCO SUPREMA,
body parts can be injured by jamming between the screen and hopper edges. When
closing, watch out for other persons who may be in the danger area.

WARNING
Be careful that all lines remote control cable, compressed air hoses, conveying pipes and
hoses) are arranged so that there is no danger of personnel stumbling over, or walking into
them.

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Chapter 5 Commissioning

5.2.4 Setting up the MEYCO Robojet Minima

Before beginning operation move the arm into a working position. To do this at running
diesel engine, switch on the main switch at the control box and use the remote control. The
operation thereafter is controlled through the remote control.

WARNING
Ensure that outriggers are extended and in position and that the vehicle is stable.

WARNING
Do not stand on the machine when operating the manipulator because serious
bodily injuries could be the result !

5.2.5 Preparation MEYCO SUPREMA

• If any material is stored in the hopper, open grill and remove these items

WARNING
When closing the heavy hopper screen of the MEYCO SUPREMA, body parts can be
injured by jamming between the screen and hopper edges. When closing, watch out
for other persons who may be in the danger area.

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Chapter 5 Commissioning

WARNING
The hopper grill must never be opened when the pump is running. It protects
personnel from accidents involving the remixer and other moving parts in the
hopper.

WARNING
Never put any body part in the hopper. This is a danger zone and could be a source
of injury even when the machine has been switched off.
CAUTION PLEASE!

WARNING
Never touch a moving part of the pump or when the motor is switched on. For your
own safety, take time and switch off the power supply and disconnect!

WARNING
Never open any part of the delivery system without first pumping backwards to
relieve the system of pressure!

5.3 Connections

5.3.1 Delivery/conveying line

WARNING
Regularly check hoses and hose connections for damage and wear (see
maintenance table). In the event of defective parts on the dosing device, it’s
accessories and in the conveying hose, health-damaging substances can spray out
– see Chapter 2 (Materials and first aid). Before manipulating the hose couplings
the machine must be switched off by the main switch.

• Mount conveyor line (steel pipes etc.)

• Connect to conveyor line (nozzle system). Check its connections and connection to
concrete-spraying pump for faultless seating.

5.3.2 Operating media

• Fill the water-box of the MEYCO SUPREMA. The connection is to the left of the hopper,
low down (looking at the hooper)
• Prepare admixture (dosing medium) in sufficient quantities and fill into tanks.

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Operation manual
Chapter 5 Commissioning

5.4 First commissioning

5.4.1 Making ready the raw products to be processed

Prepare the medium to be conveyed in a pumpable state.
Prepare the admixture or fill the admixture tank.

5.4.2 Function test according to check list

• Emergency switch released (switchbox, remote control, compressor)?
• Chassis stabilized and outriggers fully extended and locked?
• Waterbox of MEYCO SUPREMA filled?
• Accelerator or admixture in tank?
• Oil level of hydraulic tank OK?
• Check level of hydraulic oil !

5.4.3 First starting

• Check list (previous page) OK?
• Start the diesel engine and adjust diesel engine speed to 1500 up to 1800 RPM
For this information see user manual of Mamba chassis

• Switch on the main switch (Chap. 4.1.1).

• Press button 7 to energize the hydraulic system (chap. 4.1.2).

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Chapter 5 Commissioning

5.5 Final inspection

5.5.1 Hydraulic system

The hydraulicsystem should now show the following :

• Hydraulic pressure MEYCO Robojet Minima ~ 180 bar

• Hydraulic pressure accumulator ~ 200 bar

5.5.2 Electrical system

• The lamp „hydraulic system“ should be lit (Button 7, chap. 4.1.2)

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Operation manual
Chapter 6 Operation

6 Operation

List of Contents Chapter 6

Page
6 Operation.....................................................................................................................................6-1
6.1 Introduction...................................................................................................................6-3
6.1.1 Qualification of personnel...................................................................................6-3
6.1.2 Safety regulations ..............................................................................................6-3
6.1.3 Environmental protection ...................................................................................6-3
6.1.4 Carrier vehicle and diesel motor ........................................................................6-3
6.2 Check list before daily starting up..............................................................................6-4
6.2.1 Machine..............................................................................................................6-4
6.2.2 Dosing pump ......................................................................................................6-5
6.2.3 Material...............................................................................................................6-5
6.3 Switching on and off ....................................................................................................6-6
6.3.1 Switching on and off...........................................................................................6-6
6.3.2 Switching off individual functions .......................................................................6-6
6.3.3 Emergency STOP ..............................................................................................6-6
6.3.4 Operation of the MEYCO Suprema ...................................................................6-7
6.3.5 Operation of spraying manipulator MEYCO Robojet Minima ............................6-8
6.3.5.1 Starting and MEYCO Robojet Minima functions...................................6-8
6.3.6 Remote control ...................................................................................................6-8
6.3.7 Taking out of service ........................................................................................6-12
6.4 Important notes on operation ...................................................................................6-13
6.4.1 Medium for MEYCO Suprema (concrete) ........................................................6-13
6.4.2 Conveying, pumping ........................................................................................6-13
6.4.3 Water-box.........................................................................................................6-13
6.4.4 Overheating......................................................................................................6-14

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Chapter 6 Operation

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Operation manual
Chapter 6 Operation

6.1 Introduction

6.1.1 Qualification of personnel

The machine may only be operated by construction personnel who have been sufficiently
trained by the operator on the basis of these operating instructions and have had their
attention drawn to the existing residual dangers. The operating personnel ensure that, after
the end of work or in their absence, the machine cannot be switched on by unauthorised
personnel or can be otherwise dangerous.

6.1.2 Safety regulations

STOP - Pay attention to residual dangers:

First read Chapter 2 «Safety» and take note of all advice on dangers contained
therein.

WARNING
For the nozzle-man the following personal protective clothing is prescribed:
· Tightly fitting eye protectors
· Suitable respiratory protection
· Light protective clothing, boots and gloves of plastic or synthetic rubber
· Eye-rinsing flask filled with clean water
For further advice (first aid) see Chapter 2 «Safety»

Caution
For operating personnel at the machine work gloves are recommended to avoid skin
cauterisation.
For further advice (first aid) see Chapter 2 «Safety»

6.1.3 Environmental protection

Chemical additives: seal leaks. Avoid penetration of the liquids into the sewerage,
excavations and cellars. Soak them up or dam them with earth, sand or other suitable
substances. Do not rinse the road with water. Call in specialists. If the product gets into the
water table, the sewerage or the earth inform the police and fire brigade about it. Inform
these offices about the type and designation of the substance used (specifications on the
barrel).

6.1.4 Carrier vehicle and diesel motor

For operation please refer to the oparating handbook from the carrier vehicle manufacturer.

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Operation manual
Chapter 6 Operation

6.2 Check list before daily starting up

NOTE
Where to check? See illustrations in Chapter 5 «Commissioning».

6.2.1 Machine
• Check conveying line and hoses for faultless seating and good condition
• Check air and additive hoses for faultless seating and good condition
• Remote control plugged in and switched on?
• Emergency STOP switch released?

WARNING
When closing the heavy hopper screen, body parts can be injured by jamming
between the screen and hopper edges. When closing watch out for other persons
who may be in the danger area.

• Hopper screen closed?

• Water in water-box (cylinder cooling and lubrification) ?
• Sufficient hydraulic oil available?

WARNING
Before operating the MEYCO Robojet Minima make sure that the chassis is
stabilized with the stabilizers and that the extension is extended fully and locked.
No person is allowed to stand in operating area of the MEYCO Robojet Minima.

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Operation manual
Chapter 6 Operation

6.2.2 Dosing pump

WARNING
Regularly check hoses and hose connections (see maintenance table) for damage
and wear (see maintenance table). In the event of defective parts on the dosing
device, its accessories and in the conveying hose, health-damaging substances can
spray out – see Chapter 2 (Materials and first aid). Before manipulating the hose
couplings the machine must first be switched off with the main switch.

• Connections and fittings OK?

• Pump bled (air entrained)?
• Dosing medium available?

6.2.3 Material
• Sufficient material in fluid consistency available?

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Operation manual
Chapter 6 Operation

6.3 Switching on and off

6.3.1 Switching on and off

• Switch main switch from position «0» to position «1».

• Start the diesel motor (see the chassis manufacturers handbook).

To operate the MEYCO Robojet Minima ensure that the Emergency STOP switches are
released on the switch box and remote control and press button 7 (see 6.3.4).
The manipulator can now be moved using the remote control.

To switch off turn the switch back to pos. „0“.

6.3.2 Switching off individual functions

To switch off use the switches with the symbols crossed out or with the symbol „0“ or turn
the main switch to „0“ top stop all functions simultaneously.

6.3.3 Emergency STOP

After operating the the Emergency STOP switch on the switch box, remote control or
compressor, all functions of the spraymobile except the diesel motor will be immediately
switched off. Further operation is only possible after lifting the „mushroom“ button of the
Emergency STOP.

NOTICE
Do not use the emergency stop button to stop machinery under normal circumstances.
The result would be excessive wear of parts.

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Chapter 6 Operation

6.3.4 Operation of the MEYCO Suprema

For operation of equipment the below listed switches/buttons are used.

• To start the MEYCO Suprema and/or the

MEYCO Minima press button 7 (Hydraulic
system ON/OFF)

• To pump (or spray), press button 11

• To pump backwards turn switch 15

• To operate the remixer press button 9

• To operate vibrator press button 17

• To operate dosing pump press button 13

(only possible together with pumping)

NOTE
The dosing pump only starts if pumping (11) and dosing (13) is on .

NOTE
When stopping pumping, the light in button 13 remains on, indicating that dosing will
continue as soon as pumping is on again (11).

NOTICE
Ensure that the dosing pump has been properly bled so that no air is present in the
system (see chapter 6.4.2) and that the additive tank is full enough for operation.

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Operation manual
Chapter 6 Operation

6.3.5 Operation of spraying manipulator MEYCO Robojet Minima

6.3.5.1 Starting and MEYCO Robojet Minima functions

Normal operations are conducted using the remote-control.

• To operate first energize hydraulic system, using push-button no 7 (see chap. 6.3.4)

WARNING
Before any movements of the MEYCO Robojet Minima are made, ensure that the
outriggers are in working position (on the floor) and that the whole vehicle is stable,
so as to avoid any tipping or rolling away of the vehicle during operation.

6.3.6 Remote control

25 Joystick 1 Function D: Arm swivel 30 Joystick 3 Function J: Nozzle

left/right tipping forwards/backwards
26 Joystick 1 Function F: Arm 31 Concrete pumping ON/OFF
lifting/lowering 32 Concrete pumping OFF
27 Joystick 2 Function E: Equalisation 33 Dosing pump ON
lance up/down 34 Dosing pump OFF
28 Joystick 2 Function L: Lance 35 Pumping reverse
forwards/backwards 36 EMERGENCY STOP
29 Joystick 3 Function K: Nozzle swivel 37 Oscillation nozzle ON/OFF
left/right 38 Not used
40 Plug to connect with switch box

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Operation manual
Chapter 6 Operation

WARNING
When using the remote control, make sure that no persons are in the danger zone
and the responsibilities of the operating personnel must be clearly regulated and
agreed.

The following diagrams show the various movements together with the corresponding
operating elements on the remote control.

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Operation manual
Chapter 6 Operation

WARNING
Never leave the machine unattended if an automatic movement is activated.

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Operation manual
Chapter 6 Operation

WARNING
The operator must not leave the machine unattended without switching off the diesel
motor. For safety the emergency STOP should be activated on the main switch-box
or remote-control.

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Operation manual
Chapter 6 Operation

6.3.7 Taking out of service

• Clean the conveying system (hoses/pipes/nozzle) and the Suprema.

Also read chapter 7.3.2 „Cleaning the conveying line“.
• If the break is very short and the concrete is stabilised then the machine can simply be
switched off.
• Clean the dosing system hoses.

NOTE
In cold weather with danger of frost the complete dosing pump and system should be
washed with water and then completely drained. Blowing out with air might also be
necessary
.
• Clean manipulator with clean water.
• Switch off the equipment with the main switch and stop the diesel engine.

WARNING
Do not spray with a high pressure cleaner in or onto the control box and the remote
control. It could cause damage.

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Operation manual
Chapter 6 Operation

6.4 Important notes on operation

6.4.1 Medium for MEYCO Suprema (concrete)

• The medium to be conveyed must be in a pumpable state.
• To begin with, pump a uniform, thin liquid lubrificating mixture. Do not begin immediately
with stiff and dry concrete.
• Never press a lumpy medium by force into the conveying pipe.
• To achieve a constant flow rate always ensure a good filling of the hopper so that the
spraying machine does not suck any air.

6.4.2 Conveying, pumping

• Pumping is possible to a max. hydraulic pressure of 180 bar.

WARNING
If a blockage occurs the concrete pressure will reach 85 bar. To release the
pressure in the conveying line one stroke backwards should be made (reverse
pumping) and then pumping should be stopped. After checking that the hydraulic
pressure gauge is at „0“ the conveying line can be opened and the blockage
removed.

• During pauses in conveying release the pressure in the conveyor pipe by short
backwards pumping (1 to 2 strokes).

6.4.3 Water-box
From time to time check the water box for water level and that it is clean. The connection is
on the left side of the Suprema hopper (looking at hopper).

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Operation manual
Chapter 6 Operation

6.4.4 Overheating
For oil overheating at above 80° the hydraulic system switches off automatically.
Check the cooler for defect or dirt.

NOTE
On no account wash the oil tank with water. Generally the consequence is condensed
water formation and thus damage to the hydraulic pumps.

NOTE
Avoid penetration of water into any electrical installation and keep the switch-box closed
at all times..

WARNING
The hopper grill must never be opened when the pump is running. It protects
personnel from accidents involving the remixer and other moving parts in the
hopper.

WARNING
Never put any body part in the hopper. This is a danger zone and could be a source
of injury even when the machine has been switched off.
CAUTION PLEASE!

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Operating instructions
Chapter 7 Maintenance

7 Maintenance

List of Contents Chapter 7

Seite
7 Maintenance ................................................................................................................................7-1
7.1 Introduction...................................................................................................................7-3
7.1.1 Qualification of personnel...................................................................................7-3
7.1.2 Safety regulations ..............................................................................................7-3
7.1.3 Environmental protection ...................................................................................7-3
7.1.4 Carrier vehicle and diesel motor ........................................................................7-3
7.2 Maintenance table and materials ................................................................................7-4
7.2.1 Cleaning table ....................................................................................................7-4
7.2.2 Maintenance table..............................................................................................7-4
7.2.3 Material table......................................................................................................7-5
7.2.4 Carrier vehicle and diesel motor maintenance and materials............................7-5
7.3 Cleaning.........................................................................................................................7-6
7.3.1 Cleaning the wet spraying machine Meyco Suprema........................................7-6
7.3.2 Cleaning the conveying pipe ..............................................................................7-7
7.3.2.1 Cleaning with water pressure ...............................................................7-7
7.3.2.2 Cleaning with compressed air...............................................................7-8
7.3.2.3 Cleaning with compressed air and Water.............................................7-8
7.3.3 Cleaning Dosing pump.......................................................................................7-9
7.3.4 Cleaning MEYCO Robojet Minima.....................................................................7-9
7.3.5 Cleaning the hydraulic system ...........................................................................7-9
7.4 Maintenance work ......................................................................................................7-10
7.4.1 Hydraulic oil filter ..............................................................................................7-10
7.4.2 Adjust sealing S-tube .......................................................................................7-11
7.4.3 Dosing pump ....................................................................................................7-11
7.4.4 MEYCO Robojet Minima ..................................................................................7-12
7.4.5 Hydraulic system ..............................................................................................7-12
7.4.6 Carrier vehicle and diesel motor ......................................................................7-12
7.5 Trouble shooting ........................................................................................................7-13
7.5.1 MEYCO SUPREMA .........................................................................................7-13
7.5.2 MEYCO Robojet Minima ..................................................................................7-19
7.5.3 Carrier vehicle and diesel motor ......................................................................7-20
7.5.4 Electrical system ..............................................................................................7-20

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 MEYCO® Spraymobile Mamba S

Operating instructions
Chapter 7 Maintenance

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MEYCO® Spraymobile Mamba S

Operating instructions
Chapter 7 Maintenance

7.1 Introduction

7.1.1 Qualification of personnel

The machine may only be maintained by persons with sufficient experience with concrete
pumps or those who have completed instruction in maintenance approved by the
manufacturer.

7.1.2 Safety regulations

STOP - Beware of residual dangers:

First read Chapter 2 «Safety» and take note of all information on dangers contained
therein.

7.1.3 Environmental protection

Chemical additives: seal leaks. Avoid penetration of the liquids into the sewerage,
excavations and cellars. Soak them up or dam them with earth, sand or other suitable
substances. Do not rinse the road with water. Call in specialists. If the product gets into the
water table, the sewerage or the earth inform the police and fire brigade about it. Inform
these offices about the type and designation of the substance used (specifications on the
barrel).

7.1.4 Carrier vehicle and diesel motor

For maintenance please read the manufacturers handbook.

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 MEYCO® Spraymobile Mamba S

Operating instructions
Chapter 7 Maintenance

7.2 Maintenance table and materials

7.2.1 Cleaning table

(See chapter 7.3 «Cleaning»)

Part Daily or after use Weekly or after long Yearly or after

standstill 2000 ops. hours
Whole machine X
Conveying line X
Dosing equipment wash out X

7.2.2 Maintenance table

(See chapter 7.4 «Maintenance work»)

Part Daily or after use Weekly or after long Yearly or after

standstill 2000 ops. hours
Inspection of damage
X
(hoses, material)
Robojet, Lance, X
Sprayhead
Revolving ring joints X X
lubrication
Lubrication MEYCO X X X
SUPREMA**
Hydraulic oil filter X
Hydraulic oil level X
Seal S-tube X
Hydraulic oil change X *

*First oil-change after 500 hours

**MEYCO SUPREMA lubrication: The bearings should be greased at the end of the day
and after every job is complete to force out any cement or grout which may have forced it’s
way into the bearing cavity. It is better to grease the bearing whilst the machine is running
so the bearing is thoroughly filled.

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MEYCO® Spraymobile Mamba S

Operating instructions
Chapter 7 Maintenance

7.2.3 Material table

(See chapter 7.4 «Maintenance work»)

Concerns Material Quantity

Protection from rust
and concrete deposit Form oil
Hydraulic oil Summer ISO VG 46 HLP (outside temp. > 5° C) 250 l
Winter ISO VG 32 HLP (temp bis -10° C)
Grease points Machine grease as necessary
MEYCO SUPREMA, without graphite
Minima
Dosing pump gears Gear oil ISO VG 220 0,3 l
Cleaning the machine Water

7.2.4 Carrier vehicle and diesel motor maintenance and materials

For maintenance please read the manufacturers handbook.

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 MEYCO® Spraymobile Mamba S

Operating instructions
Chapter 7 Maintenance

7.3 Cleaning

7.3.1 Cleaning the wet spraying machine Meyco Suprema

WARNING
When the machine is switched on never reach into the area of the switch cylinder.
On automatic switching this cylinder executes movements which could cause
serious hand or finger crushing. First switch off the machine with the main switch.

Caution
Never touch the outlet pipe connection and coupling when the machine is switched on. On
automatic switching these move to and fro and can cause crushing of fingers. First switch
off the machine with the main switch.

Caution
When the machine is switched on never reach into the exit opening for the (decoupled)
conveying pipe. Your hand or arm could be seized by the S-tube and be injured. First
switch off the machine with the main switch.

• Release pressure in the concrete conveying, dosing medium and air lines.
• Thoroughly clean concrete from the machine with water (protect electrical parts from
wetness!).
• With the machine running (pump backwards) thoroughly rinse the hopper and conveyor
cylinder. Care should be taken that no concrete residues are still in the S-tube, as these
can quickly build up and badly influence the pumping behaviour of the machine.
• Clean conveyor pipes for concrete and dosing medium (see next Chapter)..

NOTE
For a thoroughly clean and carefully maintained machine it is recommended to spray it
with form oil before use.

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MEYCO® Spraymobile Mamba S

Operating instructions
Chapter 7 Maintenance

7.3.2 Cleaning the conveying pipe

There are three cleaning possibilities:
• Cleaning with pressure water (only recommended for short conveyor pipes)
• Cleaning with compressed air
• Cleaning with compressed air and water

WARNING
Never open the hose couplings under pressure. By the suddenly released powerful
forces the hoses can thresh around in an uncontrolled fashion and cause injuries.
From the dosing device, its accessories and the conveying hose health-
endangering substances can spray out. See Chapter 2 (Materials and first aid).
Before manipulating the hose couplings first switch off the machine with the main
switch..

7.3.2.1 Cleaning with water pressure

• Pump hopper empty.
• Relieve pressure in conveying pipe by pumping backwards.
• Couple cleaning nozzle with water-soaked cleaning sponges (balls).
• Set water pump into operation and drain conveyor pipe under pressure.

1 Water pump connection

2 Water drain valve
3 Concrete
4 Conveyor pipe
5 Cleaning sponge
6 Water
7 Cleaning connection

Fig. 7-1 Cleaning with water pressure

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 MEYCO® Spraymobile Mamba S

Operating instructions
Chapter 7 Maintenance

7.3.2.2 Cleaning with compressed air

Caution
Compressed air can expand with violence (blow-out) at the end of the cleaning operation
and so air should be slowly added and should not exceed 2 bar.

• Release pressure in conveyor pipe by convey backwards.

• Dry out with compressed air (not more than 2 bar).

1 Compressor connection
2 Air pressure relief valve
3 Compressed air

Fig. 7-2 Cleaning with compressed air

7.3.2.3 Cleaning with compressed air and Water

Caution
Compressed air can expand with violence (blow-out) at the end of the cleaning operation
and so air should be slowly added and should not exceed 2 bar.

• Release and remove conveying pipe at the MEYCO SUPREMA outlet (twist bend
towards the ground so that the concrete can flow out)
• Remove the nozzle tip and fit the cleaning cap to the injector
• Slowly open the air valve on the distributor so that air from the compressor enters the
hose to the injector. The conveying hose will then be blown out from the injector to the
MEYCO SUPREMA.
• Turn off the air at the distributor valve.
• Fill the air line between distributor and injector with water.
• Turn the air on again, slowly, at the distributor. The conveying line will then be
blown/washed out with water from the injector to the machine.
• Remove the cleaning cap from the injector.

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MEYCO® Spraymobile Mamba S

Operating instructions
Chapter 7 Maintenance

7.3.3 Cleaning Dosing pump

WARNING
Regularly check hoses and hose connections (see maintenance table) for damage
and wear (see maintenance table). In the event of defective parts on the dosing
device, its accessories and in the conveying hose, health-damaging substances can
spray out and cause cauterisation.

The pump is to be cleaned with clear water as follows:

• Place suction hose in a container with about 10 Litres of clear water.
• Switch on the pump and let it run until clear water comes out.
• Switch off pump.
• Generally the dosing system should be left full of water to enable an easy start up. The
following information should be observed.

NOTE
In the event of temperatures below freezing, the concrete-spraying pump and the dosing
system must be protected from damage by frost with anti-freeze or by evacuation.

7.3.4 Cleaning MEYCO Robojet Minima

• Wash the MEYCO Robojet Minima with water from concrete residue.

NOTE
Do not allow water to penetrate into electrical parts

NOTE
For a continuously clean and cared for machine it is recommended to spray it with forming
oil before use.

• Lubricate all sliding guides on the side of the telescope boom and the slewing ring gear
wheel.

7.3.5 Cleaning the hydraulic system

NOTE
When washing the hydraulic system, do not wash the hydraulic tank in warm condition
with cold water. Condensation as a result can rapidly reduce life time of the hydraulic
pump system

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 MEYCO® Spraymobile Mamba S

Operating instructions
Chapter 7 Maintenance

7.4 Maintenance work

7.4.1 Hydraulic oil filter

Check return oil filter on the hydraulic oil tank for contamination. If indicator is in the red
zone, when pumping at full capacity then the filter must be exhanged or cleaned. Proceed
as follows

Open the filter only when not under pressure.

NOTE
When assembling take care that all seals are clean and are carefully inserted.
Replace seals if necessary.

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MEYCO® Spraymobile Mamba S

Operating instructions
Chapter 7 Maintenance

7.4.2 Adjust sealing S-tube

From time to time (depending on wear) the sealing washer of the S-tube must be adjusted
to ensure optimal sealing. Proceed as follows:
• Slowly and alternately screw down all 4 nuts (4) of the base plate, until the closure ring
(6) is evenly touching the closure gland (14).
• With the machine running (without concrete) steadily screw down further all four nuts (4)
until the pivoting movement of the S-tube is markedly slower (beginning of jamming).
• Undo all four nuts (4) by 1/2 a turn.
• Check whether the S-tube correctly and steadily pivots.

1 S-tube
2 Sealing
washersiding
3 Base plate front
4 Nuts (4 pces.)
5 Spline
6 Closure ring
7 Upper bolts of
swivel cylinder
8 Rear bearing of
S-tube
9 Ring
10 Outlet connection
11
12 Flange for coupling
connection
13 Semirings
14 Wear plate
15 Flange
16 Flange screws

Fig. 7-3 S-tube assembly.

7.4.3 Dosing pump

Individual parts of the pump must, from time to time, especially when changing chemical
additive be thoroughly cleaned.

NOTE
Always wash out all the dosing system before changing chemical product !

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 MEYCO® Spraymobile Mamba S

Operating instructions
Chapter 7 Maintenance

7.4.4 MEYCO Robojet Minima

• Grease all bearings and sliding joints as well as the turntable gear wheel. See
maintenance table in Chapter 7.2.1.
• Worn parts must be replaced.

7.4.5 Hydraulic system

• Check regularly the function of the hydraulic system. Damaged gauges or hoses should
be replaced immediately.
• Clean the hydraulic oil coooler regularly and check it for leaks.
• Replace damaged or very dirty filter cartridges.
• Check the hydraulic oil tank for any condensation or dirt on the floor of the tank.
Release condense water, clean tank and change oil.
• Replace damaged plugs and cables on the hydraulic valves.

7.4.6 Carrier vehicle and diesel motor

For maintenance please read the manufacturers handbook.

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MEYCO® Spraymobile Mamba S

Operating instructions
Chapter 7 Maintenance

7.5 Trouble shooting

STOP - Beware of residual dangers:

Before trouble shooting refer to chapter 2 Safety. Only trained people are allowed to
make trouble shooting.

STOP - Beware of residual dangers:

For hydraulic related problems use hydraulic trained staff only,
for electric problems use electricians only to make trouble shooting.

NOTE: If in doubt with any of the following suggestions:

please contact MEYCO Service

Phone: ++41 58 958 27 00

Fax: ++41 58 958 37 22

7.5.1 MEYCO SUPREMA

Malfunction Possible reasons Repair necessary

Surging at the Not enough concrete Fill hopper above
nozzle insidethe hopper agitator shaft
Concrete not passing Check vibrator or
through the hopper screen remove obstructions
from the screen
Pumping concrete very Check concrete slump
difficult or spread.
See concrete specialist
Hardened concrete in S-tube Clean and remove
or in concrete conveying hardened concrete.
cylinders INSPECT S-TUBE
Slow S-tube change over. Check S-tube change
over pressure: (190-200
bar) fully loaded; Check
torque on S-tube bearing
(nut 2 ¼“)
Agitator not turning Check hopper for
obstructions.
Remove hardened
concrete from hopper
sides.
Concrete delivery line Check delivery line for
restriction e.g. hose bends obstructions e.g. tight
too small or partly blocked. bends.
oder teilweise blockiert

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 MEYCO® Spraymobile Mamba S

Operating instructions
Chapter 7 Maintenance

Malfunction Possible reasons Repair necessary

Blockages Mix design sand/aggregate Conctact MBT concrecte
combination specialist
Worn concrete piston seals or Replace S-tube wear
S-tube wear plate. plate and wear ring.
Check water condition for
cement contamination.
Worn s-tube wear plate and Replace S-tube wear
wear ring. Loss of cement plate and wear ring
paste back into hopper
Leaking pipe and hose joints. Replace worn clamp
Loss of cement paste gaskets
Hopper screen damaged Replace or repair screen
allowing large obstructions to
pass through
Incorrect reduction pipes Replace with standard
installed MEYCO parts
Incorrect slurry quantity when Increase quantitiy to
starting lubricate completely
Bad Incorrect air supply from Check air lines and
Spraying Pattern compressor, (leakage etc.) supply 10m3/min at 6 bar
Incorrect air supply to the Minimum 1 1/4" supply to
nozzle the nozzle
Blocked lines, kinks, leaks etc. Above 40 meters 1 1/2"
supply line
Blocked nozzle (Injector holes) STOP!
Check clean
Nozzle tip condition (old/worn) Replace Nozzle tip
Conveying cylinders Blockage in conveying lines Check hydraulic pressure
do not move but gauge for pressure
display shows (~200bar). Reverse
„Operating“ pump, free blockage in
cylinders and conveying
lines.

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MEYCO® Spraymobile Mamba S

Operating instructions
Chapter 7 Maintenance

Malfunction Possible reasons Repair necessary

Conveying cylinders Proximitor switch B1131 or Remove proximitor switch
do not move but display B1132 not working. plugs from cylinder (do not
shows „Operating“ No contact to the piston. swap). Push hydraulic piston
Gap to hydraulic piston too into most forward position.
large. Screw proximitor switch
carefully in by hand until
switch is contacting cylinder
piston then screw proximitor
out 1/2 to 3/4 turn.
Mount plug → orange light on
plug must be on.
Loose connection between When orange LED light in
proximitor switch and proximitor plug is on, the
corresponding relay. corresponding relay must be
activated.

Loose cable connection Check cable connections

between proportional Check plugs. Must be clean,
amplifier N1161 and dry and reseal.
proportional valve (10.1) or Protect valve against further
loose contact between damage or moisture.
potentiometer (R1161) and
amplifier or defect - Check potentiometer
potentiometer, or defect - Check amplifier
amplifier.

Rod chamber oil loss (see Short term repair: remove

below) one of plugs on proximitor
and pump. Wait until both
cylinders are in fully back
position. Refix plug and
continue pumping.

No accumulator pressure Check accumulator loading

Accumulator (17) circuit

Conveying cylinders out 130 bar relief valve (11.3) Check system pressure.
of sequence or on piston rod leaking Adjust relief valve to 130 bar
shortened strokes Orifice ∅0.5mm (11.5) Check and clean the orifice
blocked

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 MEYCO® Spraymobile Mamba S

Operating instructions
Chapter 7 Maintenance

Malfunction Possible reasons Repair necessary

Conveying cylinders Different causes possible Measure stroke-time of
working slow on both cylinders and contact
maximum output setting Meyco customer service

S-Tube will not change Mechanically blocked, old Clean out hopper.
concrete etc. inside hopper Inspect S-Tube for foreign
or S-Tube objects
S-Tube bearing blocked Clean out hopper, run
pump and adjust S-tube
bearing until a steady firm
change over appears (see
Chap.7.4.2)
S-Tube hydraulic system Check S-tube hydraulic
fault, i.e. low pressure pressure. Observe this
pressure while the pump
is operating.
Fully loaded accumulator
190 to 200 bar
Low system pressure Check loading valve (15.7)
pressure. If not OK,
replace valve cartridge.
Continuous relieving at Check (15.8) valve to be
valve (15.7) energized.
Dirt in the valve?

Loose solenoid connection Check plugs and

on hydraulic valve (15.11) connections from the
control panel to 4/2-way-
valve (15.11)
Slow S-tube change over Incorrect torque to S-tube Inspect pressure gauge
bearing (190bar).
If pressureOK, adjust S-
tube bearing correctly
Accumulator (17) problem, Inspect pressure gauge
ruptured diaphragm. while pumping to see
pressure drop after
change-over.
Check gas charge
pressure at accumulator
(130 bar).
Possible pump fault. Inspect pressure gauge,
inspect gear pump

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MEYCO® Spraymobile Mamba S

Operating instructions
Chapter 7 Maintenance

Malfunction Possible reasons Repair necessary

Agitator not working Mechanically blocked Clean out hopper.
inside hopper. Remove obstruction.
Hardened concrete etc. Check paddle clearance to
hopper side.
Bearing siezed either: shaft Remove hydraulic motor
bearings on gearbox or (18) from the gear box
motor bearings flange. Check its function
alone. Replace siezed
parts.
Hydraulic system problem Remove motor from the
either: driving motor (18), gear box. Check its
or the hydraulic pump function alone.
Hydraulic relief valve (15.4) Check 140 bar relief
set too low or faulty, pressure.
relieving oil into tank. Adjust if necessary.
Problem with 4/2-way-valve Check connections at 4/2-
way-valve (15.5).

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 MEYCO® Spraymobile Mamba S

Operating instructions
Chapter 7 Maintenance

Malfunction Possible reasons Repair necessary

Incorrect dosing Wrong adjustement of Readjust at hand wheel and
variable gear check dosing (see also
display).
Dosing output fluctuating or Check the suction side for
inconsistent output restrictions; maybe the
suction hose diameter is too
small. Dmin: 32 to 50 mm.
Check for possible air
bubbles on the suction side
(vacuum leaks).
Accelerator not reaching Check for leaks in the hoses
the nozzle. Blocked lines or to the nozzle. Clean out
non- return-valve. Leaks on non-return valve etc. Flush
the way to the nozzle. out accelerator lines.
Concrete not sticking, If accelerator is present then
dropping off do a local vickart test with
(Is accelerator present?) the cement. Call an MBT
expert for advice.
Check the concrete and the
air temperature (should not
be less than 5° C)

Malfunction Possible reasons Repair necessary

Not dosing Dosing pump on? Switch dosing pump on

Suction hose not receiving Check for air bubbles in the

any accelerator. suction line.
Drum empty etc. Determine cause and rectify
problem.
Dosing pump not running. Free mechanical seizure
Seized or blocked before starting again.
Clean pump with water.
Overdosing or Wrong adjustement at hand Readjust
Underdosing wheel

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MEYCO® Spraymobile Mamba S

Operating instructions
Chapter 7 Maintenance

7.5.2 MEYCO Robojet Minima

Malfunction Possible reasons Repair necessary

The Manipulator The Emergency-STOP is Release the Emergency-STOP
cannot be moved activated. switch on switch box and/or
remote-control.
No hydraulic pressure Check pressure gauge, should
available or pressure too be 190-200 bar
low Check hydraulic pump.
Remote-control is defect Check all functions according
to the electrical diagram,
including supply.
Check cable and plugs.
Individual Lever or switch is defect Check all functions according
functions/movements through damage, water, to the electrical diagram,
not operative dirt or wear. including supply.
Dry-out, clean or replace
according to defect.
Mechanical blockage. Clean, repair or replace
Bent parts, dirty joints or damaged parts according to
slides, lack of lubrication. defect.
Grease if necessary
Hydraulic valve not Check the indicator light on
functioning. coil and check supply voltage
according to electric scheme
Replace coil or valve if
necessary.
Hydraulic valve not Check the indicator light on
functioning. coil and check supply voltage
according to electric scheme
Replace coil or valve if
necessary.
Movement too slow or Incorrect hydraulic Check and adjust settings of
too fast settings. valves and flow regulator.
Automatic lance Proximity switch on lance Check proxiwithy switches for
function does not carriage defect or set correct function and replace if
work incorrectly. necessary.
Incorrect movement Valve connections are Check connections and swap
direction incorrect. over if necessary

Arm does not lower or Overload on turntable. Move the arm closer to central
only in jerks axis and try again.
Arm cannot be put Position of arm or Move the arm using the
into park position turntable is incorrect. turntable until the marked
position is correctly placed and
lay the arm back into place.

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 MEYCO® Spraymobile Mamba S

Operating instructions
Chapter 7 Maintenance

7.5.3 Carrier vehicle and diesel motor

Please read the handbooks for carrier vehicle and diesel motor

7.5.4 Electrical system

Malfunction Possible reasons Repair necessaryn

Hydraulic system Emergency-STOP is Release emergency-STOP.
does not pressurize activated

Machine stops Oil temperature is too high Check function of temperture

during operation switch (80° C = OFF)
Check function of hydraulic
cooler.

Oil level too low Fill up oil tank to required level.

Oil type according to
maintenance list

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MEYCO® Spraymobile Mamba S

Operating instructions
Chapter 8 Overhaul

8 Overhaul

List of Contents Chapter 8

Page
8 Overhaul ......................................................................................................................................8-1
8.1 Introduction...................................................................................................................8-3
8.2 MEYCO SUPREMA - removal and fitting of parts subject to wear ..........................8-3
8.2.1 Wear-plate and wear-ring .....................................................................8-3
8.2.2 S-tube....................................................................................................8-5
8.2.2.1 Removal ................................................................................................8-5
8.2.2.2 Fitting ....................................................................................................8-6
8.2.3 Conveyor piston packing ......................................................................8-7
8.2.3.1 Removal ................................................................................................8-8
8.2.3.2 Fitting ....................................................................................................8-9
8.2.4 Servicing the dosing pump .................................................................8-11
8.3 MEYCO Robojet Minima.............................................................................................8-12
8.4 Dosing system ............................................................................................................8-13
8.5 Hydraulic System........................................................................................................8-13
8.6 Carrier vehicle and diesel motor...............................................................................8-13

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 MEYCO® Spraymobile Mamba S

Operating instructions
Chapter 8 Overhaul

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MEYCO® Spraymobile Mamba S

Operating instructions
Chapter 8 Overhaul

8.1 Introduction

Qualification of personnel
The machine may only be overhauled and repaired by trained professional staff, e.g.
mechanics, electricians, who have completed training for overhaul approved by the
manufacturer.

8.2 MEYCO SUPREMA - removal and fitting of parts subject to

wear

8.2.1 Wear-plate and wear-ring

STOP - Beware of residual dangers:

For overhaul only use trained personnel.
Before overhaul read chapter 2 Safety..

WARNING
When the machine is switched on never reach into the area of switch cylinder. On
automatic switching this cylinder executes movements which could cause serious
hand or finger crushing. First switch off the machine with the main switch.

WARNING
Never open the hose couplings under pressure. By the suddenly released powerful
forces the hoses can thresh around in an uncontrolled fashion and cause injuries.
From the dosing device, its accessories and the conveying hose health-endangering
substances can spray out. See Chapter 2 (Materials and first aid). Before
manipulating the hose couplings first switch off the machine with the main switch.

Caution
Never touch the outlet pipe connection and coupling when the machine is switched on. On
automatic switching these move to and fro and can cause crushing of fingers. First switch
off the machine with the main switch.

Caution
When the machine is switched on never reach into the exit opening for the (decoupled)
conveying pipe. Your hand or arm could be seized by the S-tube and be injured. First
switch off the machine with the main switch.

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 MEYCO® Spraymobile Mamba S

Operating instructions
Chapter 8 Overhaul

Caution
Removed parts must be completely replaced, or in any case replaced by original
replacement parts. Always use new examples for securing elements (stop nuts, split pins,
springs, etc.).

WARNING
Do not adjust the pressure settings beyond the allowed values (see chapter 1)
Do not raise speeds to dangerour levels.

NOTE
When fitting the gland and ring take care that all surfaces have been cleaned and
greased. The seals must be properly inserted and must not be damaged when fitting.
Note:
• Ring: 1 O-Ring, 1 sealing washer siding
• Plate: 2 O-Rings
• The nuts of the base plate must be slowly and alternately tightened until the closure ring
touches evenly on to the closure gland.
• Re-assemble the hopper completely, attach the frame and insert the Harting connector.
• Close the hopper screen.
• Adjust the sealing of the S-tube as described in Chapter 7.4.2.

1 S-tube
2 Sealing washer
siding
3 Base plate front
4 Nuts (4 pces.)
5 Spline
6 Closure ring
7 Upper bolts of
swivelling cylinder
8 Rear bearing of the
S-tube
9 Ring
10 Outlet flange
11
12 Flange to coupling
connection
13 Semirings
14 Wear plate
15 Flange
16 Flange screws
17 Hopper side
18 Rear side

Fig. 8-1 S-tube assembly.

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MEYCO® Spraymobile Mamba S

Operating instructions
Chapter 8 Overhaul

8.2.2 S-tube

WARNING
Before working in the interior of the hopper switch the machine off at the main
switch and disconnect the power supply. In addition the pressure accumulator
should be checked for absence of pressure. Non-compliance with this regulation
can lead to serious injuries.

WARNING
When closing the heavy hopper screen, body parts can be injured by jamming
between the screen and hopper edges. When closing watch out for other persons
who may be in the danger area.

8.2.2.1 Removal
(see Fig. 8-2)
• Switch off machine at main switch (position «0»). Attach padlock.
• Check: manometer pressure accumulator at 0 bar.
• Mark position of the S-tube (1) for later re-assembly.
• Remove 8 screws (16).
• Screw 1 screw (16) each into threaded holes on flange (15) and thus the entire S-tube
approx. 5 cm
• Dismantle wear-ring (6).
• Pull out the entire S-tube from the hopper.

NOTE
Take care that the spline is free of dirt.
.

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 MEYCO® Spraymobile Mamba S

Operating instructions
Chapter 8 Overhaul

8.2.2.2 Fitting
(see Fig. 8-2)
• Bring the S-tube into the hopper through the flange opening.
• Fit the closure ring
• So position the flange (15) in the hopper that the toothing of the S-tube finds itself in the
correct position.
• Fix 8 screws (16) and screw them in more or less.
• Undo 4 nuts (4) by three to four turns.
• Tighten 8 screws (16).
• Adjust the S-tube sealing see Chap. 7.4.2.

NOTE
Take care that all seals are properly inserted and are not damaged when fitting.
.

1 S-tube
2 Sealing washer
siding
3 Base plate front
4 Nuts (4 pces.)
5 Spline
6 Closure ring
7 Upper bolts of
swivelling cylinder
8 Rear bearing of the
S-tube
9 Ring
10 Outlet flange
11
12 Flange to coupling
connection
13 Semirings
14 Wear plate
15 Flange
16 Flange screws
17 Hopper side
18 Rear side

Fig. 8-2 S-tube assembly.

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Operating instructions
Chapter 8 Overhaul

8.2.3 Conveyor piston packing

WARNING
Before working in the interior of the hopper switch the machine off at the main
switch and disconnect the power supply. In addition the pressure accumulator
should be checked for absence of pressure. Non-compliance with this regulation
can lead to serious injuries.

WARNING
When closing the heavy hopper screen, body parts can be injured by jamming
between the screen and hopper edges. When closing watch out for other persons
who may be in the danger area.

• Switch off the machine at the main switch (position «0»).

• Remove hopper part (see Chap. 8.2.1).
• In the Harting connector fit a provisional wire jumper from terminal 4 to terminal 5 (thus
making the hopper screen protective switch ineffective).
• Remove closure gland (see Chap. 8.2.1).
• Remove all electrical connectors on the accumulator charge block.
• Remove the connector at pressure switch D. The pressure switch is located behind the
proportional valve for feeding the hydraulic cylinder.
• Remove the connector from the electrical limit switch («Proximitor») at the hydraulic
cylinder and in fact at the cylinder, whose integrated conveying cylinder lies open as
seen from the hopper.

WARNING
Remove all possible objects from the feed hopper and thereafter do not reach into
the hopper (danger of injury!) so that the machine can be switched on briefly for the
movement of the piston.

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Operating instructions
Chapter 8 Overhaul

• Switch on machine at main switch (position «1»).

• Switch on main drive and pumping so that the piston in the cylinder lying open can move
completely forward to the stop.
• Switch off main drive and pumping.
• Switch off machine at main switch (position «0»).
• Check: manometer pressure accumulator at 0 bar.

WARNING
Remove all possible objects from the feed hopper and thereafter do not reach into
the hopper (danger of injury!) so that the machine can be switched on briefly for the
movement of the piston.

8.2.3.1 Removal
Now the conveyor piston packing can be replaced as follows:

The piston is located at front

The machine is switched off
Accumulator pressure is «0»

Remove safety wire

Undo 3 M10 screws and remove the cover disc.
The M12 threaded hole becomes visible.

Screw an M12 screw into the centre and with this

aid draw out the piston.

Fig. 8-3 Removal of piston

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Operating instructions
Chapter 8 Overhaul

NOTE
The exchange of the second piston packing takes place later. But first, as described
below, the new packing must be installed.

8.2.3.2 Fitting

Check parts for wear and replace of necessary.

Clean remaining parts.

Screw in 3 threaded rods M10x150 into the piston

mounting. Readjust piston with support and
locating ring and tighten evenly with 3 M10 nuts
on the piston mounting.

If the piston is properly set screw home circular

base with the 3 original M10 screws.
Insert new safety wire and twist.

Fig. 8-4 Fitting piston

• Replace the removed connector on the limit switch («Proximitor») and simultaneously
remove the connector from the other cylinder.
• Reconnect all electrical connectors on the accumulator charge block without confusing
them.

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Operating instructions
Chapter 8 Overhaul

WARNING
Remove all possible objects from the feed hopper and thereafter do not reach into
the hopper (danger of injury!) so that the machine can be switched on briefly for the
movement of the piston.

• Switch on machine at main switch (position «1»).

• Switch on main pump and conveying. Wait until the S-tube has switched once and the
piston has been driven right forwards into the cylinder lying open.
• Switch off main pump and pumping.
• Switch off machine at main switch (position «0»).
• Check: manometer pressure accumulator at 0 bar.
• Remove all electrical connectors from the accumulator charge block.

WARNING
Make sure: main switch is in position «Off». The pressure accumulator is free of
pressure. Non-compliance with this can lead to serious injuries.

The removal and fitting of the conveying piston now takes place again as described above.

• Re-insert the removed connector at the electrical limit switch («Proximitor»).

• Re-connect all electrical connectors on the accumulator charge block without confusing
them.
• Fit connector on pressure switch.
• Fit the closure gland again (see Chap. 8.2.1).
• Fit the hopper upper part again (see Chap. 8.2.1).
• The provisionally-fitted wire jumper from terminal 4 to terminal 5 in the Harting
connector must now be removed.

WARNING
Make sure that the provisional wire jumper in the Harting connector has really been
removed. If not, the hopper screen protection switch remains ineffective. In certain
circumstances this can lead to serious accidents.

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Operating instructions
Chapter 8 Overhaul

8.2.4 Servicing the dosing pump

Service and maintenance instructions for the „BREDEL PUMP" are to be found in the
attachment immediately following these instructions for MEYCO Suprema.

INFORMATION
For the universal joints we recommend grease of the type: NEVER-SEEZ from Bostik.

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Operating instructions
Chapter 8 Overhaul

8.3 MEYCO Robojet Minima

STOP - Beware of residual dangers:

First read Chapter 2 «Safety» and take note of advice on dangers contained therein.

WARNING
Before any maintenance work the machine must be switched off, electrical supply
must be disconnected and the diesel motor (if used) must be stopped.

WARNING
Never open the hose couplings under pressure. By the suddenly released powerful
forces the hoses can thresh around in an uncontrolled fashion and cause injuries.
From the dosing device, its accessories and the conveying hose health-endangering
substances can spray out. See Chapter 2 (Materials and first aid). Before
manipulating the hose couplings first switch off the machine at the main switch.

Normally maintenance work comprises one of the following tasks.

• Cleaning all parts of any remaining concrete.

• Checking all components that they are in perfect condition. If not then replacement or
correctly carried out repair work.

NOTE
With the lance and lance carrier special care should be given that the scrapers, track-
rollers and end-switches are in good condition and working properly.

NOTE
With the carrier boom, turntable and spraying head special care should be given that all
joints are clean and have their necessary freedom of movement.

• Check for cracks and repair if necessary

• Grease all bearings, joints and guides
• Check for oil leaks and seal if necessary
• Refresh paint
• Tighten all screws, bolts and nuts
• Check all cables and replace if necessary
• Check all hose connections, hoses and replace if necessary
• Check concrete lines and replace if necessary

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Operating instructions
Chapter 8 Overhaul

8.4 Dosing system

STOP - Beware of residual dangers:

First read chapter 2 Safety and take note of the information on dangers contained
therein.

WARNING
When handling chemical products wear the necessary protection clothing and take
care of the valid environmental protection regulations.

The following maintenance work is recommended:

y disassemble the dosing pump and replace worn parts
y clean out all pump components , check its condition and replace if necessary
y refer also to the technical description of the pump manufacturer (attached)
• check the pressure relief valve

8.5 Hydraulic System

To overhaul the hydraulic system, power pack etc. refer to the manufacturer's manuals in
the appendix or contact MEYCO Service.

8.6 Carrier vehicle and diesel motor

To overhaul the carrier chassis refer to the manufacturer's manuals or contact MEYCO
Service.

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Operating instructions
Chapter 8 Overhaul

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MEYCO® Spraymobile Mamba S

Operating instructions
Chapter 9 Taking out of service, storage

9 Taking out of service, storage

List of Contents Chapter 9

Page
9 Taking out of service, storage .....................................................................................................9-1
9.1 Introduction...................................................................................................................9-3
9.1.1 Qualification of personnel .....................................................................9-3
9.1.2 Safety regulations .................................................................................9-3
9.2 Taking out of service....................................................................................................9-3
9.2.1 Measures ..............................................................................................9-3
9.3 Storage ..........................................................................................................................9-4
9.3.1 General .................................................................................................9-4

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Chapter 9 Taking out of service, storage

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Operating instructions
Chapter 9 Taking out of service, storage

9.1 Introduction

9.1.1 Qualification of personnel

The machine may only be taken out of service and stored by persons who have sufficient
experience with concrete pumps or persons who have completed a training course
approved by the manufacturer.

9.1.2 Safety regulations

STOP - Beware of residual dangers:

First read Chapter 2 «Safety» and take note of the advice about dangers contained
therein.

9.2 Taking out of service

9.2.1 Measures
CAUTION
When uncoupling conveyor hoses never kink them. Increased danger of rupture by a once
kinked hose, whereby injuries could occur during operation.

• Clean well the spraying manipulator and accessories (see Chap. 7.3).
• Set main switch to «0».
• Switch off power and compressed air supplies on site.
• Disconnect electrical cable (and remote control cable if used) and disconnect or
uncouple compressed air hose.
• Remove the barrel/container connection.
• Disconnect conveying hose etc.

NOTE
Empty concrete spraying machine and dosing unit (danger of freezing if weather is cold!)

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Operating instructions
Chapter 9 Taking out of service, storage

9.3 Storage

9.3.1 General

WARNING
When closing the heavy hopper screen, body parts can be injured by jamming
between the screen and hopper edges. When closing watch out for other persons
who may be in the danger area.

CAUTION
When uncoupling conveyor hoses never kink them. Increased danger of rupture by a once
kinked hose, whereby injuries could occur during operation.

• Before storage the concrete-spraying pump must be completely cleaned and

subsequently dried.

• Under all circumstances the ground condition must permit a durable and stable
standing position for the heavy concrete-spraying machine (weight: see Chapter 1
«Technical data»).

• The mechanical parts must be protected from corosion (use oil or repaint the damaged
points).

• The additive tank must be empty

• The dosing system must be empty (maybe blow out with air).

• For temporary storage form/mould oil is recommended.

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Operating instructions
Chapter 10 Packing, transportation

10 Packing, transportation

List of Contents Chapter 10

Page
10 Packing, transportation..............................................................................................................10-1
10.1 Introduction.................................................................................................................10-3
10.1.1 Qualification of personnel ...................................................................10-3
10.1.2 Safety regulations ...............................................................................10-3
10.2 Packing ........................................................................................................................10-4
10.2.1 Unpacking ...........................................................................................10-4
10.3 Transportation ............................................................................................................10-4
10.3.1 Lifting with crane .................................................................................10-4
10.3.2 Transport by road................................................................................10-4
10.3.3 Transport securing device for manipulator MEYCO Minima ..............10-5

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Chapter 10 Packing, transportation

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Operating instructions
Chapter 10 Packing, transportation

10.1 Introduction

10.1.1 Qualification of personnel

For the transportation of the Spraymobile the relevant specialist knowledge and experience
in the transportation of heavy machines is necessary. If chemical additives are transported
with the pump then additionally necessary is: knowledge of the relevant risks and dangers,
knowledge of the relevant disposal regulations, knowledge of the relevant accident
prevention regulations and knowledge of first aid.

10.1.2 Safety regulations

STOP - Beware of residual dangers:

First read Chapter 2 «Safety» and take note of the advice on dangers contained
therein.

WARNING
It is not allowed to drive the spraymobile on official roads, nor is it to be used to
transport chemicals.

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Operating instructions
Chapter 10 Packing, transportation

10.2 Packing

10.2.1 Unpacking
Remove all packing and strapping material.

CAUTION
When uncoupling conveyor hoses never kink them. Increased danger of rupture by a once
kinked hose, whereby injuries could occur during operation.

10.3 Transportation

10.3.1 Lifting with crane

STOP
Use a fault-free means of load suspension and in your selection take account of the
weight (see Chapter 1) and the position of the centre of gravity (see above) of the
machine. Ensure that nobody is located under the suspended load or in the vicinity.
Non-conformance with this regulation can lead to death or to serious injuries.

10.3.2 Transport by road

For transport by road the spraymobile must be secured and transported on a suitable
transport vehicle.

Use people for transport who are experienced in the transport of heavy machinery.

The centre of gravity is roughly in the centre of the vehicle.

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Operating instructions
Chapter 10 Packing, transportation

10.3.3 Transport securing device for manipulator MEYCO Minima

When driving with the spraymobile MEYCO Mamba (short distances too) the main boom of
the manipulator MEYCO Minima must be supported with the transport securing device.
This is to prevent the steel construction of the manipulator from being damaged by hard
hits and vibratons.

Fig. 10-1: Spraymobile MEYCO Mamba S in transport position (transport securing device in operation)

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Operating instructions
Chapter 10 Packing, transportation

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Operating instructions
Chapter 11 Disposal

11 Disposal

List of Contents Chapter 11

Page
11.1 Introduction.................................................................................................................11-3
11.1.1 Safety regulations ...............................................................................11-3
11.1.2 Qualification of personnel ...................................................................11-3
11.1.3 Legal principles ...................................................................................11-4
11.1.4 Legal principles carrier vehicle ...........................................................11-4
11.2 Environmental protection instructions ....................................................................11-5
11.3 Substances .................................................................................................................11-6
11.3.1 Regulations .........................................................................................11-6
11.3.1.1 Sorting...............................................................................................11-6
11.3.1.2 Waste management..........................................................................11-6
11.3.2 Packaging ...........................................................................................11-6
11.3.3 Spraymobile ........................................................................................11-7
11.3.4 Working materials ...............................................................................11-7
11.4 Dismantling .................................................................................................................11-8
11.4.1 Dismantling sequence ........................................................................11-8

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Chapter 11 Disposal

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Operating instructions
Chapter 11 Disposal

11.1 Introduction

11.1.1 Safety regulations

STOP - Beware of residual dangers:

First read Chapter 2 «Safety» and take note of the advice on dangers contained
therein.

11.1.2 Qualification of personnel

If the operator himself guarantees the dismantling and recycling or disposal of the
installation, whilst conforming to the legal principles mentioned under Chap. 11.1.3
below, then for the practical execution (disassembly, decomposition, breaking down
of assemblies, separation of materials, etc.) the following suffices:

• mechanical knowledge
• knowledge and understanding of waste substances

If dangerous substances in the sense of the directive 91/689/EWG are to be disposed

of, then there is an additional requirement of:

• Knowledge of the relevant risks and dangers

• Knowledge of the relevant disposal regulations
• Knowledge of the relevant accident prevention
• Knowledge of measures for first aid

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Operating instructions
Chapter 11 Disposal

11.1.3 Legal principles

In accordance with the EU directive 75/442/EWG and 91/156/EWG disposal of the
spraying manipulator is a matter for the operator*. The operator must either hand
over the spraying manipulator to a licensed private or public collection company or
dispose of it himself in accordance with the regulations.

NOTE
If the Spraymobile is handed over to a collection company for disposal then these
operating instructions are to be handed over with it. In Chapter 2 and subsequently they
contain important safety-relevant advice for the avoidance of personal injury.

Companies which dispose of or recycle their waste themselves are subject to

approval and control. Under certain preconditions they can be freed from the
obligation of approval in so far as they take account of the requirements for
environmental protection. These companies are subject to an obligation of
notification.
Outside the EU comparable legal stipulations apply.

* for definition «Operator»see Chapter 2 Safety

11.1.4 Legal principles carrier vehicle

The disposal of the carrier vehicle must be done according the recommendations of
the manufacturer and must fulfill the regulations specific to the country of disposal.

Read the manufacturer’s handbook or contact the supplier.

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Chapter 11 Disposal

11.2 Environmental protection instructions

Waste is to be recycled or disposed of without endangering human health and without a

procedure or method being used which could damage the environment, especially without:

• Water, air, ground and the animal and plant world being endangered
• Causing undue noise or smells
• The vicinity or the landscape being influenced

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Operating instructions
Chapter 11 Disposal

11.3 Substances

11.3.1 Regulations

11.3.1.1 Sorting
The sorting takes place after breaking down the installation into waste groups; in
accordance with the directory of the current European Waste Catalogue (EWC). This
catalogue applies for all waste, irrespective of whether it is intended for disposal or
recycling.

11.3.1.2 Waste management

Waste management is to be carried out in accordance with the local authority waste
management plans; these include the following especially:

• type, quantity and origin of the waste to be recycled or disposed of

• general technical regulations
• special precautions for certain waste
• suitable sites for disposal and other disposal installations

For example these plans can specify:

• the natural or juristic persons entitled to manage waste

• the estimated costs of recycling and disposal
• messages for promoting the rationalisation of the collecting, sorting and handling of
waste

11.3.2 Packaging
Packaging (in so far as it exists, see Chap. 10) contains the substances:

• Wood
• Plastic (film)
• Styropor (filling material)

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Chapter 11 Disposal

11.3.3 Spraymobile
The spraymobile contains the substances and compounds of:

• Aluminium
• Thermosetting plastics
• Electrical material (cables, motors, components)
• Electronic material (PCBs etc.)
• Glass
• Rubber (elastomers)
• Copper
• Polyurethane
• PVC (dosing system)
• Steel (profile)
• Steel plate (cover plates, etc.)
• Thermoplastics
• Tin

11.3.4 Working materials

• Oil (see Chapter 1)
• Additives (see Chapter 1)

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Operating instructions
Chapter 11 Disposal

11.4 Dismantling

STOP
Dangerous substances. The spraymobile can contain in a liquid form:
• Chemical additives (caustic)
• Oil (combustible)

Protect yourself against accidents, observe the following pictograms:

Caustic No smoking Eye protection Protective gloves

substances

11.4.1 Dismantling sequence

STOP
Before dismantling work the spraymobile is to be securely separated from all
energy and auxiliary materials sources (electricity, compressed air, barrels of
chemicals).

WARNING
When closing the heavy hopper screen, body parts can be injured by jamming
between the screen and hopper edges. When closing watch out for other persons
who may be in the danger area.

The following tasks must be undertaken in the specified sequence or their previous
completion must be checked:

• Drain oil
• Remove chemical residues

There are no other special regulations or advice for the practical disassembly of the
concrete-spraying pump.

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Operating instructions
Chapter 12 Replacement parts catalogue and schematics

12 Replacement parts catalogue and schematics

List of Contents Chapter 12

See seperate, attached spare parts list.

For the carrier vehicle please refer to the manufacturer’s handbook.

STOP - Beware of residual dangers:

First read Chapter 2 «Safety» and take note of the advice on dangers contained
therein.

STOP
For assembly, disassembly or repair purposes the replacement parts catalogue may
only be used in connection with the relevant chapters of the operating instructions.
These contain important safety information..

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Chapter 12 Replacement parts catalogue & schematics

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