Troubleshooting

No material comes out of the gun and the pressure gauge of the mortar pipe indicates a pressure higher than the normal maximum operating pressure of 10/12 bar:

• Stop the machine by turning the main switch to the "'0" position, release the pressure in the material delivery pipes by turning the bypass lever to the vertical position; wait for the pressure indicated by the pressure gauge to drop to zero.
   
• Before loosening a fitting in the material delivery pipe or disconnecting the gun, make sure that the pressure gauge indicates a pressure of "0" and that there is no residual pressure in the pipes.

• Remove the deflector, and if necessary the gun, and remove the cause of the blockage;
   
• Before reassembling the deflector or the gun, make sure that the nozzle is free;
   
• Restart the machine to verify that the material flows freely.

• Close the gun air valve: the machine stops;
   
• Release the pressure in the material hoses by turning the bypass lever to the vertical position and wait for the pressure indicated by the pressure gauge to drop to zero before loosening a joint in the material delivery line or disconnecting the gun;
   
• Locate the point where the material hose is clogged: at this point the hose is hard and rigid;
   
• Detach the clogged hose, hit the clog with a hammer to break the "plug" that has formed, until the hardened material comes out;
   
• Start the machine for a few moments and make sure that the hose has been freed from the "plug": the material comes out regularly.

• Stop the machine by turning the main switch to the "0" position, release the pressure in the material delivery pipes by turning the bypass lever to the vertical position;
   
• Check again that the pressure gauge does not indicate any pressure;
   
• Open the connections on the pump manifold and remove the two rubber balls located inside and carefully wash the suction and delivery valve bodies;
   
• Empty the hopper, if necessary with a jet of water wash away all the material;
   
• Reassemble everything, remix the mixture correctly and start pumping again.

• Stop the machine;
   
• Tighten the belt using a belt tensioner;
   
• Resume work.

1. Mixing the material
   
   Check the mix design, if it is too sticky try changing the sand/binder ratio:
   
   - Try to avoid the use of air entraining additives;
   - Try to avoid the use of hydrated lime.
   
    
2. Pipe line
   
   Use only original Turbosol pipes, especially the first 30m.
   
    
3. Air nozzle clogged
   
   Check that:
   
   - The gun is not clogged with material;
   - The air nozzle is not clogged with material;
   - The air valve is not closed or the air tube is not bent or pinched.
   
    
4. Ball valves
   
   Check that:
   
   - The valve seats are not worn and that there is no hardened material around them that prevents the valve from moving;
   - Check the ball valves and replace them if worn.

1. Air system partially blocked
   
   Check that:
   
   - The air hose is not kinked;
   - The gun and the air nozzle are not dirty, clean them if necessary.
   
    
2. Automatic switch
   
   Check that:
   
   - The main switch of the electrical panel is not inserted, if necessary proceed to unblock it.
   
    
3. Safety devices
   
   Check that:
   
   - The cap or the vibrating sieve are correctly positioned and in place.
   
    
4. Air valve
   
   Open the air valve on the spray gun and on the flexible hose.
   
   Check the status of the pressure switch on the machine.

1. Air leaks in the line
   
   Check:
   
   - The air line and especially all the fittings for air leaks;
   - The auxiliary air valve is properly closed and those on the gun and the air line are properly open.
   
    
2. Clogged compressor filter
   
   Clean and replace if necessary.
   
    
3. Deflector
   
   Check:
   
   - The size and condition of the deflector (if necessary try different ones)
   
   - The condition and position of the air nozzle in the spray gun (if necessary try to bend it so that it fits in the center of the nozzle).
   
    
4. Mixing
   
   Try making the material softer and/or changing the quality of the binder.

1. Clogged gun
   
   Disconnect gun and clean clogged parts.
   
   Release hose pressure before opening any fittings on gun or hoses
   
    
2. Clogged material hose
   
   Disconnect gun and clean clogged parts.
   
   Release hose pressure before opening any fittings on gun or hoses
   
    
3. Clogged ball valves
   
   Open pump assembly and clean suction and discharge valves.
   
    
4. Bent material hose
   
   Locate kink and straighten hose.

1. Bypass lever
   
   Check that the bypass lever for pumping is in the horizontal position.
   
    
2. Valve block
   
   Check that the ball valves and valve seat are correctly positioned.
   
    
3. Empty hopper
   
   Always add material to the hopper, be aware that leaving it empty during pumping can cause blockages in the piping line.
   
    
4. Incorrect mixing
   
   Material cannot enter the valve block because it is too hard or too light.
   
   Check the consistency and try another mix.

1. Clogged valve assembly
   
   Clogged delivery valve assembly, probably due to improper material mixing.
   
   Flush, adjust, and start over.
   
    
2. Bypass
   
   Incorrect bypass lever position.
   
    
3. Empty hopper
   
   Add material to hopper. Note that allowing hopper to empty during pumping can cause blockages in hose line.
   
    
4. Improper mix
   
   Material cannot enter valve assembly because it is too hard or too soft.
   
   Check material consistency and try another different mix.

1. Deflector too small
   
   Replace with a larger one.
   
    
2. Grain size of material too large
   
   Grain size curve of material is too large, try changing with sand or fiber
   
    
3. Mortar mixing
   
   Mortar too poor in binder, try adding cement, lime or plasticizer.

1. Air duct partially blocked
   
   Check that:
   
   - The air line tap is not partially closed;
   - The air hose is not bent;
   - The gun nozzle is not blocked.
   
    
2. Blockage
   
   Check the pressure gauge:
   
   - If the pressure is high, the hose or nozzle is blocked, then remove the blockage and start again;
   - If there is no pressure, the suction valve assembly is blocked, then clean it and start again.
   
    
3. Engine circuit breaker
   
   Check that:
   
   - The electrical cable has the specified characteristics, that the required electrical energy is actually available;
   - The machine ignition switch;
   - The site electrical panel.
   
    
4. Safety sensors
   
   Check that:
   
   - The vibrating screen is positioned correctly;
   - The engine compartment hood is positioned correctly.

1. Clogged delivery valve
   
   Clogged delivery valve probably due to incorrect mixing of the material to be pumped. Clean the valve and change the "recipe" of the material.
   
    
2. Mixing
   
   Check the mix of the material, it may be too low in binder, try adding cement, lime or plasticizer.
   
    
3. Clogged mortar hose
   
   Find the clogged part, remove the blockage and restart pumping.
   
   Remember to release the pressure of the hose before opening any fittings, either on the gun or the hose itself
   
    
4. Bent mortar hose
   
   Locate the bent/pinched part and fix it.