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The information contained in this document is believed to correct but RISEN accepts no liability for any
errors it contains, and reserves the right to alter specifications without notice.
Rev.PZS3000 Manual-eng./06-03-05 1
Risen PZS3000 WET-MIX SHOTCRETE MACHINE User’s Manual
Catalogue
Ⅰ.Summary 1
Ⅳ.Operation 3
Ⅴ. Troubleshooting 5
Ⅵ. Maintenance 7
Ⅷ.Appendix-1 Diagram 9
The information contained in this document is believed to correct but RISEN accepts no liability for any
errors it contains, and reserves the right to alter specifications without notice.
Rev.PZS3000 Manual-eng./06-03-05 2
Risen PZS3000 WET-MIX SHOTCRETE MACHINE User’s Manual Operation
Ⅰ、Summary
Risen PZS3000 wet-mix shotcrete machine is an updated version, based the popular
wet-mix equipments in China. And it mainly is used for wet spraying concrete. With
comparing the popular wet-mix equipment, its advantages are easy sealing, smooth
stream and uniform spraying. It also has some obvious advantages such as advanced
technology, Perfect structure, stable performance, convenient operation and longevity of service
etc. It is widely employed in mining, tunnel, culvert, subway, hydropower engineering,
underground excavation engineering etc.
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Risen PZS3000 WET-MIX SHOTCRETE MACHINE User’s Manual Operation
its each hole. With this special rotor, it can improve the capacity to handle wet mixture and reduce
clearing and maintenance work.
Rotor disk: There are two rotor disks on the opposite sides of rotor, it is made of high-qualified
alloy steel and can handle concrete more than 4000m3 during its working period.
C. Sealing unit
This unit consists of upper sealing plate, lower sealing plate and clamping device, etc.
Rubber sealing plate: Here are two plates (upper and lower). Both of the upper and lower plates
are made of anti-abrasive special rubber and can handle concrete 300-400m3 during its working
period.
Clamping Device: This device is specially designed four points clamping with screw rod, by this
device, the force is acted through the screws and cylindrical springs, which works as elastic
auto-clamping device. This device can provide a constantly uniform pressure at the sealing
surfaces with a high tightening effect and low dust emission, and can avoid rubber plate
over-worn, too.
D. Vibrating hopper
This unit consists of hopper, vibrator, and screen, etc.
For this unit, with the forcing vibrating of vibrator, the wet concrete can smoothly go through the
rubber chamber.
E. Air-conveying unit
This unit consists of main air valve, upper air valve, lower air valve, pressure gauge and air
conveying line attachments, etc.
There are three ball valves separately to control main air pipe, upper air pipe leading to rotor and
lower air pipe leading to Vortex Stream Implement. A pressure gauge is mounted on the lower air
pipe to monitor the operating pressure of conveying hose.
F. Spraying unit
It consists of conveying hose and nozzle unit. Conveying hose is made of anti-abrasive rubber,
nozzle unit is made of high polymer. Water pipe, water valve and water ring are fixed on the
nozzle unit.
G. Dosing pump unit
This unit consists of dosing pump, pressure gauge, inlet hose line, adding pressure air system
and outlet hose line, etc(FIG.6).
The dosing pump is a hose pump that is used for precise adding liquid accelerator. The
advantages of this pump are reliable, high repeat dosing precision, so that the added volume of
liquid accelerator also are stability and precise. For the detailed description of dosing pump,
please refer to the Dosing Pump Manual enclosed to this Manual.
The pressure gauge of liquid accelerator, installed in the cover of the machine, is used for
watching the air pressure of accelerator hose line.
The pressure air of adding pressure air system comes from the main air hose, it is necessary to
make the liquid accelerator atomization, in this case, the liquid accelerator can be sprayed into
the nozzle with uniform condition.
H. Electric control casing
This unit consists of Breaker, contactors and overload relay, etc. For the electric route diagram,
please refer to Fig.7.
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Risen PZS3000 WET-MIX SHOTCRETE MACHINE User’s Manual Operation
Ⅳ.Operation
Operators must be trained and be familiar with this manual and the machine structure before
operating the machine.
1 Preparation before operation
A. Check all the joint points of electric control casing, and ensure all the joint points are fixed.
B. Check the lubrication in the reducers, and ensure the lubrication is right, enough and no
expired.
The required lubrication of main gearbox is No.50 Gear Oil (SY1172-77S) or No.30
Machinery Oil.
C. Check the connections of the parts, ensure that all the connections are fixed.
D. Check the Dosing pump referring to the Dosing pump manual.
E. Adjusting the adding volume of liquid accelerator
As per the demand of shotcrete project, the required volume of liquid accelerator should be adjusted
by the hand wheel of the no-class reducer, and by referring to the appendix Ⅲ, Ⅳ.
F. As per the description of FIG.1, Connect compressure air inlet hose, conveying hose, liquid
accelerator hose and nozzle. For the compressure air inlet hose, the required ID should
50mm.
G. Start the machine and make it working for a short time checking its working condition. (Note:
machine running should be the same with the arrow marked on the machine. Do not race the
machine for a long time. Referring to the dosing pump manual, and also should ensure the
rotation direction is correct.)
H. Check the clamping force on rubber sealing plate. Tighten the clamping nut step by step
until there is no air leakage from rubber sealing plate.
2. Shotcreting Operation
A. Open the main air valve and upper air valve, close the lower air valve, and then see if the air
goes through the nozzle. Then close the upper air valve and open lower air valve to see if the air
goes through nozzle. If no air or little air goes through, it indicates that the conveying hose don’t
go through. Please clean the conveying hose and ensure the conveying hose go through.
B.Open the accelerator air valve, start the dosing pump and liquid accelerator should spray from
the nozzle.
C. After the above check and preparation, now start to wet spraying concrete and open the air
valves in following order:
Completely open the accelerator air valve, main air valve, lower air valve by 2/3, upper air valve,
at this moment, the pressure of main conveying hose should be 0.2Mpa. Start main electric motor,
vibrating electric motor, dosing pump, then add the mixed concrete into the hopper and start to
wet spray concrete.
D. During spraying, the operator of machine should farther adjust the main air valve as per the
spraying man’s request. In general, the recommending spraying distance is about 0.8 to 1.2
meters.
3. Stop Spraying Concrete
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Risen PZS3000 WET-MIX SHOTCRETE MACHINE User’s Manual Operation
A. Stop to add concrete into the hopper, when confirming no concrete remains in the hopper
and no concrete is sprayed from nozzle, firstly close the dosing pump, then close vibrating
electric motor.
B. Add clean water into the hopper, the main electric motor is not closed until the clean water
flow out from the nozzle.
C. Close the main air valve, then close the accelerator air valve, shut down electric supply in the
end.
D. Clear the remainder around rotor and machine, inner of exhaust, keep the machine clean.
E. Interruptedly spraying in short time, the concrete can be remained in hopper, if the
interruptedly spraying for a long time, please don’t keep concrete in hopper, and clear the
machine in time.
4. Notice
A. During spraying, if suddenly no concrete sprays out from the nozzle, in general, there are two
possibilities:
The conveying hose is not completely blocked, but the property of concrete in the hose
changes badly, in this case, close the vibrator. After all the concrete in the hose are sprayed
out, and the pressure recovers in normal value, then restart the machine.
The conveying hose is completely blocked, in this case, shut down the machine, and clear
conveying hose.
When
During clearing machine, when remove any joint, confirm the
please ensure no pressure remains in hose/pipe. conveying
hoses are complete clean, then restart the machine.
B. During spraying, the operator of machine should pay attention to the lever of liquid
accelerator in the case, which the manufacturer doesn’t supply this case for the client, and
the pressure value of accelerator gauge. When the lever of accelerator is below the required
lever, please add the enough liquid accelerator. When the value of accelerator gauge is
beyond 0.6Mpa, please shut down the machine, and check if the accelerator hose is blocked.
C. During spraying, uniformly to add concrete into hopper is recommended.
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Risen PZS3000 WET-MIX SHOTCRETE MACHINE User’s Manual Figure
Farther Notice!
D. Attention must be paid to prevent large article entering rotor chambers to damage the machine.
E. Pleas keep the circumambience of exhaust of gearbox clean to avoid main electric motor
damage.
F. Please clear the accelerator hose to avoid the hose to be clocked after stopping spraying.
G. When clear the machine, forbid using water to flush electric control case, electric motor and any
electric elements.
Ⅴ. Troubleshooting
Phenomena Possible Reasons Solutions
Defect of fuses;
Inspect by electrician refer to Fig.7
contactors or button
Motor coil damage Check and maintain
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Risen PZS3000 WET-MIX SHOTCRETE MACHINE User’s Manual Maintenance
Upper air valve or lower Shut down machine, clear machine, then
air valve close open the valve
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Risen PZS3000 WET-MIX SHOTCRETE MACHINE User’s Manual Figure
Ⅵ. Maintenance
PZS3000 WET-MIX Shotcrete Machine is suitable for arduous environment and little trouble
occurrence. However, maintenance and care should be taken to stable its function and prolong its
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Risen PZS3000 WET-MIX SHOTCRETE MACHINE User’s Manual Maintenance
working duration.
1. Sealing Plate and Rotor Plate are key parts and must pay more attention to ensure no failure
occurs during working.
Before spraying, please check the clamping force between rubber sealing plate and rotor disk,
because if the force is too small, compressed air will leak from the friction surface with little granular
which will lead dust emission around the machine. These little granular can damage sealing plate
and make sealing degrade in a short time. If the force is too high,over wear will be occurred by
friction. Sealing plate’s temperature limit is 110℃. In working , its suitable temperature is below 80
℃.
Each shift should clear sealing plate and check it tear condition. If its rubber surface is worn to
the same height as the end of reinforce bar inside it(Fig.8) it must be repaired, grind reinforce
bar or changed, otherwise its sealing capacity will be reduced.
Check Rotor Plate once a week. If Rotor Plate is deeply carved (/1mm), it should be re-grinded.
The hole of edges in Rotor Plate should be checked frequently. It should be kept sharp all the time.
If the hole of edges are blunt; small particles will enter the friction faces and lead more wearing.
Polish Rotor Plate in time will decrease much trouble and save cost.
2. Chambers and Vortex Stream Implement are made of non-adhesive material and are not
clogged in normal condition. However, they should be checked and cleared after every shift.
3. Pay attention to speed reducer frequently.
A. Its lubrication oil should be of No.50 Gear Oil (SY1172-77S) or No.30 Machinery Oil.
B. Reducer temperature rising should not exceed 40℃.
C. After every shift, the clogged material on Reduce surface should be cleared off.
D. Monitor Oil level indicator regularly, fills it up when lubrication oil is not enough.
E. Change new lubrication oil after 250 working hours (about 3 mouths).
F. Check it regularly if there is any oil leakage of Reducer and handles it in time.
G. Add lubrication grease to the bearing on the square shaft of Rotor every week.
4.Check the liquid accelerator hose line
Check and clear the hose every week.
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Risen PZS3000 WET-MIX SHOTCRETE MACHINE User’s Manual Figure
1-1.5mm lower than the surface of Rotor disk. More attention should be paid that the pin must not
be higher than the surface of Rotor disk so as not to damage Rubble Sealing Plate.
Ⅷ.Appendix-1 Diagram
1.Overall layout
2.Overall structure
3.Working principle
4.Transmission system of gearbox
5.Detailed list of bearings and gears
6.Exploded drawing of rotor assy.
7.Detailed list of rotor assy.
8.Conveying principle of liquid accelerator
9.Electric control system principle
10.Structure of rubber sealing plate
11.Detailed list of consumption parts
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Risen PZS3000 WET-MIX SHOTCRETE MACHINE User’s Manual Dosing Pump
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Risen PZS3000 WET-MIX SHOTCRETE MACHINE User’s Manual Figure
Overall Structure
FIG..2
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Risen PZS3000 WET-MIX SHOTCRETE MACHINE User’s Manual Dosing Pump
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Risen PZS3000 WET-MIX SHOTCRETE MACHINE User’s Manual Figure
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Risen PZS3000 WET-MIX SHOTCRETE MACHINE User’s Manual Dosing Pump
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Risen PZS3000 WET-MIX SHOTCRETE MACHINE User’s Manual Figure
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Risen PZS3000 WET-MIX SHOTCRETE MACHINE User’s Manual Dosing Pump
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Risen PZS3000 WET-MIX SHOTCRETE MACHINE User’s Manual Figure
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Risen PZS3000 WET-MIX SHOTCRETE MACHINE User’s Manual Dosing Pump
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Risen PZS3000 WET-MIX SHOTCRETE MACHINE User’s Manual Figure
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Risen PZS3000 WET-MIX SHOTCRETE MACHINE User’s Manual Dosing Pump
Key cement is a remarkable composite reinforced hose which connects to the inlet and outlet
joints. The rotor of pump is directly installed the output shaft of reducer, and two special design
shoes are symmetrically installed in the body of rotor. When the rotor rotates, the hose is
squeezed again and again, and the material in the hose also is continuously pump with rated
output.
The special lubrication is filled at a required lever into body of pump, which can act as lubricating
and cooling, thus promote the life of hose.
The rotor Rev. can be no-class adjusted, so the output of pump also is variable.
3.Operating
1. Check the connections of the parts, ensure that all the connections are fixed.
2. Check the indicator of reducer, pump body, and ensure that the oil volume is enough and
correct.
3. Connect the inlet and outlet hose/pipe, and ensure the sealing between the hoses is good.
And the pressure gauge in the outlet line is required to monitor the output pressure.
4. Start the pump at a short time, and ensure the direction to comply with the request.
5. The hand wheel should be adjusted only when the pump is working, and forbid to adjust
hand wheel when the pump shut down. For adjusting the required output with less than 0.8
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Risen PZS3000 WET-MIX SHOTCRETE MACHINE User’s Manual Figure
4.Maintenance
1. Variator must be lubricated by Ub-1 or Ub-3 traction liquid. And don’t add the engine oil, gear
oil into this variator. The lever of traction liquid should reach to the oil tag. The reducer should
be lubricated by gear oil 130-160EP. And required replaced traction liquid period is every
2000 hours.
2. Check the lever of special lubrication in the pump body, if renewing the lubrication, the
recommending volume is about 600ml.
3. When the distort of hose is heavy, please change the hose timely.
5.Main Technical Data
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Risen PZS3000 WET-MIX SHOTCRETE MACHINE User’s Manual Dosing Pump
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