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Cart-Away Dry Batching System with Scanner

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The control panel of the scanner dry concrete loading systems allows complete control over the concrete mixing process. This batch plant fills concrete mixing trailers made by Cart-Away, concrete …

The control panel of the scanner dry concrete loading systems allows complete control over the concrete mixing process. This batch plant fills concrete mixing trailers made by Cart-Away, concrete titan, short stop and Ucart.

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  • 1. TABLE OF CONTENTS • Owner’s Information Page 2 • Before Beginning: READ ME FIRST! Page 3 • Rules For Safe Operation Page 6 • Material Selection and Control Page 8 • Water Requirements Page 9 • MixMaster Software Installation Page 10 • MixMaster Operating Procedures Page 12 • CBL Loading Unit Operating Procedures Page 14 • Calibration Procedures Page 15 • Conveyor Belt Adjustment Page 17 • Adverse Weather Preparations Page 20 • General Maintenance Page 22 • 24/7 Customer Support (How To Reach Us) Page 24READ ALL SAFETY AND OPERATING INSTRUCTIONS PRIOR TO USING THIS EQUIPMENT. 1
  • 2. OWNERS MANUAL FOR Model 6 Cart-Away CBL Loading UnitsCustomer Name:______________________________________________Equipment Type:__________________________________________________Equipment Serial Number:__________________________________________Purchase Date:_____________________READ ALL SAFETY AND OPERATING INSTRUCTIONS PRIOR TO USING THIS EQUIPMENT.Please have the above information available when ordering parts or seeking anyinformation on your equipment. The Parts and Service Department is available toyou 24 hours a day, seven days a week. Weekdays call: 800-909-9809 from 6a.m. to 4 p.m. (PST). For weekend or evening service call: 503-435-9446 or 530-219-0550. 2
  • 3. BEFORE BEGINNINGAll of us here at Cart-Away Thank You for becoming a member of the Cart-AwayFamily of Customers! We are very confident that you have purchased the bestequipment which is built with the highest quality and supported by the mostknowledgeable staff in the industry.For our new Family Members, many of the terms we use to describe ourequipment, and different parts of it, will be new to you. As we strive to update ourequipment regularly based on suggestions from the users and new innovationsfrom the industry, even some of our current Family Members may find that somedescriptions have been changed or updated. Before you begin reading thismanual, please take a moment to familiarize yourself with some of the terms weuse for the Model 6 CBL unit you have purchased: • CBL: Cart-Away Belt Loader. The term we use for the loading system you have purchased. This is referred to in this manual as the CBL Loading Unit or simply CBL Unit. • Hopper Unit: This is the portion of the loading unit that holds the sand & gravel. You may have a CBL1 (single hopper) or CBL2 (double hopper). In a CBL2 unit, we will refer to the hoppers as “Front” and “Rear”. The “Front” hopper is immediately behind the control panel and has a short conveyor belt, the “Rear” hopper is behind that and has a longer conveyor belt. • Silo: The cement storage silo. At twenty feet tall, this unit is the largest piece of equipment you will receive from Cart-Away and will hold the cement powder. • Baghouse: Four feet square and about seven feet tall, this piece of your equipment sits behind the silo and is connected to it by a flexible rubber hose. The Baghouse catches any dust released when filling the silo with cement powder. • Cement Auger: Sometimes just referred to as the “Auger”, this is basically an eleven foot long tube that bolts to the bottom of the Silo and delivers cement powder to the Loading Belt. • Loading Belt: This is the belt that the aggregates and cement fall onto and leads to the mouth of the Mixing Trailer. This Loading Belt swings nearly 120° to load numerous ready trailers from a joystick on the main operating panel. It is sometimes referred to as the “Main Loading Belt”. • Hopper Belt: This is a conveyor belt that is under the hopper and sends aggregates to the Loading Belt. In a CBL1 (single hopper) unit you have one of these belts. In a CBL2 (double hopper) unit you have two. As in the Hopper Unit description above, we commonly refer to the two belts as “Front Hopper Belt”, or “Rear Hopper Belt”. • Control Panel: This is the electrical panel on the side of the unit that has the controls to operate the functions of the unit. • Three-Way Valve: This is a solenoid valve on the hydraulic block that controls two functions: The raise/lower/left/right movement of the Loading 3
  • 4. Belt and also the Cement Auger. While in Maintenance Mode you will need to scan this function ‘ON’ to activate the Cement Auger.• Maintenance Mode: This is the ‘Mode’ that the CBL Unit will go into after scanning the top barcode of the ‘Maintenance Sheet’, described later.• Doghouse: This the housing below the hopper conveyor belt(s) that holds the main hydraulic block. During installation, our technician may adjust some hydraulic relief cartridges on the hydraulic block. However, you will rarely have to do such adjustments after installation.• Hydraulic Relief Cartridge: A relief vale located on the main hydraulic block in the Doghouse that regulates over-pressuring of the system.• Water Manifold: A series of galvanized piping and solenoid valves bolted to the underside of the Doghouse that controls the flow of water.• Add-Water Hose: A manually operated hose that allows the addition of water to the Mixing Trailer after loading to “fine-tune” the mix.• Drum Water Fill: This is the water line inside the Load Conveyor that adds water to the Mixing Trailer during the loading process.• Dust Mister: This is the water line inside the Load Conveyor that provides a mist of water in a ‘water halo’ that reduces dust emissions between the end of the Loading Belt and the mouth of the Mixing Trailer.• Discharge Gate: A rubber sliding ‘gate’ that sets the amount of aggregates discharged from the Hopper Belt(s). You will use the ‘Gate’ during calibration of the aggregates.• MixMaster Program: The Model 6 CBL units come with a master computer program that allows you to enter the ‘mix recipe’ and print a barcode receipt in the front office for your customer to take to the operator of the CBL loading unit. This program also allows maintenance sheets to be printed as well as the important calibration work orders. In addition, the history of your sales can be tracked here.• Barcode: A series of vertical lines that vary in thickness and are printed close together. Each barcode is about three inches long and contains the information to be conveyed to the computer in the CBL unit.• Mix Recipe: Much like a chef uses a recipe to create a fine dish, the MixMaster program creates it’s own recipe for good concrete! This ‘recipe’ is printed out as a barcode to be read by the AccuScan Barcode Reader at the CBL unit to produce the concrete you have sold. This recipe will include cement and water content, as well as telling the CBL unit which hopper(s) to dispense aggregates from.• AccuScan Barcode Reader: This is the device that the operator of the CBL will use the scan the barcode on the receipt printed from the front office. Once scanned, this will tell the computer in the loading unit exactly what to dispense to the Mixing Trailer.• ‘Time Stamp’ Barcode & ‘Recipe’ Barcode: Each customer receipt printed from the MixMaster program contains two barcode prints. The top one is the ‘Time Stamp’. As often will happen on a busy day, one customer may get his receipt for concrete, but has to load other materials or may not be the next in line to get hooked to a trailer. To avoid the exact loading of concrete per receipt printed, each one is stamped for the time he received his receipt at the counter. Each customer has thirty minutes to get concrete loaded from the CBL unit from the time the receipt is printed. 4
  • 5. Below the Time Stamp is the ‘Recipe’ Barcode. This barcode tells the computer in the CBL unit what materials to dispense. This ensures that what your customer ordered is exactly what they get. An additional security factor of the Recipe barcode is that once scanned it can’t be scanned again, eliminating using a receipt a second time.• Maintenance Sheet: This is a sheet of paper printed by the MixMaster Program that has the barcodes of each individual function of the CBL unit. This sheet allows you to individually start and stop any function of the CBL unit for routine maintenance or inspection. Our installation crew will ask that you print one during set-up to fine tune the machine for your use. After that you will print one periodically for preventative maintenance or trouble-shooting. Note: Once the top barcode of the Maintenance Sheet is scanned a red light on the side of the control panel will flash. This tells the CBL Unit computer that it’s in the Maintenance Mode. The CBL unit computer will not accept any Time Stamp or Recipe Code scans until the red button below the flashing light is pressed. We highly recommend, for safety and security reasons, only maintenance personnel use this sheet and after using it, return it to the front office for immediate disposal.• Calibration Work Order: Calibration is a task that allows you to control the amount of aggregates and cement that you are dispensing. We recommend calibrating your CBL unit no less than once a month. This small effort is paramount to controlling costs. Once the procedure is performed, the employee having done it has a place to sign and date the receipt. We suggest keeping these work orders in a log book. If you ever have questions, please don’t hesitate to contact us. See page 25 for details. 5
  • 6. RULES FOR SAFE OPERATIONThis equipment is a sophisticated, yet simple, piece of machinery. It is designedto transfer aggregate and cement at high speed. Synchronization of moving partsis regulated electronically and is instantaneous. Anything caught in these movingparts may be crushed or torn in a fraction of a second. Therefore, it is extremelyimportant that all safety precautions be strictly adhered to in order toprevent an easily avoidable injury. 1. Know the equipment’s controls and how to stop it quickly. Read this Owner’s Manual! 2. Remember: Synchronization of moving parts is regulated electronically and is instantaneous. Anything caught in these moving parts may be crushed or torn in a fraction of a second. 3. Instant stopping of all moving components is achieved by pushing in the large red ‘HYDRAULIC PUMP’ switch. 4. Do not allow children to operate this machinery. Do not allow adults to operate it without proper instruction. 5. Pay attention to who is around the equipment. Caution everyone to stay away from all moving parts. Keep customers at a safe distance. 6. Keep your eyes and mind on the machine’s procedures. Don’t let other interests distract you. 7. Always operate the equipment while standing in front of the control panel. 8. Clear the work area of objects that might be tripped over or fall into moving parts. 9. Always disengage power to the equipment, and ‘lock-out’ the control panel, before making adjustments or repairs unless otherwise instructed by this manual or the Service Department at Cart-Away. 10. Take all possible precautions when leaving the machine unattended, such as disengaging the power. 11. Always disengage the power before reaching onto the loading belts. DO NOT under any circumstances reach onto any conveyor belts while the power is on. 12. Do not allow anyone to stand or walk under the main loading belt at any time. 13. Never place hands or feet on or in moving parts. 14. Always wear substantial footwear. 15. Do not wear loose fitting clothing that could get caught in moving parts. 16. Wear eye protection when operating the equipment. 17. Only operate the equipment outdoors or in a well ventilated area. 18. Wear dust mask when doing end of day sweep or when operating under very windy conditions. 19. Use care when moving the loading belt structure. 20. When loading a customer never allow anyone to stand close to the discharge end of the loading belt. 21. Only operate the equipment on a level surface and only when secured firmly to the footing plates. 22. Keep the loading belt in good working order and keep all safety devices in place. 6
  • 7. 23. Keep all nuts, bolts, and screws tight to be sure that the equipment is in safe working order.24. Keep belt tensions properly adjusted and regularly check tracking.25. Do not change the factory settings of the electrical or hydraulic components unless instructed by a factory technician or the Customer Service Department.26. Use the equipment only in daylight or good artificial light.27. Never make a mechanical adjustment while the equipment is running unless advised to do so in this manual or the Customer Service Department.28. Never work on or in the control panel without the advice of the Customer Service Department or a licensed electrician.29. Always disengage main power to the control box before resetting any contactors.30. If you don’t know…ASK!!! (See page 25) 7
  • 8. MATERIAL SELECTIONA single hopper unit (CBL1) allows you the ease of buying a singular pre-mixedcon-mix to supply your Customers with a consistent mix for their Cart-Awayneeds.With a two hopper system (CBL2) you have a variety of mixes to offer to yourcustomer. With that comes the choices you need to make in the materials youoffer:If you are able to buy pre-mixed con-mix in your area, with a CBL2 you can offerthe Customer a choice between two different mixes. For instance, a pea gravelmix for fence posts, block wall grouting, exposed aggregate, or a shallow pour.Or a larger aggregate mix for more strength or deeper pours. You may even beable to realize more profit from one mix to the other.If you are not able to buy pre-mix ‘con-mix’ (also known in some areas of thecountry as ‘c-mix’, ‘salt-and-pepper’, etc) in your area you will need to choosebetween a sand and an aggregate to put in each hopper. This also has it’sadvantages. You can vary the ratio of sand to aggregate to accommodatevarying requirements of your customer. You can also turn off the aggregatehopper and run a sand slurry mix for them in certain circumstances.Regardless of your situation, the material you choose plays in important part in aproper mix design.Remember this: You are not making concrete the same way a large ready mixcompany does. Where they mix 7-10 yard batches, you produce 1-2 yardbatches. Fluctuations in materials will affect you much more than them.For your equipment to operate with optimum results it is necessary to maintain amaximum degree of quality control over the materials used in your operation.Changes in the location that your suppliers get their aggregates, different veins ofaggregates, and different cleaning and loading procedures may ultimately affectthe desirability of the materials you use in your mix designs.Changes in the materials will directly affect your equipment. New calibrationsmust be done any time you change aggregate suppliers. Seasons may alsoaffect your material in regards to water content. Pay attention to water contentand adjust the mix accordingly. 8
  • 9. WATER REQUIREMENTS PER YARD OF CONCRETEWhile this CBL unit uses a holding tank and pressure pump to maintain thecorrect volume and pressure needed to run the specialized water systemfunctions, the actual amount of water required per yard of concrete can varywidely due to seasonal changes and customer requirements.This requires a partnership between the front office where the concrete is soldand the CBL unit operators in the yard. During installation and set-up, ourinstaller will coach you on the importance of this.The ‘rule of thumb’ is one gallon of water per cubic foot of concrete. That’s 27gallons of water per cubic yard. However, we recommend a starting point of 18-20 gallons. This may or may not be the right amount for you, and the watercontent of your material will change this setting as the seasons change, but this agood starting point.This ‘target amount’ will be entered into the MixMaster Software duringinstallation and training. It will be very important for the CBL operators to conveyany change in the ‘target amount’ to the personnel at the front office/counter. Note: The amount entered is the amount used for 1 yard. The MixMaster Program will take care of reducing or increasing this amount for the different loads.Please Note: The factory installer will assist you in this during set-up and training,but keep in mind that as seasons change, so do water requirements. The ‘targetamount’ can be changed by the MixMaster program user at any time, but wesuggest doing so after consulting the ‘partner’ in the yard that is loading anddispensing materials.This ‘target amount’ will leave the mix slightly dry. NEVER send out a wet loadwith a customer. Not only does the extra water dilute the mix, there is a chanceof spillage from the trailer with an overly wet load. IF YOUR CUSTOMERWANTS A WET LOAD, THEY CAN ADD WATER AT THEIR LOCATION!If you have any questions at all, please ask the factory service technician duringinstallation or see page 25 of this manual for contacting us. 9
  • 10. MixMaster Software InstallationThe MixMaster program is a very easy to use Windows-based program thatwill guide you through order taking, allow the printing of Calibration WorkOrders and Maintenance Sheets, and even allow you to extract history ofsales in a multitude of ways. This software comes installed in the laptopcomputer Cart-Away provides for you. However, should you need to installthis software on another computer, below are the installation instructions.1. Before you begin: Exit out of all other programs open on the computer.2. Insert the CD into the CD Drive.3. The CD should Auto-Start by itself, but if it does not, do the following: • Go to ‘Start’ at the bottom left of the screen to pull up the ‘Start’ menu. • Click on ‘Run’. • Click on ‘Browse’ • Double click on the CD drive for your computer (usually D:) if available. If not, open the menu using the arrow on the right side of the ‘Look In:’ window. Then double click on the CD drive. • A list of programs will appear. Double click on ‘Cart-Away Setup’.4. The Auto-Start menu will appear. Follow the simple directions to download the program. It is highly recommended that you use the default settings offered during setup!5. At the end of the setup procedure you will be asked to restart the computer. It is highly recommended that you do so!6. Once the computer has restarted, you will have the MixMaster software icon on your desktop and also in the ‘Start’ menu.It’s time to begin using the MixMaster Program to set up your features, setthe time on your loading unit, and allow our installer to complete Set-Up ofyour CBL Loading Unit. It is important that power has been connected to theCBL unit in the yard before beginning this procedure.1. Double-click on the Mixmaster icon on the desktop or in the ‘Start’ menu.2. In the upper left corner click ‘Options’. This will drop down a menu.3. Click ‘Customer Name’. This will allow you to put your business name at the top of the printed recipe page. Type your business name and click ‘Save’.4. In the upper left corner click ‘Options’ again. 10
  • 11. 5. Select ‘Set PLC Time’. This will lead you to a screen that will allow you to print a barcode page that will tell the PLC computer in the CBL unit what time it is.6. IMMEDIATELY take the printed page to the CBL unit and use the AccuScan Barcode Reader to scan the bar code. The yellow, green, and red lights will flash once or twice to show the time is registered. • Why is this important? Because every recipe page you print not only has the recipe of the mix to be made spelled out, it is also ‘time-stamped’. This time-stamp allows the customer time to hook the vehicle to a trailer or perhaps load other goods before getting their concrete. However, this time-stamp also prevents the customer from bringing back an old recipe page and getting concrete another day without paying. The time-stamp is good for 30 minutes.7. In the upper left corner click ‘Options’ again.8. Click ‘Print Maintenance Sheet’ and print one copy.9. In the upper left corner click ‘Options’ again.10. Click ‘Print Calibration W/O (Work Order) and print one copy.11. By printing these pages you will enable our installer to complete the Set- Up of you CBL Loading unit. The installer will now adjust system functions and set calibration of the CBL unit. We advise that the personnel using and/or maintaining this unit be present for this operation. 11
  • 12. OPERATING PROCEDURES FOR THE MIXMASTER PROGRAM 1. Open the Mixmaster Program by double-clicking the icon on the desktop or in the ‘Start’ menu of the computer. 2. After the program opens, you will see a very simple screen that will spell out the ingredients of the mix. 3. First, select the number of sacks of cement. Options are from 4 to 8 sack mix. 4. Second, select the quantity of concrete. Options include ¼ yard to 2 yards. 5. Third, select the amount of water to be added to the materials. The curser can slide the mark in 5 gallon increments and the arrow buttons on the keyboard can go one gallon at a time. We recommend using the curser to drag to a number and use the arrow keys on the keyboard to refine the water addition. 6. Next, select the hopper(s) you will be dispensing aggregate from. Each will flash red when selected. NOTE: • With a single hopper unit (CBL1) you will always select ‘Front Hopper’. • With a double hopper unit (CBL2) you will have the following choices: a. If you use separate mixes of aggregates in each hopper (for example: 3/8 mix in the front and 3/4 mix in the rear) you will need to choose the appropriate hopper (‘Front’ or ‘Rear’) for the customer’s mix design. b. If you have sand in one hopper and aggregate in the other hopper, you will select both ‘Front’ AND ‘Rear’ hoppers. 7. Last, you will type in the Customer Name, Customer Address (we recommend using the address they are pouring at), and Customer phone (we recommend using the phone number that the customer is pouring at. A mobile/cell phone number is better). 8. Once these items have been selected, press next. 9. The ‘Validate Order’ window will appear. In the upper right you can verify the customer information. The lower left will advertise the mix design you have entered and you can verify it with the customer. The lower right portion of the window allows you to ‘Return’ and edit the information or continue with the ‘Next’ button. The ‘Next’ button will lead to printing the recipe page. 10. Once the options are firm, print the recipe page. It will come out with complete directions for operating the Mixing Trailer as well as recipe and time-stamp barcodes. 11. Send the customer to trailer hook-up and loading of the concrete. 12
  • 13. OPERATING PROCEDURES FOR THE CBL LOADING UNIT1. Turn main power on at the control panel. The red red on the side of the panel will turn on showing the computer has been activated. The Scanner unit will also beep showing readiness.2. Pull on the red ‘HYDRAULIC PUMP’ switch to start the hydraulic system.3. Using the joystick on the panel, swing the loading conveyor to the proper position for loading of the trailer. Adjust height as necessary. The conveyor should be positioned so that the rubber skirting is nearly touching the edge of the loading drum on both sides and at the top.4. Ready the Rotating Drum Mixing Trailer: • Start the engine on the trailer. Set the throttle at wide open. • Rotate the MIX/DUMP knob clockwise as far as it will go.5. Use the AccuScan Barcode reader to scan first the top line of code (Time- Stamp information). The AccuSanner will be ‘beep’ when the code is read and the yellow ‘Pause’ light will flash.6. Next, use the AccuScan Barcode reader to scan the bottom line of code (Recipe). The AccuSanner will be ‘beep’ when the code is read and the green ‘Start’ light will flash.7. The MixMaster Computer in the CBL Loading Unit now has the recipe of the mix the customer purchased and is ready to dispense materials.8. By pressing the green ‘Start’ button the CBL Loading Unit will dispense materials automatically. All systems will start and stop automatically!! • NOTE: You can pause the operation by pressing the yellow ‘Pause’ button at any time. Pressing the green ‘Start’ button again will resume the loading.9. The hopper conveyor(s), main loading belt, cement auger, and dust suppression nozzle will come on and continue to run until they time out based on the computer’s settings. The hopper conveyor(s), and cement auger will stop automatically when the computer times out, but the main loading belt and dust suppression nozzle is time delayed and will stop approximately 3 seconds after the timer reaches zero.10. Using the joystick on the panel, move the loading conveyor out of the way and then check the mix in the trailer. Add water from the ‘add-water’ hose, located on the loading conveyor, as necessary. (See page 9.)11. Send customer out after reviewing operating instructions for the trailer. 13
  • 14. 12. If you have other customers backed up and ready to load, move the loading belt to the appropriate position, and repeat steps 4-11. 13. If no other customers are waiting, push off ‘HYDRAULIC PUMP’ switch to turn machine off.The order of the above procedures are suggestions only, but we at Cart-Away have found this to be the most efficient way to operate the equipmentand recommend that you follow these steps in order as well. Deviating fromthese steps can cause a loss of efficiency that will result in longer stand bytime for your customer. 14
  • 15. CALIBRATION PROCEDURES Make sure that the cement silo is full and the aggregate hoppers filled.1. Cement calibration: Equipment needed: Hanging scale (ranging up to 35+ pounds) and kitchen garbage bags (preferably with the ‘draw string’). A. Print a ‘Calibration Work Order’ from the MixMaster software at the front desk/office. This will print a Work Order to calibrate all materials from the CBL unit. This section of the manual will focus on Cement Calibration. B. Remove the discharge sock from the end of the cement auger discharge spout. C. Place one of the kitchen garbage bags under the cement auger. Use the ‘draw-strings’ to loop over the auger to hold the opening of the bag under the discharge spout. D. Pull on the red ‘HYDRAULIC PUMP’ switch. E. Use the AccuScan Barcode reader to scan the “Calibrate Cement” barcode printed. F. The green ‘Start’ Button will flash signaling that the CBL Unit computer is ready to calibrate cement. G. Press the green ‘Start’ button to start the calibration. Necessary systems will start and stop automatically! H. The cement auger will run for 5 seconds and stop. I. Weigh the bag of cement. The target weight for cement calibration is 31.3 pounds of cement. J. If the weight is not on target, then you will need to adjust the speed of the cement auger. To do so, follow these steps: • Locate the blue cover for the hydraulic components under the conveyor belt(s). This component consolidation area is called the ‘Doghouse’. • Remove the cover of the dog house. • Locate the flow control valve for the cement auger. The valve is approximately 4” square and has a swinging arm on it for adjustment. It will be located bolted to the front of the Doghouse. • Adjust the lever of the flow control valve up or down accordingly and retest until you achieve the correct weight of cement for calibration. 15
  • 16. K. Install discharge sock on the end of the cement auger and use the hose clamp to secure it.2. Aggregate calibration: (equipment needed: provided calibration container and material deflector) The calibration container is specifically marked to measure the material. Proper calibration will leave the container level at the appropriate line. Note: The calibration container is marked for mixed aggregates as well as separate aggregates. If using separate aggregates in a CBL2 Loading Unit repeat these directions as instructed below. A. Print a ‘Calibration Work Order’ from the MixMaster software at the front desk/office. This will print a Work Order to calibrate all materials from the CBL unit. This section of the manual will focus on Hopper Calibration. B. Place the material deflector on the loading conveyor and place the calibration container beneath it to catch the aggregate. C. Use the AccuScan Barcode reader to scan the “Calibrate Front Hopper” barcode printed. D. The green ‘Start’ Button will flash signaling that the CBL Unit computer is ready to calibrate cement. E. Press the green ‘Start’ button to start the calibration. Necessary systems will start and stop automatically! F. The front hopper aggregate belt and loading belt will run for 5 seconds and stop. The Loading Belt will run for an additional 3 seconds to clear it of all materials. G. Check the material in the calibration container. Note: It will be necessary to smooth the material to a flat surface inside the calibration container, but do not pack the material down!! H. The target is filling the calibration container to the appropriate line. Adjust the discharge gate higher or lower by using a large pair of channel-lock pliers or a pipe wrench to turn the adjusting nut on the gate until you’ve reached the target. I. Once the target is reached, repeat the process at least twice to ensure an accurate flow from the hopper conveyor. Following this step: • For a CBL1 (Single Hopper Unit) continue to step J. • For a CBL2 (Double Hopper Unit) repeat steps A-I. J. The loader is now calibrated to deliver one cubic yard in two minutes. 16
  • 17. CONVEYOR BELT ADJUSTMENTThe tracking of the belts is set at the factory and again during installation, butnumerous things can affect it. Follow the steps below to adjust the tracking ofconveyor belts:Note: Wear of the belts, changing a belt, and improper loading of thehopper can effect the tracking. These and other conditions warrantattention to the belt at all times. DO NOT wait for a belt to show wearbefore performing these procedures!CERTAIN SAFETY PRECAUTIONS ARE OUTLINED IN THE FOLLOWING PROCEDURES. FOLLOW THEM TO ENSURE THE SAFETY OF EMPLOYEES DURING THIS MAINTENANCE!!A Hopper Belt is a belt that runs beneath a hopper to deliver material tothe loading conveyor. You may have single hopper unit (CBL1) ordouble hopper unit (CBL2). For hopper belt(s) adjustment follow stepsbelow for each belt:1. Print a ‘Maintenance Sheet’ using the MixMaster Program.2. Prepare to unload the CBL unit hopper(s) by readying a tractor in front of the loading conveyor to catch material.3. Use the AccuScan barcode reader to scan the top barcode on the Maintenance Sheet. This will turn on the Maintenance Mode. Once the barcode is scanned, the red light on the side of the panel will flash.4. Note that the Maintenance Sheet shows each individual function of the CBL unit with ‘ON’ and ‘OFF’ barcodes placed side by side.5. Pull the main ‘HYDRAULIC PUMP’ switch to turn on the CBL unit pump.6. Scan the Load Conveyor ‘ON’ barcode. The Load Conveyor will immediately begin to run.7. Scan the individual hopper(s) ‘ON’ barcode (ONE AT A TIME AS NECESSARY).8. The selected Hopper Belt will run. Allow them to run until empty. If necessary, scan the ‘OFF’ barcode to turn off the hopper and allow the tractor to empty it’s bucket.9. Repeat steps 7 & 8 until all Hopper(s) of the CBL unit are empty.10. THE FOLLOWING SAFETY PRECAUTIONS MUST BE FOLLOWED BEFORE PROCEEDING: 17
  • 18. • A second employee will be required to do the adjusting of the belt, while an operator stands by at the control panel to shut down the system in case of emergency.11. Using the Maintenance Sheet, scan the ‘ON’ barcode for the Hopper Belt you wish to adjust tracking on.12. Have the other employee at the rear of the machine watch the belt as it comes around the pulley and enters the hopper at the back of the slider bed.13. The conveyor belt should enter the opening of the hopper evenly with the same amount of space between the edges of the belt and the edges of the slider bed on both sides.14. If this is not the case, adjustment of the rear pulley shaft will be necessary. Follow the procedures outlined below: • All directions concerning ‘left’ and ‘right’ are in relation to the travel of the conveyor belt away from you (toward discharge end). • If the belt is tracking to the right, it will be necessary to straighten the pulley at the take-up frame on that side. This is done by tightening the adjustment bolt on the right take-up frame. • Note: Make adjustments gradually! A small (1/4) turn of the adjustment bolt will create noticeable movements of the belt! • After making small adjustments, return to the rear of the hopper and watch the belt. It will track toward center at each adjustment. Continue adjustments until the belt tracks to the center and stays there. Note: The belt needs to be run for at least one full minute to ensure that center tracking has been achieved. • If the belt is tracking to the left, the left take-up frame bolt will need to be adjusted by following the above procedures.15. When the belt is tracking correctly, scan the ‘OFF’ barcode to turn the Hopper Belt off. Use the above procedure for additional belts as necessary.16. To exit the Maintenance Mode, press the red button on the side of the control panel.The Load Conveyor belt is the angled belt that carries the materials fromthe hopper belts and the cement up to the mouth of the mixing trailer.To adjust the Load Conveyor belt:1. Print a ‘Maintenance Sheet’ using the MixMaster Program.2. Use the AccuScan barcode reader to scan the top barcode on the Maintenance Sheet. This will turn on the Maintenance Mode. Once the barcode is scanned, the red light on the side of the panel will flash.3. Note that the Maintenance Sheet shows each individual function of the CBL unit with ‘ON’ and ‘OFF’ barcodes placed side by side. 18
  • 19. 4. Pull the main ‘HYDRAULIC PUMP’ switch to turn on the CBL unit pump.5. Scan the Load Conveyor ‘ON’ barcode. The Load Conveyor will immediately begin to run.6. THE FOLLOWING SAFETY PRECAUTIONS MUST BE FOLLOWED BEFORE PROCEEDING: • A second employee will be required to do the adjusting of the belt, while an operator stands by at the control panel to shut down the system in case of emergency.7. Have the other employee at the rear of the Loading Belt watch the belt as it comes around the pulley and travels forward.8. The conveyor belt should cross the rear pulley evenly with the same amount of space between the edges of the belt and the edges of the pulley on both sides.9. If this is not the case, adjustment of the rear pulley shaft will be necessary. Follow the procedures outlined below: • All directions concerning ‘left’ and ‘right’ are in relation to the travel of the conveyor belt away from you (toward discharge end). • If the belt is tracking to the right, it will be necessary to straighten the pulley at the take-up frame on that side. This is done by tightening the adjustment bolt on the right take-up frame. • Note: Make adjustments gradually! A small (1/4) turn of the adjustment bolt will create noticeable movements of the belt! • After making small adjustments, return to the rear of the loading belt and watch the belt. It will track toward center at each adjustment. Continue adjustments until the belt tracks to the center. Note: The belt needs to be run for at least one full minute to ensure that center tracking has been achieved. • If the belt is tracking to the left, the left take-up frame bolt will need to be adjusted.10. When the belt is tracking correctly, scan the ‘OFF’ barcode to turn the Loading Conveyor belt off.11. To exit the Maintenance Mode, press the red button on the side of the control panel 19
  • 20. Adverse Weather PreparationsAdding hot water and chemical treatment to the concrete you provide willlengthen the selling season in colder climates. However, in some climates duringthe colder months it may be necessary to prepare your equipment for temporaryshutdown to prevent failure or breakage of systems. This shutdown could last anevening, or up to a month or more during severe winter conditions.If your equipment was installed in a climate that has harsh weather conditions,and a shutdown period is mandatory, follow the steps outlined below to protectsystem functions and components.Water System: 1. Turn off the main water valve at the inlet from the ground supply to the holding tank. Properly insulate the water supply hose from the ground. 2. Remove one end of the supply line leading to the holding tank and drain the water from it. 3. Print a ‘Maintenance Sheet’ using the MixMaster Program (see page 10) . 4. Use the AccuScan barcode reader to scan the top barcode on the Maintenance Sheet. This will turn on the Maintenance Mode. Once the barcode is scanned, the red light on the side of the panel will flash. 5. Note that the Maintenance Sheet shows each individual function of the CBL unit with ‘ON’ and ‘OFF’ barcodes placed side by side. 6. Pull the main ‘HYDRAULIC PUMP’ switch to turn on the CBL unit pump, which will start the water pump. 7. Scan the Drum Water Fill ‘ON’ barcode. The Drum Fill solenoid will activate immediately and begin pumping out the remaining water in the main water line. 8. When water stops coming from the drum fill line, which should take only a few seconds, scan the ‘OFF’ barcode to turn the solenoid off. 9. Push the main ‘HYDRAULIC PUMP’ switch to turn off the CBL unit pump, which will stop the water pump. DO NOT RUN THE WATER PUMP WHEN DRY!! 10. Remove the bottom ¼” plug from the pump housing to drain the remaining water in the pump head. 11. Remove the ‘add-water’ hose from the Water Manifold. Drain the hose, and store it inside or under warm cover. (The water manifold is the section of galvanized plumbing that controls the water flow from the pressure 20
  • 21. pump. To find it, follow the water line from the pressure pump to the manifold.) 12. With the add-water hose removed, open the hose bib it was connected to. Open any other hose bibs on the unit. 13. Remove the Dust Mister and Drum Water Fill rubber hoses from the Water Manifold and allow them to drain.Hopper(s):The steel of the hoppers will hold cold temperatures. In doing so, the steel canfreeze the moisture in the aggregates and they will remain frozen long after thesun has come up and the day warmed.To avoid this, it is recommended that the hopper(s) be emptied and remainempty during sever winter months. Follow steps 1-8 of “CONVEYOR BELTADJUSTMENT” to empty the hopper(s). See page 18.Note: The above procedures cover nearly all situations. We cannot account for some situations due to assembly or installation differences. Severe climates may need additional measures for complete protection. Our Service Department is available 24 hours a day, 7 days a week to answer any questions. See page 25 to contact us. 21
  • 22. GENERAL MAINTENANCEStrict adherence to the following maintenance procedures will prolong the lifeof the equipment and reduce repair costs. While preventative maintenance ison everyone’s mind, sometimes the CBL Unit and trailers are left behind dueto their location in the yard and the fact that they require little attention.However, from time to time, these units will require your attention to preventforeseeable problems. We advise you to take the following steps to insureproper function of the equipment:DAILY: • Clean the area around and under the equipment. Be sure that the Release Agent pump is unplugged at the end of each day. (if applicable) • Pressure wash the machine paying special attention to the loading conveyor, belt wiping brush, and front of the hopper. (DO NOT USE A PRESSURE WASHER DIRECTLY ON THE CONTROL PANEL!)EVERY WEEK: • Grease all of the bearings on the machine. One to two pumps of a grease gun will be all that is necessary. Note: All of the bearings on your machine are ‘sealed’ bearings. Do not over grease them or you will blow the seals! • Check hydraulic fluid level. As necessary fill with AW32, or similar, 10 WT hydraulic fluid. • We recommend that you calibrate once a week in varying seasons. As moisture content in the aggregate changes, so will the calibration. The cement also varies in it’s density after repeated filling of the silo. • Check the tracking of both conveyor belts. For the hopper belt this is done by standing at the rear of the hopper. Look at the belt where it enters the hopper. It should be centered on the trough and not to one side or the other. For the loading belt, look at the rear pulley. The belt should be centered there as well. If this is not the case see ‘CONVEYOR BELT ADJUSTMENT’ on page 18.EVERY 6 MONTHS: • Turn on the machine and check the gauge on the hydraulic filter housing. If the gauge reads in the yellow or red, replace the filter.EVERY YEAR • Replace the hydraulic filter yearly regardless of the reading of the pressure gauge on the filter housing. 22
  • 23. AFTER EVERY FILLING OF THE CEMENT SILO: • Open the bag house and shake the bags to remove any cement dust clinging to them. • Place a small container below the discharge gate at the base of the bag house. Open the discharge gate and allow the cement to fall into the container. As this will be a very small amount, pour the cement onto the exposed portion of the hopper conveyor belt to be mixed in with the next load of concrete you make. 23
  • 24. CUSTOMER SUPPORTWe at Cart-Away Concrete Systems have manufactured and installed for you thefinest equipment of it’s type at your location. Our technician assembled theequipment for you and trained your personnel. But we realize that there may beoccasions that will require you to contact us in matters concerning operation,maintenance, or ordering parts for your machine.As Customer Service is as much a part of our company as manufacturing andselling our equipment, we provide you with 24 hours a day, seven days a week,ability to reach us. If you have ANY questions regarding this equipment, itsoperation, or maintenance needs contact us: WEEKDAYS: 800-909-9809 FROM 6 AM TO 4 PM (PT) AFTER HOURS AND WEEKENDS: 503-435-9446 -OR- 503-472-4234 24