Draft status
This manual is currently in draft form and may be updated as technical information, images, and procedures are added or revised.
Equipment and Component Identification
Use this visual reference to identify the principal equipment and machine components named in this manual. The catalogue will be completed as approved M-PR 3.1 images and configuration-specific details are provided. Always confirm the installed component, equipment label, and machine configuration before following a procedure.
Production Line Equipment
Production machine
M-PR 3.1 Block Making Machine
The central forming unit of the production set. It uses the selected mould to form the prepared concrete mix into products.
Material preparation
Aggregate Bunker
Receives the production materials before they are transferred toward the mixer.
Material transfer
Conveyor Belts
Transfer material between the bunker, mixer, and block machine. Each conveyor must be identified by its function and material-flow direction during installation.
Material preparation
Pan Mixer
Combines the production materials into the concrete mix supplied to the block machine.
Forming and Material Transfer Components
Internal material transfer
Filling Box
The moving component inside the block machine that carries the prepared concrete mix to the mould area and distributes it into the mould.
Product forming
Mould
Defines the shape and dimensions of the finished product. The installed mould must be verified as compatible with the M-PR 3.1 before installation or operation.
Control, Hydraulic, and Vibration Components
Electrical control
Electrical Panel
Contains the terminal groups used for the main electrical supply, hydraulic motor, vibration motors, and vibration pedal connections. Refer to Section 3 for the verified assignments.
Hydraulic system
Hydraulic Oil Tank
Stores the hydraulic oil used by the machine. The filler/breather cap and side-mounted oil level and temperature sight gauge are visible. Confirm the oil specification and required level before starting the hydraulic pump.
Hydraulic system
Oil Level Sight Gauge
Shows the visible hydraulic-oil level in the tank. The °C and °F markings indicate oil temperature, not fill level.
Hydraulic drive
Hydraulic Motor
The motor connected through terminal group 3X2. Its observation viewpoint and required rotation direction must be verified before normal operation.
Vibration system
Vibration Motors 1 and 2
Provide vibration for the forming process and are connected through terminal groups 3X3 and 3X4. Each direction reference requires a fixed observation viewpoint.
Operator control
Vibration Pedal
The foot-operated control connected through terminal group 4X2. Its approved operating and test procedure must be followed before use.
Safety and Preparation
Authorized personnel only
Electrical, hydraulic, lifting, alignment, and commissioning work must be performed by appropriately trained and authorized personnel using the approved machine drawings, site procedures, and applicable regulations.
Before any work starts, isolate all applicable energy sources using the site-approved lockout procedure and verify the safe machine state. The final manual must define the exact isolation points and verification method for this machine configuration.
Draft Completion Requirements
- Required — Machine configuration: installed equipment and configuration.
- Required — Personnel: competencies and authorization required for each task.
- Required — Safety: PPE, isolation points, stored-energy controls, and stop-work conditions.
- Required — Tools: approved hand tools, lifting equipment, measuring equipment, and torque tools.
- Verification required: technical reviewer, approval status, and approval date.
1. Conveyor Belt Installation
This section identifies the conveyor arrangement, support details, and mixer-to-conveyor transfer point shown in the supplied reference media. Final placement, alignment, adjustment, anchoring, and acceptance must follow approved installation documents and machine-specific values.
Installation Data
| Required field | Information to provide | Status |
|---|---|---|
| Conveyor identification | Equipment tag and function | Required |
| Orientation | Reference viewpoint and material-flow direction | Required |
| Positioning | Reference dimensions, support height, and anchoring points | Required |
| Alignment | Measurement points and permitted tolerance | Required |
| Belt adjustment | Approved tension or tracking specification | Required |
| Connections | Fasteners, guards, sensors, cables, and torque values | Required |
Reference media only
The photographs and videos below help identify component relationships. They do not define installation dimensions, floor requirements, anchor specifications, fastener grades, tightening torques, alignment tolerances, belt settings, or an approved work sequence.
Conveyor Assembly Reference States
Use the numbered photographs to distinguish the supplied belt and roller components, the conveyor before belt installation, and the conveyor after mechanical assembly.
State references, not assembly steps
These photographs identify visible assembly states. They do not define component quantities, an installation sequence, fastener requirements, belt-tension settings, alignment tolerances, or acceptance criteria.
1 — Conveyor Belt Components
2 — Conveyor Before Belt Installation
3 — Assembled Conveyor
Conveyor Arrangement and Support Layout
Use the overview to identify the inclined conveyor and its braced support structure. Confirm the conveyor identity, material-flow direction, final position, support heights, and anchoring points against the approved installation drawing.
Support-Leg Connection Details
The close views identify the leg-to-frame joint and the floor-level footplate. Use them to recognize the components only; obtain the approved fastener, torque, anchor, floor, and assembly requirements before installation.
Visual description
The camera moves around the inclined conveyor and shows the braced support legs, floor-level footplates, and bolted leg-to-frame connections from several angles. No assembly sequence or measurement is demonstrated.
Mixer-to-Conveyor Transfer Point
The mixer discharge must be correctly positioned relative to the conveyor intake so material enters the belt path as intended. The supplied media shows the relationship and material flow, but does not provide installation dimensions, clearances, or alignment tolerances.
Visual description
The camera shows the mixer discharge and the conveyor intake from several angles while material passes through the transfer point. The recording demonstrates the visible flow path but does not establish dimensions, clearances, or alignment tolerances.
Approved Installation Procedure
Completion Checks
- Required: approved alignment and tracking acceptance criteria.
- Required: support fastener, floor anchor, guard, sensor, and cable inspection points.
- Required: approved mixer-to-conveyor transfer-point clearance and alignment criteria.
- Verification required: installer name, measurement record, date, and reviewer.
2. Hydraulic Oil and Working Pressure
Prevent hydraulic-system damage
Do not start the hydraulic pump until the tank has been filled to the required level and the oil specification has been confirmed for this machine.
Oil Specification and Quantity
| Item | Value | Status |
|---|---|---|
| Recommended oil | No. 80 oil | Recommended |
| Recommended quantity | 100 L | Recommended |
| Required fill level | Match the visible oil level shown on the sight gauge in the reference photograph | Required |
Fill-level Reference
How to read the reference
Use the visible oil level in the sight gauge as the filling reference. The printed °C and °F markings show oil temperature; they are not fill-level values.
Filling Procedure
- Use the recommended oil. No. 80 oil is recommended.
- Add the oil while watching the sight gauge. The recommended quantity is 100 L; use the sight gauge rather than volume alone to determine the final fill point.
- Stop at the reference level. Stop filling when the visible oil level matches the level shown in the photograph above.
Working Pressure and Adjustment
Authorized personnel only
Hydraulic working-pressure adjustment must be performed only by trained and authorized personnel.
Required working pressure
Maintain the hydraulic working pressure between 100–120 bar. Adjust the pressure with a hex key (Allen key) at the adjustment point located behind the hydraulic control lever assembly.
3. Electrical Panel Connections
Electrical hazard — qualified electricians only
Keep the installation de-energized and locked out until the approved wiring diagram, supply characteristics, protective-earth connection, terminal assignments, conductor requirements, protection devices, and tightening torques have been verified.
Source Documents and Supply Data
- Required: approved wiring-diagram number and revision.
- Required: incoming supply voltage, frequency, phases, and permitted tolerance.
- Required: protective-earth arrangement and verification method.
- Required: conductor specifications, protection devices, and terminal tightening torques.
- Required: site isolation and pre-energization sign-off procedure.
Connection Assignments
Connect the electrical panel using the terminal-group assignments below. Verify every terminal label against the approved wiring diagram before connecting a conductor.
| Terminal group | Connection |
|---|---|
| 3X1 | Main electrical supply |
| 3X2 | Hydraulic motor |
| 3X3 | Vibration motor 1 |
| 3X4 | Vibration motor 2 |
| 4X2 | Vibration pedal |
Electrical Panel Reference
Use labels and the approved schematic
The photograph is an orientation aid. Do not rely on conductor color alone; the terminal labels and the approved wiring diagram must agree.
Pre-energization Verification
- Required: point-to-point connection inspection.
- Required: protective-earth and protection-device verification.
- Required: terminal torque and conductor-label record.
- Verification required: qualified electrician name, date, drawing revision, and authorization to energize.
Motor direction test required
After all motor connections have been completed and the pre-energization checks have been signed off, test the rotation direction of the hydraulic motor and both vibration motors. Follow Section 4 — Motor Rotation Checks before normal operation.
4. Motor Rotation Checks
Direction requires a fixed viewpoint
Every rotation direction must state the exact observation side and show a direction arrow. Do not record only clockwise or counterclockwise without the viewpoint.
Motor Direction Schedule
| Motor ID | Function | Rated Power | Rated Speed | Observation Viewpoint | Required Direction |
|---|---|---|---|---|---|
| 1 | Vibration | 4 kW | 3,000 rpm | Rear view | Clockwise |
| 2 | Vibration | 4 kW | 3,000 rpm | Rear view | Counterclockwise |
| 3 | Hydraulic | 5.5 kW | 1,500 rpm |
Approved Jog-test Procedure
Procedure pending
Add the machine-specific safe test configuration, responsible personnel, communication method, jog duration, expected indication, stop conditions, and approved correction procedure. Do not add a generic phase-swapping instruction.
5. Mould Installation
Crushing and stored-energy hazards
The final procedure must define the safe machine state, isolation points, mould mass, approved lifting points, handling equipment, exclusion zone, alignment references, fasteners, and torque values before installation begins.
Installation Prerequisites
| Required field | Information to provide | Status |
|---|---|---|
| Mould identity | Part number, revision, and compatibility | Required |
| Handling data | Mass, centre of gravity, lifting points, and approved lifting equipment | Required |
| Safe machine state | Isolation points and stored-energy controls | Required |
| Upper mould connection position | Raise the upper mould connection hydraulically to its highest position before positioning the mould. | Required |
| Installation data | Alignment references, clearances, fasteners, and torque values | Required |
| Acceptance criteria | Inspection points and authorization before powered movement | Required |
Step-by-step Installation Procedure
The blocks below demonstrate the format. Replace them with the approved number and order of actions. Keep one action per step, place the warning beside the affected action, and add the matching photo or captioned video.
-
Step 1 — Position the Selected Mould
Before the mould is positioned, raise the upper mould connection hydraulically to its highest position. The selected mould is positioned on the machine for installation.
Video 1: The selected mould is positioned on the machine for installation. Audio transcript: no speech. -
Step 2 — Identify the Correct Bolt Positions
Two types of bolts are used: short and long. The video shows where each bolt type must be installed.
Video 2.1: Two types of bolts are used: short and long. The video shows where each bolt type must be installed. -
Step 3 — Hand-tighten the Mould Fasteners
Install the bolts and fit the nuts. Do not fully tighten the nuts at this stage; hand-tightening is sufficient. Final tightening must be completed after the mould has been aligned in a later step.
Video 3: Install the bolts and fit the nuts. Do not fully tighten the nuts at this stage; hand-tightening is sufficient. Final tightening must be completed after the mould has been aligned in a later step. Completed Hand-tightened State
The video and photograph below show the fasteners after hand-tightening has been completed. The nuts remain hand-tight until the mould alignment is complete.
Video 4.1: The completed hand-tightened fastener state. 
Photo 4.2: Close view of the completed hand-tightened fastener state. -
Step 4 — Connect the Upper Mould
Lower the upper-mould connection plate. Hand-tighten all bolts as shown in the video.
Video 5: The upper-mould connection plate is lowered and all bolts are tightened by hand. Secure and Align the Upper Mould
Secure and align the upper mould in three stages:
- Partially tighten all upper-mould bolts with a pneumatic impact wrench. Do not fully tighten the bolts at this stage.
- Lower the upper mould slightly into the lower mould and align the moulds using short vibration pulses. This alignment is shown from 01:20 to 01:45 in the video.
- After the moulds are engaged and aligned, fully tighten all upper-mould bolts with the pneumatic impact wrench.
Video 6: The upper-mould bolts are partially tightened, the moulds are engaged and aligned using short vibration pulses (01:20–01:45), and the bolts are then fully tightened. -
Step 5 — Secure the Lower Mould
After vibration alignment is complete, fully tighten the lower-mould nuts one at a time in an alternating sequence between opposing sides, as shown in the video.
Video 7: After vibration alignment, the lower-mould nuts are fully tightened one at a time in an alternating sequence between opposing sides. -
Step 6 — Perform the Final Mould Movement Check
After all lower- and upper-mould bolts have been fully tightened, move the moulds and check for binding or abnormal resistance.
Video 8: The fully secured lower and upper moulds are moved to check for binding or abnormal resistance.
Post-installation Inspection
- Required: mould position, alignment, clearance, fastener, and torque checks.
- Required: guard, tool, lifting-equipment, and exclusion-zone clearance checks.
- Verification required: independent inspection and explicit authorization before powered movement.
6. Final Pre-start Checklist
| Check | Required record | Status |
|---|---|---|
| Conveyor installation | Identity, alignment, adjustment, guards, and sign-off | Verification required |
| Hydraulic oil and pressure | Oil type, fill quantity, level, 100–120 bar working-pressure verification, conditions, and leak check | Verification required |
| Electrical panel | Drawing revision, terminal record, protective earth, torque, and electrician sign-off | Verification required |
| Motor directions | One signed record and media reference for every motor | Verification required |
| Mould installation | Identity, alignment, fasteners, guards, inspection, and authorization | Verification required |
| Safety systems | Approved emergency-stop and safeguarding test record | Verification required |
Sign-off Record
- Required: machine model and installed configuration.
- Required: installer, electrician, commissioning technician, and reviewer names.
- Required: inspection date, document revision, open issues, and final approval status.