USE AND MAINTENANCE MANUAL

TWIN SHAFT MIXER MODEL MAO 7500/5000

CUSTOMER: SICOMA NORTH AMERICA MODEL: MAO 7500/5000 SERIAL No.: 12846 YEAR: 2011 SICOMA s.r.l. Via Brenta, 3 PONTE VALLECEPPI (PG), Italia Tel. +39-75-5928120 Fax. +39-75-5928371 sito: http://www.sicoma.it e-mail: sicoma@sicoma.it

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SOCIETA ITALIANA COSTRUZIONE MACCHINE

ATTENTION:

THE NON-APPLICATION OF THE USE AND MAINTENANCE REGULATIONS MENTIONED IN THE PRESENT MANUAL WILL ENTAIL AUTOMATICALLY THE LOSS OF ALL WARRANTY AND INSURANCE COVERINGS.

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INDICE INTRODUCTION CONDITIONS OF GUARANTEE DIMENSIONS SCHEME TECHNICAL FEATURES MACHINE SCHEME TECHNICAL SPECIFICATIONS

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INSTRUCTIONS FOR USE AND MAINTENANCE

1) GENERAL DESCRIPTION OF MACHINE AND IDENTIFICATION PLATES 1.1) IDENTIFICATION PLATE POSITION

2) HOW TO USE AND KEEP THE INSTRUCTIONS MANUAL 2.1) WHOM THIS INSTRUCTIONS MANUAL IS MEANT FOR 2.2) PURPOSE OF THE INFORMATION GIVEN BY THE INSTRUCTIONS MANUAL 2.3) INSTRUCTIONS MANUAL LIMITATIONS 2.4) HOW TO KEEP THE INSTRUCTIONS MANUAL 2.5) WARNINGS

3) HANDLIG AND INSTALLATION OF THE MACHINE 3.1) RECEIPT OF THE MACHINE 3.2) PERSONNEL REQUIREMENTS 3.3) ISTRUCTIONS FOR LIFTING AND MOVING THE MACHINE 3.4) FIXING POINTS 3.5) STATIC AND DYNAMIC LOADS 3.6) CHECKING OIL AND HYDRAULIC FLUID 3.7) MACHINE DISCHARGING AND OVERTURNING

4) ELECTRIC CONNECTIONS 4.1) ELECTRIC CONNECTIONS 4.2) CONTROL PANEL INDEPENDENT OF THE SYSTEM MASTER PANEL 4.3) JUNCTION BOX 4.4) GENERAL SYSTEM CHARACTERISTICS 4.5) POWER SUPPLY CONNECTIONS AND EARTH 4.6) ELECTRICAL CONNECTIONS FOR LOW MOTION DRIVE DEVICE

5) USES OF THE MACHINE 5.1) WHAT IS THE MACHINE DESIGNED FOR 5.2) TYPE OF USE 5.3) OPERATOR 5.4) MATERIALS WHICH MAY BE USED IN THE MACHINE 5.5) RESTRICTIONS OF USE 5.6) WORKING ENVIRONMENT 5.7) WORKING OUTDOORS

6) TECHNICAL DESCRIPTION OF THE MACHINE 6.1) DESCRIPTION OF THE MACHINE

6.1.1) MIXING TANK 6.1.2) TANK LINING 6.1.3) MIXING ARMS 6.1.4) MIXING BLADES

6.1.5) UNLOADING 6.1.6) SHAFT SEALS 6.1.7) MIXING REDUCTION GEARS 6.1.8) REDUCTION GEARS HOUSING 6.1.9) MIXING MOTORS 6.1.10) SLOW MOTION DRIVE 6.1.11) MOBILE LOADING SKIP 6.1.12) USE OF THE MANUAL EMERGENCY PUMP 6.1.13) MIXER SUPPORTING STRUCTURE 6.1.14) SERVICE FLOOR 6.1.15) MIXING SYSTEM 6.1.16) SEQUENCE OF OPERATIONS DURING A MIXING CYCLE 6.2) DESCRIPTION AND POSITION OF CONTROLS 6.3) SAFETY DEVICES 6.3.1) MAXIMUM PRESSURE VALVE AND PRESSURE SWITCH 6.3.2) MIXER TANK PROTECTION GUARDS 6.3.3) INSTRUCTIONS FOR THE USE OF THE KEY TRANSFER SAFETY SYSTEM 6.4) TECHNICAL DIAGRAMS AND TABLES

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6.4.1) JUNCTION BOX DIAGRAM 6.4.2) HYDRAULIC DIAGRAM 6.5) SOUND TESTS 6.5.1) MACHINE OPERATING CONDITIONS 6.5.2) MEASURING CONDITIONS 6.5.3) AVERAGE LEQ

7) INSTRUCTIONS FOR THE USE OF THE MACHINE 7.1) USE OF THE MACHINE 7.1.1) LOADING PHASE BY MOBILE OR FIXED SKIP 7.1.2) RECOMMENDED MIXING PHASE FOR : 1) PREMIXED MIXTURE FOR LOADING INTO CONRETE TRANSIT MIXERS 2) MIXTURE FOR MANUFACTURED AND PREFABRICATED ELEMENTS 7.1.3) PAHSE OF LOADING BY BELT 7.1.4) UNLOADING PHASE 7.1.5) CLEANING

8) SAFETY DEVICES: CALIBRATION CONTROL 8.1) MAX PRESSURE VALVE 8.2) PRESSURE REGULATOR 8.3) CHECKOUT OF MAX PRESSURE VALVE 8.4) CHECKOUT AND REULATION OF TRANSMISSION BELTS TENSION

9) INSTRUCTIONS FOR MAINTENANCE 9.1) CHANGE OF LUBRICATING OIL 9.2) CHANGE OF HYDRAULIC OIL IN OIL-PRESSURE SYSTEM 9.3) SEALS LUBRICATION 9.3.1) WORKING 9.4) GREASING 9.5) CHECK OF BOLT TIGHTNESS 9.6) CHECK OF PARTS SUJECT TO WEAR 9.7) ADJUSTMENT OF MIXING BLADES AND PERIPHERAL BLADES 9.7.1) ADJUSTMENT OF MIXING BLADES 9.7.2) ADJUSTMENT OF PERIPHERAL BLADES 9.8) SWING OUT DRIVES OPENING AND CLOSING PROCEDURE 9.8.1) DISASSEMBLY OF ELECTRIC MOTORS 9.8.2) REASSEMBLY OF ELECTRIC MOTORS 9.8.2) DISASSEMBLY OF MIXING REDUCTION GEAR 9.8.3) REASSEMBLY OF MIXING REDUCTION GEAR 9.8.4) CHECK OUT OF TRANSMISSION BELTS TENSION 9.8.5) ADJUSTMENT OF TRANSMISSION BELTS 9.9) DISASSEMBLY AND REASSEMBLY OF MIXING SCHAFTS AND SEALS 9.9.1) DISASSEMBLY AND REASSEMBLY OF MIXING SHAFTS 9.9.2) DISASSEMBLY AND REASSEMBLY OF SEALS 9.10) CHANGE OF DISCHARGE DOOR SEALS

10) SAFETY DEVICES 10.1) INSPECTION DOOR BLOCK 10.2) AUTOMATIC CONTROL DEVICE 10.2.1) LEVEL DETECTOR 10.2.2) THERMAL DETECTOR FOR REDUCTION GEAR AND HYDRAULIC PUMP OIL 10.2.3) THERMAL DETECTORS FOR MOTORS 10.3) BLACK BOX FOR ALARMS REGISTRATION

11) DISMANTLING OF THE MACHINE

12) SPARE PARTS MANUAL 12.1) GENERAL 12.2) HOW TO ORDER SPARE PARTS 12.3) SPAREPARTS ORDER FORM

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SPARE PARTS - GRAPHIC TABLE CONTENTS TAV. 0 - TANK AND WEAR SECTORS (Fe, Hardox, Ny-Hard) TAV. 1 - SHAFTS, ARMS AND BLADES TAV. 2 - OIL SEAL UNIT MOTOR SIDE TAV. 3 - OIL SEAL UNIT SIDE OPPOSED TO MOTORS TAV. 4 - MOTORS AND TRANSMISSION TAV. 5 /5A - MIXING REDUCTION GEAR UNIT TAV. 6 / 7 / 8 - DISCHARGE DOOR TAV. 9 - HYDRAULIC CYLINDER TAV. 10 - HYDRAULIC SYSTEM DIAGRAM TAV. 11 - HYDRAULIC POWER PACK TAV. 12 /12A - LUBRICATION CONTROL DIAGRAM TAV. 13 /13A /13B /13C - MIXER COVER TAV. 14 - ELECTRICAL DIAGRAM TAV. 15 /15A /15B

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INTRODUCTION

Dear Customer, SICOMA S.r.L. would like to thank you for purchasing this product and invite you to: - Read the instructions in this manual: they give the sequence of checks and preliminary work required for

transport, installation, use and maintenance of the machine and a series of tables complete with lists for easy identification and ordering of spare parts.

- If there are any problems, contact the manufacturer or area representative. - In order not to damage the machine or impair its correct operation, we recommend the use of ORIGINAL

spare parts.

CONDITIONS OF GUARANTEE

The guarantee period is meant for a single shift of 8 hours per working day. The machine is guaranteed for a period of 60 (sixty) months for the mixing group (reduction gears and bearings of the axes). As to all the other mechanical parts, seals included, the guarantee is of 12 (twelve) months from starting the machine. However, this effective date begins after max. 6 (six) months from the delivery date under the condition that the machine has been kept in a protected place. For electrical parts, the guarantee of their manufacturers is valid. The guarantee includes replacement of detective parts free of charge (except for particulars subject to wear and tear). Transport charges and travelling expenses (journey / board / lodging) for a possible technical intervention are to the charge of the customer. The working hours of the technicians at site and replacement of the defective parts are to the charge of the producer. The guarantee ceases immediately if the machine or one of its components is damaged because of: - negligence in its use - unsuitable custody - if the machine is disassembled, repaired or altered by not authorized personnel - transport made without the obligatory caution - circumstances which cannot be ascribed to manufacturing defects. Prolongation of the guarantee following a damage is excluded. Moreover, cancellation of the contract, compensation for: technical or other downtime and direct or indirect damage to persons or belongings due to an improper use of the machine are excluded.

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DIMENSIONS SCHEME

-1- water inlet into the mixing tank by pump; -2- water inlet into the mixing tank by water scale

N.B.: the loading skip is available only for the models up to MAO 6000/4000. THE DIMENSIONS MIGHT VARY DUE TO TECHNICAL IMPROVEMENTS.

MOD. MAO A B C D E F G H I L M N N1 N2 O

mm 2000 1870 2950 1480 390 900 240 730 20 910 1085 1290 740 740 1700 1500/1000 inch 78,740 73,622 116,142 58,268 15,354 35,433 9,449 28,740 0,787 35,827 42,717 50,787 29,134 29,134 66,929

mm 2320 2132 3505 1700 460 1025 240 980 27 947 1290 1520 740 740 1900 2250/1500 inch 91,339 83,937 137,992 66,929 18,110 40,354 9,449 38,583 1,063 37,283 50,787 59,843 29,134 29,134 74,803 mm 2320 2132 3505 1700 460 1025 240 980 27 947 1290 1520 740 630 1900 3000/2000 inch 91,339 83,937 137,992 66,929 18,110 40,354 9,449 38,583 1,063 37,283 50,787 59,843 29,134 74,803 mm 2320 2132 3505 1700 460 1025 240 980 27 947 1290 1520 740 740 1900 3750/2500 inch 91,339 83,937 137,992 66,929 18,110 40,354 9,449 38,583 1,063 37,283 50,787 59,843 29,134 29,134 74,803 mm 2600 2152 4070 1720 435 1150 240 1110 27 1000 1350 2080 740 740 2472 4500/3000 inch 102,362 84,724 160,236 67,717 17,126 45,276 9,449 43,701 1,063 39,370 53,150 81,890 29,134 29,134 97,323 mm 2600 2152 4070 1720 435 1150 240 1110 27 1000 1350 2080 740 740 2472 5000/3350 inch 102,362 84,724 160,236 67,717 17,126 45,276 9,449 43,701 1,063 39,370 53,150 81,890 29,134 29,134 97,323 mm 2600 2152 4500 1720 435 1150 240 1110 27 1000 1450 2530 740 740 2925 6000/4000 inch 102,362 84,724 177,165 67,717 17,126 45,276 9,449 43,701 1,063 39,370 57,087 99,606 29,134 29,134 115,157

mm 2600 2152 4500 1170 435 1150 240 1110 27 1000 1450 2530 740 740 2925 7500/5000 inch 102,362 84,724 177,165 46,063 17,126 45,276 9,449 43,701 1,063 39,370 57,087 99,606 29,134 29,134 115,157

mm 2600 2260 5650 1990 270 1150 240 980 30 1010 1455 2960 740 740 3340 9000/6000J inch 102,362 88,976 222,441 78,346 10,630 45,276 9,449 38,583 1,181 39,764 57,283 116,535 29,134 29,134 131,496 mm 2600 2260 6685 1990 270 1150 350 980 30 1010 1455 - 1500 1500 3340 12000/8000J inch 102,362 88,976 263,189 78,346 10,630 45,276 13,780 38,583 1,181 39,764 57,283 - 59,055 59,055 131,496

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CARATTERISTICHE TECNICHE / TECHNICAL FEATURES /

MODELLO MAO/S MAO/S TYPE 1500/1000 2250/1500 3000/2000 3750/2500 4500/3000 5000/3350 6000/4000 7500/5000

9000/6000 Janus

12000/8000 Janus

CAPACITA VOLUMETRICA DI CARICO DRY FILLING CAPACITY

l Cu.yd

1500 2

2250 3

3000 4

3750 5

4500 6

5000 6.6

6000 8

7500 10

9000 12

12000 16

RESA PER CICLO (SOFFICE) YELD PER CICLE (UNVIBRATED CONCRETE)

l Cu.yd

1200 1.56

1800 2.4

2400 3.2

3000 4

3600 4.8

4000 5.33

4800 6.4

6000 8

7200 9.6

9600 12.8

RESA PER CICLO (VIBRATA) YELD PER CICLE (COMPACTED CONCRETE)

l Cu.yd

1000 1.33

1500 2

2000 2.67

2500 3.3

3000 4

3350 4.4

4000 5.33

5000 6.6

6000 8

8000 10.5

TEMPO DI CICLO (ESCLUSO IL CARICO) (*)

CYCLE TIME (LOADING EXCLUDED) (*) s 90 90 90 90 90 90 90 90 90 90

RESA ORARIA (SOFFICE) YELD PER HOUR (UNVIBRATED CONCRETE)

m3/h cu.yd/h

40 52

72 96

96 128

120 160

144 192

200 267

192 256

240 320

288 384

320 427

RESA ORARIA (VIBRATA) YELD PER CICLE (COMPACTED CONCRETE)

m3/h cu.yd/h

30 40

60 80

80 107

100 133

120 160

134 178

160 213

200 267

240 320

240 320

POTENZA MOTORI DI MESCOLAZIONE MIXING MOTORS POWER

kW HP

2 x 22 2 x 30

2 x 30 2 x 40

2 x 37 2 x 50

2 x 45 2 x 60

2 x 55 2 x 75

2 x 75 2 x 100

2 x 75 2 x 100

2 x 90 2 x 125

4 x 55 4 x 75

4 x 75 4 x 100

POTENZA MOTORE CENTRALINA IDRAULICA HYDR. PACK MOTOR POWER

kW HP

0.75 1

1.5 2

1.5 2

1.5 2

2.2 3

2.2 3

2.2 3

2.2 3

2.2 3

2.2 3

POTENZA MOTORE SKIP (VELOCITA NORMALE) SKIP MOTOR POWER (STANDARD SPEED)

kW HP

1 x 7.5 1 x 11

1 x 11 1 x 15

2 x 11 2 x 15

2 x 11 2 x 15

2 x 15 2 x 20

2 x 15 2 x 20

2 x 18 2 x 25

- - -

POTENZA MOTORE SKIP (DOPPIA VELOCITA DISCESA) SKIP MOTOR POWER (DOUBLE SPEED DESCENT)

kW HP

1 x 7.5/8.8 1 x 11/12

1 x 12/15 1 x 15/20

2 x 7.5/8.8 2 x 11/12

2 x 12/15 2 x 15/20

2 x 15/18.5 2 x 20/25

2 x 15/18.5 2 x 20/25

2 x 18/22 2 x 25/30 - - -

POTENZA MOT. SKIP (DOPPIA VEL. SALITA E DISCESA) SKIP MOTOR POWER (DOUBLE SPEED UP / DOWN)

kW HP

1 x 12/15 1 x 15/20

1 x 18.5/22 1 x 25/30

2 x 12/15 2 x 15/20

2 x 18.5/22 2 x25/30

2 x 18.5/22 2 x 25/30

2 x 18.5/22 2 x 25/30 - - - -

PEZZATURA MAX. INERTI MAX. SIZES AGGREGATES

mm inch

0 180 0 7

0 180 0 7

0 180 0 7

0 180 0 7

0 180 0 7

0 180 0 7

0 180 0 7

0 180 0 7

0 180 0 7

0 180 0 7

GIRI ALBERI DI MESCOLAZIONE MIXING SHAFTS SPEED rpm 24.3 24.3 24.3 24.3 24.3 24.3 24.3 24.3 24.3 24.3

PALE DI MESCOLAZIONE MIXING BLADES 8+2+2 12 + 2 + 2 12 + 2 + 2 12 + 2 + 2 16 + 2 + 2 16 + 2 + 2 20 + 2 + 2 20 + 2 + 2 28 + 2 + 2 36 + 2 + 2

PESO A VUOTO (MACCHINA SENZA SKIP) WEIGHT/EMPTY MIXER (W/OUT SKIP)

kg lb

4500 9920

7430 16380

7530 16600

7630 16820

9300 20500

9750 21470

11900 26240

12000 26450

14200 31200

14200 31200

PESO A VUOTO (MACCHINA CON SKIP) WEIGHT/EMPTY MIXER (W/SKIP)

kg lb

6200 13640

9530 21000

11280 24870

11480 25300

13850 30500

14250 29100

16400 33870 - - -

CARICO STATICO (MACCHINA SENZA SKIP) STATIC LOAD (W/OUT SKIP) kg 7000 11030 12330 13630 16500 17790 21500 24000 28600 28600

CARICO STATICO (MACCHINA CON SKIP) STATIC LOAD (W/SKIP) kg 10600 16130 20080 22480 27050 28990 35000-

CARICO DINAMICO (MACCHINA SENZA SKIP) DYNAMIC LOAD(W/OUT SKIP) kg 11200 17650 19728 21808 26400 28464 34400 38400 45760 45760

CARICO DINAMICO (MACCHINA CON SKIP) DYNAMIC LOAD (W/SKIP) kg 16960 25800 32128 35968 43280 46384 56000-

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SCHEDA TECNICA / TECHNICAL SPECIFICATIONS / SPECIFICATIONS TECHNIQUES

CAPACITA VOLUMETRICA DI CARICO / DRY FILLING CAPACITY / CAPACITE VOLUMETRIQUE DE CHARGEMENT Lt. 7500

RESA PER CICLO (calcestruzzo non vibrato) / CONCRETE OUTPUT PER CYCLE (FRESCH) / RENDEMENT PAR CYCLE (MOU) Lt. 6000

RESA PER CICLO (calcestruzzo vibrato) / CONCRETE OUTPUT PER CYCLE (compacted) / RENDEMENT PAR CYCLE (vibr) Lt. 5000

TEMPO PER CICLO (compreso il carico) / CYCLE TIME (loading included) / TEMPS PAR CYCLE (chargement compris) Sec. 90**

RESA ORARIA (calcestruzzo vibrato) / CAPACITY PER HOUR (compacted) / RENDEMENT PAR HEURE (vibr) m/h 120**

POTENZA MOTORI DI MESCOLAZIONE / MIXING MOTORS POWER / PUISSANCE MOTEURS DE MALAXAGE HP/kW 125/90 + 125/90

TENSIONE DI ALIMENTAZIONE MOTORI DI MESCOLAZIONE / MIXING MOTORS VOLTAGE / TENSION MOTEURS DE MALAXAGE V 480/ 60Hz

POTENZA MOTORE CENTRALINA OLEODINAMICA / HYDRAULIC POWER PACK MOTOR POWER / PUISSANCE MOTEUR CENTRALE HYDRAULIQUE HP /kW 10/7.5

TENSIONE DI ALIMENTAZIONE CENTRALINA OLEODINAMICA / HYDRAULIC POWER PACK VOLTAGE / TENSION CENTRALE HYDRAULIQUE V 277/480 60Hz

TENSIONE DI ALIMENTAZIONE BOBINE ELETTROVALVOLE / ELECTROVALVE COIL VOLTAGE / TENSION BOBINE ELECTROVANNE 110V AC 60HZ

GIRI MOTORI DI MESCOLAZIONE AL 1 / MIXING MOTORS SPEED / VITESSE MOTEURS DE MALAXAGE 1750 rpm

RIDUTTORI / REDUCTION GEARS / REDUCTEURS 2

GIRI ASSI DI MESCOLAZIONE AL 1 / MIXING SHAFTS SPEED / VITESSE AXES DE MALAXAGE 24.3 rpm

PALE DI MESCOLAZIONE / MIXING BLADES / PALES DE MALAXAGE 20

PALE RASCHIANTI / SCRAPING BLADES / PALES RACLEUSES 2+2

** ATTENZIONE: IL TEMPO PER CICLO E LA RESA ORARIA POSSONO VARIARE SECONDO IL TIPO DI CALCESTRUZZO PRODOTTO E DALLE CARATTERISTICHE DELLIMPIANTO SU CUI LA MACCHINA E INSTALLATA ** ATTENTION: THE CYCLE TIMES AND THE CAPACITY PER HOUR MAY VARY DEPENDING ON THE TYPE OF CONCRETE PRODUCED AND ON THE FEATURES OF THE PLANT WHERE THE MACHINE IS INSTALLED ** ATTENTION: LE TEMPS PAR CYCLE ET LE RENDEMENET PAR HEURE PEUVENT VARIER SELON LE TYPE DE BETON PRODUIT E LES CHARACTERISTIQUES DE LINSTALLATION SUR LAQUELLE LA MACHINE EST MONTEE

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1) GENERAL DESCRIPTION OF MACHINE AND IDENTIFICATION PLATE IDENTIFICATION PLATE AND CE MARKING

LIFTING POINT PLATE

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1.1) IDENTIFICATION PLATE POSITION

LIFTING POINT PLATE

LIFTING POINT

LIFTING POINT PLATE

LIFTING POINT

MACHINE DATA PUNCHED IN

IDENTIFICATION PLATE CE MARKING

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2) HOW TO USE AND KEEEP THE INSTRUCTIONS MANUAL

This section gives information on how to use the manual and the limitations of the manual. 2.1 WHOM THIS INSTRUCTIONS MANUAL IS MEANT FOR This instruction manual is intended for: -Transport, loading and unloading personnel -Operators and contractors -Maintenance personnel 2.2 PURPOSE OF THE INSTRUCTION MANUAL INFORMATION The manual gives instructions on how to use the machine, technical details, instructions on moving, installation, adjustment and use, as well as maintenance and spare parts ordering. 2.3 INSTRUCTIONS MANUAL LIMITATIONS This manual being a summary of the main procedures to follow, it can never be a substitute for an experienced operator. The instruction manual refers to the technology current at the time of purchase and the manufacturer reserves the right to update the instruction manual and equipment without reference to any previous instructions manuals and products, except in exceptional cases. 2.4 HOW TO KEEP THE INSTRUCTIONS MANUAL The manual should be kept with care in order to last as long as the machine. Two copies of the section on moving the machine are supplied (this allows both transport and unloading personnel to refer to this section without having to consult the main text). If the manual is mislaid or destroyed, you can request another copy either from the area representative or directly from the manufacturer. Please indicate the machine type, the serial number and the year of manufacture. 2.5) WARNINGS

IMPORTANT: Never carry out any operations or manoeuvres if you have doubts. Contact the manufacturer or area representative for advise. The manufacturer takes no responsibility for damages caused by the machine to property, persons or the product in the event of: -Incorrect use of the machine or use by unqualified personnel -Incorrect installation -Electricity supply faults -Want of maintenance -Unauthorised procedures or modifications -The use of non-original spare parts -Total or partial non-compliance with the instructions -Exceptional circumstances

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3) HANDLING AND INSTALLATION OF THE MACHINE This section gives information on how to load and unload, move and install the machine. 3.1 RECEIPT OF THE MACHINE The machine is supplied without any packing, it is pre-assembled and ready for connection to the electricity supply.

IMPORTANT: On receiving the machine, check it for possible damages during transport. If it has been damaged: A) Contact the area representative B) Make a written report C) Send copies of the report to: -The transport companys insurance company -The transport company -The manufacturer or area representative

3.2 PERSONNEL REQUIREMENTS No special training is required by personnel moving the machine. However, this operation should be undertaken by persons who know how to operate lifting equipment. 3.3 INSTRUCTIONS FOR LIFTING AND MOVING THE MACHINE The machine can be lifted by means of an overhead crane, a self-propelled crane, a high-lift truck or other suitable means having a minimum capacity of twice the weight of the machine. The machine has suitable lifting points on the ends of the tank (see section 1.a) which are identified by a sign (see fig.2). If for transport reasons the mixer arrives overturned with respect to its working position, please operate as indicated in paragraph 3.7. For overall dimensions and weight see fig.6.

IMPORTANT: The correct balance of the load has to be checked. In case of accidental collision, check the extent of possible damage immediately and, if necessary, contact the manufacturer.

3.4 FIXING POINTS The machine is provided with anchorage plates. For the positions of these fixing holes, see fig.6. At the request of the customer, latticework support may be supplied together with the appropriate assembly and fixing diagrams. For those machines equipped with a skip, bolt the rail to the protruding beams fixed to the machine. Then connect further sections until the skip is in a position to load inert material through the opening in the mixer.

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WARNING: BEFORE INSTALLING THE MIXER IS STRONGLY RECOMMENDED TO CHECK THE PLANARITY OF THE PLATFORM OF SUPPORTING STRUCTURE. THE NON PERFECT

HORIZONTALITY COULD CAUSE PROBLEMS ON SEALING SYSTEMS, GEARBOXES AND ALSO DEFORMATION ON MIXER STEEL TANK.

SICOMA WILL BE NOT RESPONSIBLE IN CASE OF NON OBSERVANCE OF THE ABOVE MENTIONED WARNING.

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3.5) STATIC AND DYNAMIC LOADS The static and dynamic loads of the machine are given in the following table.

MACHINE WITHOUT SKIP MACHINE WITH SKIP MACHINE TYPE

EMPTY Kg STATIC Kg DYNAMIC Kg EMPTY Kg STATIC Kg DYNAMIC Kg

MAO 1500/1000

MAO 2250/1500 7430 11030 17650 9530 16130 25800

MAO 3000/2000 7530 12330 19750 11280 19900 31850

MAO 3750/2500 7630 12490 20000 11480 20250 32400

MAO 4500/3000 9300 16400 26250 13580 26950 43150

MAO 5000/3350 9700 17100 27380 13980 27700 44420

MAO 6000/4000 11900 19200 31200 16400 35000 56000

MAO 7500/5000 12000 20500 33300 / / /

MAO 9000/6000 JANUS 14200 28530 45650 / / /

MAO 12000/8000 JANUS The loads given above are some of the indicative values to be taken into consideration when calculating the strength of the supporting structures. If the machine is supplied with a support structure, follow exactly the procedure shown in the assembly diagram. 3.6 CHECKING OIL AND HYDRAULIC FLUID LEVELS

IMPORTANT: On receiving the machine (and therefore before it is started), check the oil level in the mixing units, the hydraulic pump, the supports and the bearings. If, for transport purposes, the machine has been overturned with respect to its working position, the chambers containing the lubricating oil (bearings - reduction gearboxes) as well as the oil tank of the hydraulic main unit are closed with special caps WHICH HAVE TO BE REPLACED before starting the machine with breather-caps which are placed inside a box marked COLLO A .

3.7 MACHINE DISCHARGING AND OVERTURNING (Valid for MAO 4500/3000, MAO 6000/4000 and Janus models) To discharge and overturn the mixer operate as follows:

a) Hook the mixer on the two upper raising points cover side and on the upper anchorage plates (picture6a)

b) Raise the mixer and put it on the floor. c) Detach the raising hooks situated on the anchorage plates(picture 6b). d) Pull the machine by both hooks keeping it balanced on two foothold plates (picture 6c). When the

centre of gravity of the machine overcomes its centre line, lower the machine until the four anchorage plates touch the floor.

e) After this, the machine can be hooked to the four lifting points at the ends of the tank which are signaled by plates and it can be put into the working position (fig. 6d)

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ATTENZIONE DOPO IL RIBALTAMENTO DELLA MACCHINA ED IL SUO POSIZIONAMENTO SOPRA LA POSTAZIONE DI LAVORO SOSTITUIRE I TAPPI OLIO SENZA SFIATO CON QUELLI IN DOTAZIONE [fig. 1] CONTENUTI NELLA SCATOLA CONTRADDISTINTA CON LA LETTERA A . IMPORTANTE ESEGUIRE TALE OPERAZIONE PER EVITARE LAUMENTO DI PRESSIONE DELLOLIO CAUSATO DAL RISCALDAMENTO NELLE RISPETTIVE CAMERE DI CONTENIMENTO.

ATTENTION AFTER HAVING OVERTURNED THE MACHINE AND POSITIONED IT IN ITS WORKSPACE, PLEASE REPLACE THE OIL CAPS WITH THE SUPPLIED BREATHER CAPS [fig.1] WHICH YOU FIND IN THE CARDBOARD BOX WITH THE LETTER A. THIS IS VERY IMPORTANT FOR AVOIDING AN INCREASE OF THE OIL PRESSURE DUE TO THE WARMING UP IN THE RELEVANT RETAINING CHAMBER.

ATTENTION APRES LE RENVERSEMENT DE LA MACHINE ET SON POSITIONNEMENT SUR SON POSTE DE TRAVAIL, IL FAUT REMPLACER LES BOUCHONS DE LHUILE AVEC LES BOUCHONS A EVENT FOURNIS [fig.1] CONTENUS DANS LE CARTON MARQUE PAR LA LETTRE A . CETTE OPERATION EST TRES IMPORTANTE AFIN DEVITER LAUGMENTATION DE LA PRESSION DE LHUILE DANS LES RESPECTIVES CHAMBRES DE LIMITATION.

PRECAUCIN DESPUS DE LA INCLINAR LA MQUINA Y SU POSICIN EN EL ENCHUFE, REEMPLAZO DE ESTACIN DE TRABAJO SIN PURGA ACEITE CON LAS INCLUIDAS [FIG. 1] EN LA PARTE INFERIOR MARCADOS CON "A". ES IMPORTANTE PARA EVITAR ESTA HACIENDO PROPSITO DE AUMENTAR LA PRESIN CAUSADA POR GASLEO DE CALEFACCIN EN SUS PROPIOS CUARTOS DE CONTENCIN.

* n 4 TAPPI PER SFIATO SUPPORTI ALBERI [fig. 2] ; * n 2 TAPPI PER SFIATO RIDUTTORI [fig. 3] ; * n 1 TAPPO PER SFIATO CENTRALINA [fig. 4] .

Fig. 1 Set Tappi/Cap Kit/Set de bouchons/Kit

de tapos

Fig. 2 Tappi da sostituire (tenute posteriori e anteriori)/Caps to be replaced (Rear and

front sealing)/Bouchons da remplacer (Tenues posterieur et anterieurs)/Tapos da

remover (tenutas posteriores Y anteriores)

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Fig. 3 Tappi da sostituire (Riduttori di mescolazione)/Caps to be replaced (Mixing

Gearboxer)/Bouchon da remplacer (Reducturs de malaxage)/Tapos da remover (Reductores

de mezcoladora)

Fig. 4 Tappi da sostituire (Centralina oleodinamica)/Caps to be replaced (Hydraulic power Pack)/Bouchons da

remplacer (Centrale hydraulique)/Tapos da remover (Bomba hydraulica)

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ILLUSTRATION OF UNLOADING AND OVERTURNING OF THE MACHINE

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4) ELECTRIC CONNECTIONS This section gives all the information necessary for making electrical connections to the control panel. 4.1 ELECTRIC CONNECTIONS The only connection necessary is the one between the control panel and the power supply, by means of a cable supplied by the customer.

IMPORTANT: The cable for electric connection must comply with UNI EN 60309-1-2 regulations. The voltage drop must also be checked and should comply with the formula: V = K x L x I < 4% V where: K = cable coefficient L = cable length

4.2 CONTROL PANEL INDEPENDENT OF THE SYSTEM MASTER PANEL A control panel is provided, if required, to operate the mixing motors, unloading door and skip door (if the machine is equipped with a mobile skip). This panel is on the machine and is connected directly to the motors and end switches. On request, the panel can be positioned at a distance from the machine and, in this case, it is connected by cable to a junction box mounted on the machine. (For cable section, see paragraph 4.1). 4.3 JUNCTION BOX The junction box contains a terminal block for connecting the main oil-pressure cylinder, skip (if provided) and other auxiliaries. The limit switches are of the normally-closed contact type and are connected by three-pole cable. (For cable section, see paragraph 4.1). 4.4 GENERAL SYSTEM CHARACTERISTICS The control panel (see point 4.1) must be connected to a differential switch and to earthed in compliance which IEC 363 - Art. 413.1 or alternatively: Vc = Rt * Is < 50V Vc = Contact voltage Rt = Earth resistance Is = Differential switch sensitivity current If national laws or regulations call for more restrictive values for Rt, these must be respected. 4.5 ELECTRICITY SUPPLY CONNECTIONS AND EARTH Connection to the electricity supply must be made by a qualified electrician.

IMPORTANT: The machine does not require any additional earth. The system earthing is sufficient. The mixing blades, when rotating, have to converge towards the centre at the bottom and diverge at the top (see fig.7) for facilitating the discharge of the mixture. Check the direction of rotation of the mixing motors according to the indicators on the motors (fig.7a). Since the two mixing units are connected mechanically, it is necessary to start one motor at a time and to check that the direction of rotation corresponds to the one indicated by the signal on each motor.

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4.6 ELECTRICAL CONNECTIONS FOR LOW MOTION DRIVE DEVICE (IF PRESENT)

The auxiliary motor for the washing system has been put into the mixer for giving the operator the opportunity to have the mixing shafts rotate at a very low speed and with very little torque without problems for the security of the maintenance employees during the final washing phase which is made manually. The device permits to have the shafts rotate even when the inspection hatch is completely open.

WARNING: BEFORE TRYING OUT ITS FUNCTIONING THE CORRECT SENSE OF ROTATION OF THE MIXING MOTORS HAS TO BE CHECKED. When starting up, only one check of the sense of rotation with small accelerations has to be made (i.e. current supply for a very short time interval). If you have the motors rotate in opposite sense, the reduction gear for low speed

motion will work under conditions of turn multiplication and thus damage the connected auxiliary motor.

CONNECTION OF THE AUXILIARY MOTOR: The auxiliary motor (the terminals of which are brought to the junction box of the mixer) has to be connected in order to operate singularly, i.e. when the mixing motors are stopped and are in a condition of security (without possibility to start accidentally).

By means of a manual remote control with a DOUBLE SAFETY PUSHBUTTON (see below for specs), the operator can start the device for the low motion of the shafts. So it will be possible to clean the machine even if the doors are open and still work in conditions of complete safety.

The standard supply of the motor is with a 380V connection, but it can be adapted to the voltage required by the customer. When doing the connection, please always check the sense of rotation of the auxiliary motor. If latter is not correct the motor will rev freely but without transmitting any movement to the motor pulleys

MOTORS SENSE OF ROTATION ALWAYS CHECK THE SENSE OF ROTATION : IT MUST BE CORRECT AND IN AGREEMENT WITH THE DIRECTION OF THE GEARBOXES IN ORDER TO OBTAIN THE FOLLOWING SHAFT ROTATION:

AUXILIARY MOTOR

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ADDITIONAL SAFETY SPECIFICATIONS AND INTERACTIONS BETWEEN SLOW MOTION DRIVE AND HIGH PRESSURE WASHING SYSTEM

1. Nozzles rotation should be possible only with closed high top cover doors. Consequently should be provided a signal to consent nozzles rotation from main control panel, as a 0 potential contact NO. This signal decay whenever voltage is cut off to mixing motors and to the others devices by the safety lock; when the consent signal is opened , from washing system control panel shouldnt be possible start nozzles rotation but only pump motor.

2. The commutation between manual gun and nozzles is effected by a 3-way valve. In manually operating mode, with disabled nozzles rotation, is allowed water passage only by manual gun.

3. Slow motion drive motor should be fed only when main motors are not fed, as when consent signal described at point 1 is missing.

4. Slow motion drive commands shouldnt be provided on panel control board but only in a push-button portable keyboard (because the operator should start slow motion drive from a position with his own visual control). The push-button portable keyboard is fitted as follows:

a) Double safety pushbutton start for shaft rotation (for double-hand command) b) Mushroom emergency button c) Key lock to disable the manual keyboard if the operator should get into the mixer, forbidding other

operators to accidentally start the slow motion drive 5. Once given double-hand command, after 3 second the slow motion motor should stop automatically, even

if the operator maintain pressed the double-hand command. To go on with the slow rotation is necessary to release the double-hand command and to press again both buttons

6. The portable keyboard should be with a plastic shell (as overhead crane) and with insulating grade suitable for installation site environment conditions.

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MIXING ARMS SET-UP

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CHECK THE SENSE OF ROTATION OF THE MIXING ARMS

IMPORTANT: Before starting up the machine, start one motor at a time for checking the correct sense of rotation. The motors have to follow the sense of rotation indicated by the signal on the motor cover.

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5) USES OF THE MACHINE This section gives general information on the uses of the machine and describes the main functions and restrictions as to use. 5.1 WHAT IS THE MACHINE DESIGNED FOR The machine has been designed for mixing materials of different natural and chemical types (the substances which may be used are detailed below). Owing to the specialised nature of the machine, it is not possible to use it for other purposes and the owner must not figure out other methods of use, as directed by point 1.1.2, letter C of 89/392 CEE standards. 5.2 TYPE OF USE The machine is designed for industrial and handicraft use. 5.3 OPERATOR No special technical knowledge is required to use the machine. A careful reading of this manual is sufficient, but experience and knowledge of the product to be used are a very important factor. 5.4 MATERIALS WHICH MAY BE USED IN THE MACHINE Inert substances in powder or granular form (particles of a maximum of 80 mm. For particles up to 200 mm, stellite-plated steel blades can be supplied) concrete, lime and mortar, refractory substances, chemical colourings, silica sand, resins, etc., with or without the addition of liquids such as water, additives, cold or hot bitumen. 5.5 RESTRICTIONS OF USE Inert substances with grain sizes which are greater than the values in the table concerning the technical features Clays with a humidity rate of approximately 15%. Semi-dry concrete mixture, although homogeneous, can cause the mixing shafts to increase in diameter due to material adhering to them. This reduces the mixing force of the arms. In this case it is essential to equip the machine with a washing system. 5.6 WORKING ENVIRONMENT On request, the machine can be supplied with systems which enable it to be used in environments with risk of explosion (ATEC certification) or which are particularly aggressive such as salty, acid and alkaline environments. 5.7 WORKING OUTDOORS Using the machine outdoors is no problem, but it is advisable to protect the electric components and the cement scale by covers.

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6) TECHNICAL DESCRIPTION OF THE MACHINE In this section, the working of the machine is described and all the elements are given to operators and maintenance attendants for a better understanding of the correct use and a quick spotting of possible faults or malfunctions. 6.1 DESCRIPTION OF THE MACHINE 6.1.1) MIXING TANK It is made of thick steel sheet, it is OMEGA shaped and supported by a rigid tubular frame which guarantees the best yielding resistance and thus the constant alignment of the axles obtained by machining the support flanging. The complete tank is protected by an upraised fairing to give easy access and facilitates the inspection of the mixing devices. Rubber strips on the doors guarantee a perfect dustproof sealing and a key-operated safety device stops the mixing operation if the inspection door is opened. 6.1.2) TANK WEAR LININGS: Structured in interchangeable and bolted sectors, they are made in wear-proof steel with a medium hardness of 320HB, for inner vertical walls, and in wear-proof Ny-Hard cast iron tiles with a medium hardness of 500630HB for the inner OMEGA shaped walls. 6.1.3) MIXING ARMS: They are made in spheroid perlitic cast-iron with an helicoidal shape. They are set in such a position to guarantee a perfect homogenizing of the mixture, to reduce as much as possible wear and tear and to assure cleaning without the use of rings. 6.1.4) MIXING BLADES: in Ny-Hard cast iron with a medium hardness of 550600HB. For mixtures with particles of more than 200 mm it is necessary to use steel blades with stellite coating. 6.1.5) UNLOADING: is operated by a rectangular sector on the whole length of the rank, which by rotating eccentrically assures a perfect tightness, even for very fluid mixtures. A rubber tightness is positioned on the whole discharge perimeter. The opening sector is operated by a hydraulic cylinder (for example MAO 2250/1500 3000/2000) and by two hydraulic cylinders (for example from MAO 4500/3000 up to MAO 12000/8000), with a 3-position end switch which, in addition to opening and closing, allows an intermediate opening for making unloading into a truck mixer easier. The hydraulic gear case, of current production, is equipped with a manual pump for the emergency unloading. On request the unloading door is equipped with an interchangeable, anti-wear, steel-coated conveyor chute with a rubber sock for unloading into trucks and an anti-drip diaphragm which is hydraulically operated. When the opening button is pressed, the correspondent solenoid in the solenoid valve is excited and the pump stop is operated by the opening micro-switch which is positioned on the rotating axis of the door. When the closing button is pressed, the correspondent solenoid in the solenoid valve is excited and the pump stop is operated by a pressure switch placed on the circuit. The closing micro-switch has to be used only to indicate the position of the door and activate possible automatic devices. The motor of the pump stops at each cycle end. The hydraulic cylinders or cylinder (Table 7) automatically compensates the stroke which increases due to the wearing of the rubber strip (table 6). To improve the tightness of the rubber gasket, it is necessary to set the regulator screw of the pressure switch (Table 9A). Rotating the screw in a clockwise direction, the closing pressure increases, while, rotating the screw in a counter-clockwise direction, the pressure decreases. In case the seal is faulty because of concrete sticking to the rubber and liquid mortar leaks, it is recommended to increase the cutting angle of the plate which is welded to the bottom of the tank, in order to reduce the contact area with the rubber.

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6.1.6) SHAFTS SEALS: each seal is assured against concrete leakage from the mixing tank through the axle holes by a special sealing system. The grease lubricated seal is made of a Neoprene ring, the compression of which against a steal segment is divides by four tie rods for the compensation of its wear. Ample space avoids, even in case of mixture leakage, that this mixture reaches the bearing which is placed in a separate chamber lubricated by oil bath. 6.1.7) MIXING REDUCTION GEARS: They are of epicyclical type and have been designed and improved with the time just to withstand the heavy working stress even for more that one a shift. The low number of input revolutions assures a low working temperature of the reduction gears and warrantees a longer duration and minor risks of oil leakage on the input flange. Power transmission between motors and reduction gears is operated by means of pulleys with trapezoidal belts. Shaft rotation synchronism is guaranteed by a homokinetic joint. At request, hydraulic joints can be supplied for fluxing the starting of the mixing axles even with a complete load. 6.1.8) GEARBOX SUPPORTS: Each one of the two mixing reduction gears is joined to the tank by a gearbox support which, in case of maintenance of bearings and seals, can be removed in order to make disassembling and assembling easier. Since the year 2007, all the mixer models can be supplied with connection joints of the reduction gears to the mixing tank. 6.1.9) MIXING MOTORS: They have variable power, voltage and frequency values and are currently produced in insulating class F, tropicalized and with an IP55 protection. It is recommended never to start the motors when the tank is full (if a hydraulic joint is not provided), but ot open the unloading door trough the solenoid valve or to use the manual emergency pump to unload the mixture. 6.1.10) SLOW MOTION DRIVE FOR THE SHAFTS: for making cleaning and maintenance of mixing arms and blades easier, a small gear motor can be supplied which is fitted to the pulley of one of the two mixing motors. By impulses, it allows to make both mixing shafts rotate at low speed in order not to cause a movement by inertia in case of arrest. This device allows the operators to work at the inside of the tank and to eliminate the use of the powerful mixing motors which, if activated by impulses, cause damage to the contacts of the remote control switches. 6.1.11) MOBILE LOADING SKIP: (if supplied with the machine) truncated cone shaped for a good material containing. It unloads the aggregates into the mixer through a hinged door without outlet of cement dust. It slides on four rollers inside an U shaped frame. Standard inclination of the frame is 60,(on request it can be realized from 45 to 75 and a vertical version is available with tipping discharge). A special lifting system consists in one or two winder drums powered by a twin disk self-break electric-motor-reduction unit which keeps the skip perfectly vertically even with eccentric loads. Adjustable micro switches stop it at both ends In case of cable failure, a safety device avoids the bucket to fall down and a micro switch stops the up or down movement of the motor if the skip comes to a standstill along the rails during free descent. The skip can be fixed on the mixer as a preload container or it can be fitted with a balance for the aggregates dosing. The discharge is powered by a hydraulic or pneumatic cylinder.

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6.1.12) USE OF THE MANUAL EMERGENCY PUMP: In case of blackout or any other cause provoking the blocking of the oleodynamic gearcase, the unloading door can be opened by means of the manual emergency pump as follows:

1) - Undo the two taps indicated with the red arrows to bypass the automatic hydraulic

circuit and connect the manual branch. Now the piston is connected to the manual section of the hydraulic power pack and can be operated with the lever.

2) - The small lever gives the direction of the hydraulic circuit. It must be rotated on the left to operate the piston in one direction, or on the right to operate the piston on the other direction. In order to understand what is the right direction, the hand lever will not move if the piston is at the end of its run.

ATTENTION: MAKE SURE THAT YOU TIGHTEN THE TWO TAPS AT POINT 1 AFTER THE MANUAL OPERATION TO RECONNECT THE HYDRAULIC CIRCUIT TO THE AUTOMATIC BRANCH OF THE HYDRAULIC POWER PACK. LEAVING THE TWO TAPS UNDONE WILL AFFECT THE OPERATION OF THE AUTOMATIC HYDRAULIC CIRCUIT.

6.1.13) SUPPORTING STRUCTURE OF THE MIXER (if required): A portal frame in lattice work, 5 mt high and calculated for a maximum of steadiness also in zones with a high degree of seismic risks. 6.1.14) INSPECTION PLATFORM (if required): in corrugated sheet iron, it is assembled around the mixing tank in order to facilitate maintenance of the machine. A stair with handrail, produced according to the accident prevention standards, gives access to the catwalk. The machine is anyhow provided with a platform for facilitating the operations of checking the mixture, cleaning, ordinary and extraordinary maintenance. 6.1.15) MIXING SYSTEM: mixing is made by two horizontal axes which rotate counter-currently. On both axes, a number of arms is assembled which varies with the size of the machine (see technical specifications). The particular helicoidal shape of the arms, completed by the shape of the mixing blade, in addition to the intersected rotation gives the mixture a circular motion which avoids separation of the aggregates in presence of components with different specific weight or with a wide grading curb and assures in a short time perfect homogeneity. The optimal distribution of the components which are poured into the mixing tank allows to obtain concrete with a better strength with the same weight of cement, which in some cases is of 20%, with a minor quantity of water. In the technical specifications the mixing time for each model is reported.

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LINE WARNING LIGHT

START BUTTON

SKIP ASCENT

DISCHARGE DOOR OPENING

MASTER SWITCH

THERMAL PROTECTION WARNING LIGHT

EMERGENCY STOP

SKIP STOP

SKIP DESCENT

DISCHARGE DOOR STOP

DISCHARGE DOOR CLOSING

6.1.16) SEQUENCE OF OPERATIONS FOR ONE MIXING CYCLE: .Start up of mixing motors. .Closure of unloading door. .Introduction of granular and/or powder material by belt, fixed or mobile skip. .Dry mixing for at least 20 seconds. .Introduction of water, chemical additives and colorants (if required) maximum 10 seconds. .Final mixing. .Unloading of mixture. .Cleaning of tank and mixing parts by manual or automatic washing system (if provided) and recovery of

the water used for the next cycle. 6.2 DESCRIPTION AND POSITION OF CONTROLS (if supplied) All controls are shown on the electronic control of the figure (fig.8). On request, a push-button panel can be supplied for remote control.

On request, a push-button panel for remote control can be supplied. At the upper part of the panel is the main switch for door blocking, the warning lights which signal the progress of the cycle, the intervention of the thermal profile of each single motor. At the lower part we have: - The push-buttons for starting and stopping the mixing; it works as an emergency sto, too; - The push-buttons for ascent, stop and descent of the mobile skip (for models with mobile skip) alternatively the commands will be used for opening and closing of the butterfly valve of the aggregates input (for machine with fixed skip); - The push-buttons for opening and closing the discharge of the cement scale; - The push-buttons for opening and closing the discharge door. 6.3 SAFETY DEVICES 6.3.1) MAXIMUM PRESSURE VALVE AND PRESSURE SWITCH The hydraulic circuit is equipped with a valve to protect against anomalous pressure increases which could damage system components; The circuit also has a pressure switch which stops the main cylinder motor when the door reaches the fully closed position. To verify and to calibrate the maximum pressure valve and the pressure switch see paragraph 8.3.

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6.3.2) MIXER TANK PROTECTIVE GUARDS The machine has protective guards to prevent contact with moving parts. The guards are equipped with a safety system with key transfer which does not allow to open the cover. When the mixer is working, it is possible see over the tank through an inspection door which is equipped with a safety grate. 6.3.3) INSTRUCTION FOR THE USE OF THE KEY TRANSFER SAFETY SYSTEM This system consists of two safety locks; one is applied on the control board (near to the main switch), the other one on the inspection door of the mixer. The characteristic of this system is that both locks can be unlocked by just one key. During the normal running of the machine, the key is bound to the lock placed on the main switch. To open the inspection door, it is necessary to switch off the main switch (voltage drop on the plant), to turn the key anti-clockwise (main switch blocked - See Fig. 9), to take it off and insert it inside the inspection door lock Now, by turning the key we unblock the mechanical standstill as well as the constraint of the key in the lock (See Fig. 9a). STARTING INSTRUCTIONS 1.While the key is in the lock placed on the machine, close the mixer door and block it with the stopping device. 2. To take off the key, turn it anti-clockwise in order to block the lock. 3. Insert the key inside the lock placed by the customer near to the main switch on the control board. 4. Turn the key in order to release the switch and start the machine (the key remains bound to the lock of the switch). STOPPING INSTRUCTIONS FOR OPENING THE DOOR 1. Bring the switch to the off position and block it by turning the key. 2. Take off the key. 3. Insert the key inside the inspection door lock. 4. Unlock the stopping device by turning the key . At this point the stopping device can be taken off (the key

remaining bound to the inspection door lock). ONLY NOW THE GUARD CAN BE OPENED.

6.4 TECHNICAL DIAGRAMS AND TABLES 6.4.1) JUNCTION BOX DIAGRAM For the electrical diagram see table 15 6.4.2) HYDRAULIC DIAGRAM For the hydraulic diagram see table 8 6.5 SOUND TESTS 6.5.1) MACHINE OPERATING CONDITIONS Mixer during the mixing phase

6.5.2) MEASURING CONDITIONS The noise-level measurements have been made at 1 metre from the surface of the machine, at 1.60 metres above ground level, on the four median axes of the support base in accordance with E.E.C. MACHINE DIRECTIVES 89/392 (Point 1.7.4, section "f").

6.5.3) AVERAGE Leq ( A ) Leq = 65 dB ( A )

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7) INSTRUCTIONS FOR THE USE OF THE MACHINE This section details the correct use of the machine. 7.1) USE OF THE MACHINE Detailed description of the main mixing phases indicated in the previous chapter, i.e.: - Loading of aggregates, cement - Dry premixing - Water introduction - Final mixing - Mixture discharge - Discharge door closing - Wash-out 7.1.1) LOADING PHASE BY FIXED OR MOBILE SKIP 1) the mixing tank has to be empty; 2) close the protection guards of the machine and block them by means of the supplied safety device 3) close the discharge door of the mixer by pushing the appropriate button 4) start the mixing motor by pushing the appropriate button 5)begin to load the machine by pushing the appropriate buttons (see chapt. 6.2) The time needed for loading by skip is of about 5 (for the mobile skip, the time for ascent is excluded). We recommend to introduce cement at the centre of the mixer and at the centre of the axes by a screw feeder for gradual feeding for about 15 or by a break-work device in case of use of the electro-hydraulically operated valve, this for avoiding clusters of material which prolong the mixing time and cause the formation of lumps. 7.1.2) RECOMMENDED MIXING PHASE FOR: -1- PREMIXED MIXTURE FOR LOADING TRANSIT MIXERS

a) dry-mix aggregates and cement for 10 b) check possibly the humidity of the mixture by probe Time used varies between 30 to 60. c) introduce water (may be filled in by water network by high-pressure autoclave) or by direct downpour from water scale; average time for water feeding 10 d) final mixing for 20 e) time for mixture discharge 10 f) time for closing the discharge door 3

For more information see graphic No 1 -2- MIXTURE FOR MANUFACTURED AND PREFABRICATED ELEMENTS

a) dry-mix aggregates and cement for 15 b) check possibly the humidity of mixture by probe Time used varies between 30 to 60. c) introduce water (may be filled in by water network by high-pressure autoclave) or by direct introduction from water scale; average time for water feeding 10 d) final mixing for 47 e) time for mixture discharge 10 f) time for closing the discharge door 3

For more information see graphic No 2 On the whole, each cycle has a duration which varies from 60 for loading transit mixers to 100 for manufactured and prefabricated elements which might go up to 160 in case of humidity checks of the mixture by probes.

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7.1.3) LOADING PHASE BY BELT a) the tank has to be empty b) close the protection guards of the machine and block them by means of the supplied safety device c) close the discharge door of the mixer by pushing the appropriate button d) start the mixing motor by pushing the appropriate button begin to load the machine by pushing the appropriate buttons The time for loading by belt counts for dry premixing time and at the same time with the aggregates, the cement can be loaded; after the scale zero, water can be let in without premixing. Depending on the capacity of the belt, the loading and the premixing times vary; a final mixing time of about 15 is sufficient (for premixed for loading into transit mixer) and of about 45 (for mixture, manufactured and prefabricated element) for a perfect homogeneity of the mixture. For more information see graphics Nos. 3 and 4.

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GRAPHIC No. 1

GRAPHIC No. 2

29

GRAPHIC No. 3

GRAPHIC No. 4

IMPORTANT: in case of water dosing by humidity probes, the cycle time increases for a minimum of 30 to a maximum of 60. IMPORTANT: the cycle time may vary depending on the type of concrete to be produced and on the characteristics of the plant the machine is installed in.

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7.1.4) UNLOADING PHASE Unloading is made through the door at the bottom of the tank; for opening push the appropriate button. The time for complete unloading of the tank is for about 20. The time for closing the oor is of about 3. 7.1.5) WASHING At the end of the working cycle, wash the shafts, the arms and the blades in order to remove remainders of fresh mixture. IMPORTANT: we recommend the use of an automatic wash-out system (supplied on request) which cleanses the mixing components at the end of the unloading phase before a new mixing cycle begins. The water used for washing is recuperated for the following mixture. In case of manual cleaning DO NOT USE A HAMMER to remove remainders of mixture. Violent chocks to the mixing blades may cause their breakage. IMPORTANT: in case of mixing of half-dry or fluid concrete or when using resins, the cleaning of the machine at the end of each shift or at least before any production stop with a duration which is longer than the time of setting of the mixture is recommended IMPORTANT: in case of black-out it is recommended to empty the machine by opening the discharge door by means of the manual pump on the hydraulic power pack in order to facilitate motors starting if they do not have a hydraulic joint.

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8) SAFETY DEVICES: CALIBRATION CONTROL 8.1) MAXIMUM PRESSURE VALVE Check at least once a year the working conditions of the maximum pressure valve on the hydraulic power pack. The valve is calibrated for a pressure of 120/150/200 bar according to the mixer model and it has been tested before the shipment of the machine. 8.2) PRESSURE REGULATOR The pressure regulator controls the stop of the pump in the hydraulic power pack; in case of failure, the pump goes on idling with consequent overheating of the oil which might cause damage to the seals and finally the seizure of the pump. Check at least once a year the working conditions of the pressure regulator in proximity of the electro-valve. We recommend to apply a timer regulated for 3-4 seconds and operated by the micro switch of the door closure. IMPORTANT: in case the machine is supplied without control board, we recommend to operate the pump motor by single cycles of opening and closing and to stop the motor during the intermediate phases. 8.3 CHECKING THE MAXIMUM-PRESSURE VALVE AND PRESSURE REGULATOR Do as follows: a) Loosen the nut on the control screw (this screw has a hexagonal recess) situated on the electro-valve unit. b) Turn the screw clockwise one revolution. c) Check that the pressure gauge shows a rise in pressure.

d) Turn the screw back to the original position and tighten the nut.

IMPORTANT: If the pressure shown on the pressure gauge does not vary, change the valve.

8.4 CHECKING AND ADJUSTMENT OF TRANSMISSION BELTS TENSION For checking and adjusting the belts tension see chapt. 9.5 par. 9.8.5-6.

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9) INSTRUCTIONS FOR MAINTENANCE The machine has been designed and constructed so as to reduce maintenance to a minimum. This section gives information on ordinary maintenance to be carried out on schedule. IMPORTANT: before starting any work on the machine, turn off the power using the isolating switch on the control panel. 9.1) REPLACEMENT OF LUBRICATING OIL Authorised personnel: Operator Since the reduction gears have been designed not to consume oil, change the oil EVERY 4000 HOURS or at least EVERY 2 YEARS. 9.2) REPLACEMENT OF HYDRAULIC OIL IN THE OIL-PRESSURE SYSTEM Authorised personnel: Operator When changing the oil, completely drain the system included the pipes of one or more cylinders. IMPORTANT: When changing or topping up oil in the reduction gears, the hydraulic system or the bearings, use the type of oil shown in the table below. BRAND REDUCTION GEARS HYDRAULIC SYSTEM BEARINGS TYPE ISO-UNI 150 ISO-UNI HM 46 ISO-UNI G 150 QUANTITY Litres 16 Litres 10 Litres 0.5 each BP GR150XP HLD46 GR150XP TEXACO MEROPA LUBR.L150 RAND OIL HD 46 MEROPA LUBR.L150 AGIP BLASIA 150 OSO 46 BLASIA 150 ESSO SPARTAN EP 150 NUTO H46 SPARTAN EP 150 MOBIL MOBILGEAR 629 DTE25 MOBILGEAR 629 SHELL OMALA OIL 150 TELLUS S 46 OMLA OIL 150 TOTAL CARTER EP 150 AZOLLA 46 CARTER EP 150 ROLOIL EP 150 LI 46 EP 150 IMPORTANT: do not dispel oil in the surroundings. For disposal please contact specialised Companies (eg. Used Oil Consortiums). 9.3 SEALS LUBRICATION (IF REQUIRED) Authorised personnel: Operator The centralised lubricating system by grease mounted on the machine consists of: The new lubrication system air-grease has been conceived for improving the seal greasing efficiency. The system consists of 4 independent cylinder-syringes operated by a derivation of the compressed air installation present in any working site. The cylinders are filled with grease and feed the four sealing groups. The peculiarity of this new system is that, as it has no pumping dispenser, it is possible to avoid the frequent events of damage to the piston due to impurities in the grease. Furthermore, the cylinders are hermetic so that they may be filled with grease only by the special device which is supplied (to be connected to the grease pistol): this protects from incidental use of dirty grease. The system is supplied with all the necessary devices for its functioning. The customer has only to make the derivation of the compressed air installation as described hereunder. As to the electric connection of the mixer, all remains as for the mixers with electric grease pump (see technical description hereunder). 9.3.1) OPERATION Bring a compress air system branch line 12mm air tube with 3/8 female connection close to the mixer (left part of motor side). Connect the pipe to the special connector 3/8 BPS, included in the kit (1) 9031G0001F1. The first part of whole kit includes: filter, moisture discharge valve (part. (2), instead of a standard 3-way valve), manometer, pressure regulator, pressure switch, electrovalve, discharge silencer.

33

The manometer (3) indicates the air pressure at the bottom of the filter and the air compression level has to be between 2,8 bar and 3 bar. The manometer is already pre-set to a pressure between 2,5 and 2,8 bar. The access of the air to the four tanks (one for each seals group) is regulated by a pneumatic electrovalve (4) which opens only when the mixing motors are started up. A PROPER SIGNAL FROM THE OPENING OF THE POWER SWITCH MUST BE PROVIDED. The presence of the oil pressure switch (5), set at 2 Bar, gives an additional safety: during the opening of the electro valve the sensor detects if the lubrication system has enough pressure. When the pressure drops below 2 Bars, an alarm is activated informing the operator that the compressed air distribution system must be checked urgently to avoid any damage. If there are no anomalies, the compressed air is pushed to the pipes (6) connected to n.04 distributors, where n.04 cylinders (7) keep under pressure the related tanks (8). From the tanks the grease flows slowly and regularly towards the seal housings. When the grease tank is almost empty, a limit switch with a round head (9) is activated by a cam placed on the head of the cylinder (10). As a consequence, the alarm system is activated informing the operator that the mixer must be stopped and the grease tanks must be filled in using a gun, which has to be connected to each one of the n.04 rapid male plugs (11). The grease tank may be filled in only when the mixer motors and the compressed air system are off (valve (4) unexcited = pressure on discharge) Fill in the grease until the stem of the cylinder is at stroke end (7). When the grease tanks (8) are completely filled the operator must stop filling, otherwise an opportune safety valve deflects the exceeding grease flow outside the tanks. The mixer may be started only when the refilling is completed. IMPORTANT: as could be small differences on grease ejection speed between the four tanks, all the limit switches are connected in series to the main alarm signal: therefore, it is enough that one of the tank have reached the minimum level that turns on the alarm signal. All the above mentioned alarms could be started by a simple electrical connection to the standard synoptic panel usually supplied with the mixer. In case of after market installation of 9031G0001F1 set, the Technical Assistance will supply the electrical scheme and the installation procedure. IMPORTANT: use adhesive and water-repellent grease with an optimal expansion resistance. The recommended consistence is NGL1

34

35

9.4) GREASING Authorised personnel: Operator Greasing of the unloading door bearings , of the hydraulic cylinder pivots and of the motors supports pivots is made trough standard greasers. IMPORTANT: grease every 250 hours or at least once in a month. Use grease grade UNI MX2 (see table hereunder).

BRAND AGIP BP ESSO MOBIL ROL SHELL TEXACO TOTAL

TIPO GR MU EP2

LTX2-EP BEACON 2

MOBIL PLEX 47

LITEX EP2

SUPER GREASE

R2

MULTIFAK MP2

MULTIS EP2

9.5) CHECK OF BOLT TIGHTNESS Check the tightness of the bolts on the arms and blades of both the mixing and the peripheral arms after several mixing cycles and after replacement of any part or adjustment. After some mixing cycles and, afterwards, after each 2000 working hours, check the tightness of the pulley and homokinetic joint. A torque wrench is recommended for this work to ensure that bolts are tightened to the correct torques, as given in the table below.

Diam. screw

Torque Nm.

Diam. screw

Torque Nm..

Diam. screw

Torque Nm..

Diam. screw

Torque Nm..

Diam. screw

Torque Nm.

Diam. screw

Torque Nm.

M. 4 3 M.16 215 M. 4 4 M.16 300 M. 4 5 M.16 360

M. 5 6 M.18 290 M. 5 8 M.18 410 M. 5 10 M.18 490 M. 6 10 M.20 410 M. 6 15 M.20 580 M. 6 17 M.20 700 M. 8 25 M.22 560 M. 8 36 M.22 790 M. 8 43 M.22 950 M.10 50 M.24 710 M.10 70 M.24 1000 M.10 84 M.24 1200 M.12 86 M.27 1050 M.12 121 M.27 1450 M.12 145 M.27 1750

CLAS

S 8.

8

M.14 135 M.30 1400

CLAS

S 10

.9

M.14 195 M.30 2000

CLAS

S 12

.9

M.14 230 M.30 2400 9.6) CHECK OF PARTS SUBJECT TO WEAR Inner linings, arms and blades are liable to wear and have to be checked periodically. Their replacement is recommended when: - the linings thickness is worn down to 2-3 mm - arms and blades are worn for over 50% After replacement we recommend to tighten the fixing bolts by means of a wrench set to the values given in the table at point 9.5. For blades adjustment see point 9.7. 9.7) ADJUSTMENT OF MIXING BLADES AND PERIPHERAL BLADES The mixing blades as well as the peripheral blades need to be adjusted periodically for guarantee of a perfect efficiency of the machine. If the regulation of the blades near to the bottom and the walls of the tank is not done regularly, gravel might get jammed between the blades and the lining sectors, which increases the strain of the relative mixing shaft with the risk of breakage of the blades which receive shocks and the wear of the blades.

36

9.7.1) ADJUSTMENT OF MIXING BLADES This operation has to be done as follows: a) Loosen the clamping screws b) Rest the blade onto a distance piece which has a thickness of about 3 mm and which is put between the blade and the highest point of the tank bottom c) Reblock the screws by means of a torque wrench which has to be calibrated as to the table at point 9.5.

FIG. 10 N.B.: In position 1 the distance piece between the blade and the bottom lining is of about 3 mm(adjustment point for the blade) which will increase up to 11 mm at the lo west point of the tank bottom (pos. 2). This is due to the fact that the omega-shape of the tank is made by two different curvatures, the first one going from the highest point of the tank (pos. 1) to the point which is indicated at pos. 3 while the second one goes from pos. 3 to the point which is indicated at pos. 2. This solution has been adopted for facilitating discharging and for avoiding gravel to jam under the mixing blades.

PARETE PALA

PALA

FONDO

WALL BLADE

BLADE

BOTTOM

37

9.8 SWING OUT DRIVES OPENING AND CLOSING

1) First of all remove the universal joint protection just unlocking the

screws and pulling out the two half casing

2) Disconnect only on one side the universal joint unlocking the six fixing screws

3) Remove the two (for each hand) M22 screws with nuts and washers. The drives will be opened just turning them out.

BEFORE CLOSING AGAIN PLEASE BE SURE OF THE PERFECT BLOCK

ALIGNEMENT CHECK ALSO CORRECT MIXING BLADES AND

ARMS PHASIS PAR. 4.5

B

A

38

9.8.1) ADJUSTMENT OF PERIPHERAL BLADES This operation has to be done as follows: a) Loosen the clamping screw b) Rest the blade towards the wall by means of a distance piece which has a thickness of about 3 mm and which is put between the blade and the most protruding point of the side wall. c) Reblock the screws by means of a torque wrench which has to be calibrated as to the table at point 9.5. IMPORTANT: It is mandatory to check the tightening of the screws after the machine has performed several mixing cycles.

d) Pull out the belts e) Sustain the motor with the proper hook f) Unscrew the bolts g) Put the motor on a service plan to do the necessari maintenance operations. In case of declared damege please send the motor to workshop for inspection and repairement.

9.8.2) REASSEMBLY OF ELECTRIC MOTORS a) Secure the electric motor and position it on the support b) Block the motor by screws without tightening them completely c) Check the flatness of the motor and align it by means of register screws d) Check the alignment between the two internal parts of the driven and the driving pulley as indicated in the scheme below.

e) After both pulleys have been aligned, complete the tightening of the screws.

39

9.8.3) DISASSEMBLY OF MIXING REDUCTION GEARS For disassembly of the mixing reduction gears, please proceed as follows: a) Carry out the operations in par. 9.8.1 up to point d included b) Disassemble the homokinetic joint by loosening the screws c) Disassemble the big pulley by loosening the screws d) Empty the reduction gear box from lubricating oil e) Secure the reduction gear by their holds on the flange f) Loosen the nuts g) Pull out the reduction gear and fix it to the service platform for verification. In case the damage is serious, bring the reduction gear to a workshop for reparation. 9.8.4) REASSEMBLY OF MIXING REDUCTION GEAR For reassembling the mixing reduction gear, it has to fastened to the mount (Table 5 Pos. 11) as indicated in the scheme hereunder.

CLAMPING SCREWS GEARBOX-SUPPORT

REDUCTION GEAR

GEARBOX-SUPPORT

CLAMPING SCREWS GEARBOX-SUPPORT

40

9.8.5) CHECK OUT OF TRANSMISSION BELTS TENSION a) Remove the covers of the protection guards b) Check if all the belts are in a good state of repair; they must not show points of wear due to skidding

IMPORTANT: If one or more belts are worn, do replace them immediately.

c) Make a pressure (P)or 100 N (about Kg. 10) at the center of each belt and check the flexion (f) of the belt which must not exceed (f) cm. 2 (see fig. 9)

9.8.6) ADJUSTMENT OF TRANSMISSION BELTS If the belts are slack it is mandatory to reinstate their tension; this is done as follows: a) Loosen the lock nuts of the tie-rods b) Turn the nuts clockwise By this movement the motor support turns downwards and the belts are tightened. When the belts are tight as described in par. 8.4.1 c, block the nuts as they were originally IMPORTANT: for maintaining parallelism of the motors support, it is mandatory to turn the nuts (TABLE 5 a POS. 33) in asynchron mode.

DRIVEN PULLEY (ON REDUCTION GEAR)

DRIVING PULLEY (ON MOTOR)

41

9.9) DISASSEMBLY AND REASSEMBLY OF MIXING SHAFTS AND SEALS 9.9.1) DISASSEMBLY AND REASSEMBLY OF MIXING SHAFTS If for reparation one or both mixing shafts have to be disassembled, insert supporting rafters under the axes at the inside of the mixing tank and do as follows: IMPORTANT: before starting any operation, make sure that in the main panel no alimentation voltage is present. a) Check the phase of the mixing arms by taking a benchmark at the inside of the tank (for example the

position of an arm); b) Disassemble arms and blades; c) Disassemble the safety guards of the motor pulleys (table.5a pos.23); d) Disassemble the homokinetic joint (table.5 pos.5); e) Remove the belts and the pulleys (table 5 pos. 7-9); f) Empty the reduction gears from oil: g) Loosen the screws of the reduction gears (table.5 pos. 15-19-20) ; h) For security reasons and for easing it out, hook the reduction gear to a lifting system i) Remove the gearbox-support by slipping off the camping screws from the tank (table.5 pos. 11-12-15-16); j) Disassemble the supports : - remove the 4 nuts indicated by the red sign - remove the 6 screws TCEI indicated by the blue sign

- slip out the complete support while the sealing rubber and the locking device remain on the shaft

k) Remove the supporting pins from the shaft to be disassembled at the inside of the mixing tank and slip the

shaft out from the freer and easier side of the service platform taking care to disassemble the distance pieces as soon as possible

For reassembly do as above in reverse order, following also the picture sequence on next page

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DIMA GUARNIZIONE COD. 0225G000111

ATTENTION: Before slipping out the shaft it is convenient to protect both ends of the shaft and the bearings in order to preserve the rectified seat of the bearing rings from shocks to the walls of the mixer.

43

9.9.2) DISASSEMBLY AND REASSEMBLY OF SEALS To replace the seal, please operate as follows: a) Repeat the operation described at points 10.9.1 a-b-c-d-e-f-g-h-i-j-k ; b) Pull out the bearing (Table 3 Pos. 11 and Table 4 Pos. 12) from its seating; c) Check the condition of the bush (table3 pos. 7), and if necessary replace it; d) Clean thoroughly the grinded parts of the axis and the bush on which the oil seals work and position the

seating of the seal ring by means of the template supplied with the spare parts; e) Check the locking of the ring seating by operating on the screws at its inside; f) Check the seating which has to be free of impurities, burrs or marks; g) Insert the steel ring half-group by the use of the pliers supplied with the spare parts; The use of the tools is necessary for avoiding creases which, under the thrust of preloading could cause oil leaks. IMPORTANT: We recommend the replacement of the complete seal, not of only one of both parts, even it if is in good conditions.

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9.10) CHANGE OF DISCHARGE DOOR SEALS The discharge door has rubber seals which make sure from oil leaks. A seal is fitted onto the mixing tank, another one onto the door and it rests against a plate which is welded on the mixing tank. The cylinder corrects automatically the wear of the rubber seal and increases its motion by the action of the pressure regulator which senses the pressure of the door against the rubber. To replace the rubber seal of the door, operate as follows: a) Open the door by means of the hydraulic cylinder (Table. 7) b) Loosen the tightening screws of the seal which has to be changed c) Replace the rubber seal by sectors d) Position again the screws without tightening them e) Check the alignment of the rubber seal sectors f) Tighten the screws

For the replacement of the rubber, operate as follows: a) Open the door by means of the hydraulic cylinder b) Remove the screws, replace the rubber seal by sectors c) Position the screws of point b and tighten them

45

10) SAFETY DEVICES 10.1) INSPECTION DOOR LOCK The protection covers of the tank are equipped with a safety system with a key transfer lock. The use of this device is described at par. 6.3.3 of page 26. 10.2) AUTOMATIC CONTROL DEVICE All the MAO mixers have an exclusive system with electric and/or visual monitoring of the lubricating and hydraulic oil and the overheating of motors and oil during the working cycle. This device is inserted in a control panel placed on the mixer and provided with a synoptic for immediate spotting of possible anomalies. 10.2.1) LEVEL DETERCTOR For seal lubrication tank, hydraulic power pack tank and mixing reduction gears, it is visual and electric. Per lubrificazione cuscinetti (assi di mescolazione) di tipo visivo. 10.2.2) THERMAL DETECTOR FOR REDUCTION GEAR AND HYDRAULIC PUMP OIL In the case of each mixing reduction gear and in the tank of the hydraulic pump a sensor for the detection of the lubrication oil temperature is installed. If the temperature of the oil exceeds the threshold of 80, the sensor activates an alarm, both by light and sound, on the main switchboard. The alarm signal remains active until the oil temperature has returned under the threshold of 80 10.2.3) THERMAL DETECTORS FOR MOTORS The mixing motors have o protection which is connected to the winding and which gives a signal to the main switchboard if the temperature inside the motors exceeds the threshold of 120. The alarm signals remains active until the temperature has returned under the threshold of 120. NOT: Each use of electricity is wired to the junction box on the machine to allow monitoring even on the control board if this is considered necessary. This electric connection has to be made by the customer. 10.3) BLACK BOX FOR ALARMS REGISTRATION On request, the mixer may be supplied with a recording box (Black Box) of all the work of the mixer. The following checks are recorded: - Working time - Absorption of each motor - Temperature of each motor - Level and temperature of each lubricating or hydraulic oil tank - Grease level - Record and duration of each alarm - Possibility to program ordinary and extraordinary maintenance

46

ALARM BOX All MAO mixers are equipped with a set of sensors connected to the alarm box for a continuous screening of the mixer. In Appendix 3 the electronic card is reported, just for completeness of information.

SENSOR DESCRIPTION

L4 LUBRICATING OIL LEVEL OF THE GEARBOXES

L3 OIL LEVEL OF THE HYDRAULIC CIRCUIT

L2 PROGRESSIVE DISPENSER OF THE AUTOMATIC GREASING SYSTEM (if present)

L5 SEALS LUBRICATING GREASE LEVEL (if present)

L6 HYDRAULIC CIRCUIT OIL TEMPERATURE

L7 / L8 MIXING GEARBOXES TEMPERATURE

L12 / L13 MIXING MOTORS TEMPERATURE

L14 / L15 SKIP MOTORS TEMPERATURE

L9 SLACK CABLE EMERGENCY SWITCH (if present)

The alarm box must be fed with a voltage of 24V AC (50 or 60 Hz), connecting wires 21 and 22 of the junction box. For details on the terminal box of the junction box, Appendix 4 shows the scheme which is put into the junction box before shipment. Feeding of the lubricating pump takes place through the card of the alarm box. WARNING: Wires 25 and 26 of the junction box must be connected to the main control board of the plant to detect possible malfunctionings. In case the Alarm Signal gets ON, the operator can complete the mixing cycle, but immediately after the discharge it is recommended to stop the mixer and identify the problem. It is also possible to connect all the sensors to the main control board to identify the malfunctioning directly from control cabinet. IMPORTANT: terminals 25 and 26 of the junction box must be connected to the main control board of the plant to signal possible malfunctions and alarms. In case of activation of the Temperature and Level Alarm it is possible to finish the mixing cycle in progress but as soon as it is finished the mixer must be stopped and, by means of the synoptic panel of the alarm box the origin of the alarm has to be established and the necessary checks have to be made. It is also possible to connect all the sensors and oil level gauges to the main control board in order to recognize the origin of the alarm from the control booth.

47

ANALYSIS OF DAMAGES TO ALARM BOX

System Description The scopes of the alarm box, which is positioned at the back of the mixer, are: -Alimentation of the grease pump ( 24 V DC internal connection supplied by the producer). -Gathering and transferring to the general control panel the presence of possible anomalies by an alarm signal. On the signalling panel, leds are arranged which identify the types of malfunctioning (it may be possible to transfer also individual signals to the general panel). The synoptic presents:

- a power feeding (SYNOPTIC PANEL POWER FEEDING 24V AC 150W) from the main terminal of the mixer connecting the appropriate terminals to the general control panel

- an input (CONTACT MIXER POWERED, normally open); - an output (LEVELS AND TEMPERATURE ALARM, normally closed)

Card Installation/ Putting it into use

-Check the power feeding to be correct: in the internal terminal box of the synoptic, on the terminals 1-2, 24V AC have to be present -Be sure that the 24V AC which are used for the card are dedicated only for power feeding of this circuit. Otherwise a separate transformer with output 24VAC 150W has to be arranged. -Check all of the sensor connectors (levels and temperature): no earthing connection (mass) has to be present; for testing, it is sufficient to put the tester for ohm and check with an earthed iron tip that there is no continuity by disconnecting one wire after the other from terminal 13 to terminal 25 (in the terminal box inside the synoptic). -Once the card has been connected, check if on terminals 7-8 there is a pure contact which is closed when the mixer starts. -At the output, use terminals 10 and 11 (normally opened contact) for alarm signalling.

Fuse Breakage The fuse could be damaged for following reasons: -excessive power absorption by the pump (because of a block caused by the use of impure grease) -wrong wiring of the electronic card -presence of water in the electric part and particularly in the connectors (connected with the thermostats, level and pump motor indicators) -damage to one of the electronic card cables -defect of the electronic card.

What to do Check the type of problem and refer to the Technical Assistance for working out an action for reparation (the Technical Assistance will evaluate warranty possibility). Information to give to Technical Assistance: - The fuse burnt out immediately after having been introduced or after some time from the machine starting? - Has there been only one damage event? - How much time after installation the problem occurred? - Is the power feeding of the card correct? Has an appropriate transformer with a 24 V output been installed for the alarm box?

48

11) DISMANTLING OF THE MACHINE For dismantling of the machine it is sufficient to disconnect the electric cables which arrive to the switchboard. If the machine has a support, a scheme with indications for disassembly is provided. The machine may be dismantled or scrapped without the necessity of special precautions; however it is necessary to empty the reduction gears and the seals from oil, the hydraulic circuit from hydraulic oil, to disassemble plastic and rubber parts (cables, seals etc.) and to dispose of these materials through authorised companies. IMPORTANT: Dispose properly of lubricating and hydraulic oil. Please contact specialised Companies (for example Used Oil Consortiums).

12) SPARE PARTS MANUAL 12.1) GENERAL The spare parts manual is made up of a series of drawings which refer to a general table (Table 0), and grant and easy and quick spotting of the spare parts to be ordered. 12.2) HOW TO ORDER SPARE PARTS For ordering spare parts, you will have to fill in the scheme indicated in the enclosed form, following all the indications required; most important is to indicate the type of machine, the serial number of the machine, the year of production. IMPORTANT: In order to avoid errors, we recommend to photocopy the form, to fill it out and to send it to the manufacturer or to the agent.

49

SPARE PARTS ORDER FORM For ordering spare parts, please fill in the present form completely for making the procedure easier and avoiding errors in supply. DATE:_____________________ CUSTOMER: ____________________________________________________________ MIXER MODEL: _________________________________________________________ SERIAL NUMBER: _______________________________________________________ YEAR OF MANUFACTURE:_____________

TABLE TO BE FILLED IN:

CODEE TABLE POSITION IN TABLE DESCRPTION Q.ty

MEANS OF SHIPMENT:______________

STAMP AND SIGNATURE OF CUSTOMER:

_____________________________

IMPORTANT: in order to avoid errors and to speed up the lead time, each time you order spare parts it is mandatory to indicate the SERIAL NUMBER of the mixer

50

SPARE PARTS TABLES

TWIN SHAFT MIXER MODEL MAO 7500/5000

SICOMA s.r.l. Via Brenta, 3 PONTE VALLECEPPI (PG), Italia Tel. +39-75-5928120 Fax. +39-75-5928371 sito: http://www.sicoma.it e-mail: sicoma@sicoma.it

51

PARTICOLARI COMUNI

COMMON ITEMS

DESCRIZIONE DESCRIPTION

MODELLO MAO/S MAO/S TYPE

1500/1000 2250/1500 3000/2000 3750/2500 4500/300

0 5000/3350 6000/4000 7500/5000

9000/6000 Janus

12000/8000

Janus

CODICE CODE MOPC1 MOPC3 MOPC3 MOPC3 MOPC4 MOPC4 MOPC4 MOPC4 MOPC4 MOPC4 Pala centrale con viteria/ Central blade + hardware/

Paleta central + tornillos/ Pelle centrale N. PEZZI N. PCS 8 12 12 12 16 16 20 20 28 36

CODICE CODE MOPDS1S MOPD3 MOPD3 MOPD3 MOPD4 MOPD4 MOPD4 MOPD4 MOPD4 MOPD4 Pala raschiante destra con viteria/ Right Scraper blade

+ hardware/ paleta derecha + tornillos N. PEZZI N. PCS 2 2 2 2 2 2 2 2 2 2

CODICE CODE MOPS1S MOPS3 MOPS3 MOPS3 MOPS4 MOPS4 MOPS4 MOPS4 MOPS4 MOPS4 Pala raschiante sinistra con viteria/ Right Scraper blade

+ hardware/ Paleta izquierda + tornillos N. PEZZI N. PCS 2 2 2 2 2 2 2 2 2 2

CODICE CODE MOPR1S MOPR4 MOPR4 MOPR4 MOPR4 MOPR4 MOPR4 MOPR4 MOPR4 MOPR4 Pala rettangolare con viteria/ Rectangular blade +

hardware/ paleta lateral + tornillos N. PEZZI N. PCS 4 4 4 4 4 4 4 4 4 4

CODICE CODE MOBM1S MOBM2 MOBM2 MOBM2 MOBM2 MOBM2 MOBM2 MOBM2 MOBMC9 MOBMC9

Braccio centrale/ Central Arm/ Brazo central N. PEZZI N. PCS 8 12 12 12 16 16 20 20 28 36

CODICE CODE MOBMSX1S MOBM4RA MOBM4RA MOBM4RA MOBM4RA MOBM4RA MOBM4RA MOBM4RA MOBMD9 MOBMD9

Braccio laterale destro/ Right Arm / Brazo derecho N. PEZZI N. PCS 2 2 2 2 2 2 2 2 2 2

CODICE CODE MOBMDX1S MOBM3RA MOBM3RA MOBM3RA MOBM3RA MOBM3RA MOBM3RA MOBM3RA MOBMS9 MOBMS9

Braccio laterale sinistro/ Left Arm/ Brazo izquierdo N. PEZZI N. PCS 2 2 2 2 2 2 2 2 2 2

CODICE CODE @ MOCS1 MOCS1 MOCS1 MOCS1 MOCS1 MOCS1 MOCS1 MOCSB MOCSB

Stringibraccio/ Arm coupling/ Manguito N. PEZZI N. PCS @ 16 16 16 20 20 24 24 32 40

CODICE CODE MOMO13 MOMO2 MOMO3 MOMO46 MOMO4 MOMO5 MOMO5 MOMO7 MOMO4 MOMO4 Motori di Mescolazione/ Mixing motors/ Motor de

mezcla N. PEZZI N. PCS 2 2 2 2 2 2 2 2 4 4

CODICE CODE MORI3D/3S MORI3D/3S MORI3D/3S

MORI4D/4S

RV164

MORI4D/4S

RV164

MORI4RD/RS

MORI67D/7S

MORI4D/4S MORI67D/

7S Riduttori di mescolazione/ Mixing gearboxes/ Reductores de mezcla

N. PEZZI N. PCS 1+1 1+1 1+1 1+1 2 1+1 2 1+1 1+1 2+2 2+2

CODICE CODE MOPF4 MOPF4 MOPF4 MOPF4 MOPF6 MOPF6 MOPF6 MOPF4 V0634S

Puleggia Condotta/ Driver Pulley/ Polea conducida N. PEZZI N. PCS 2 2 2 2 2 2 2 4 4

CODICE CODE MOPM1B MOPM2 MOPM2 MOPM4 MOPM7 MOPM7 MOPM7 MOPM4

0226G0082B2/ 0226G0085L1

Puleggia Motrice/ Motor Pulley/ Polea motriz N. PEZZI N. PCS 2 2 2 2 2 2 2 2 3/1

CODICE CODE V0354 V0354 V0354 V0315 V0315 V0315 V0315 V0315 Cinghie di trasmissione/ Trasmission Belts/ Correa de

transmissin N. PEZZI N. PCS 12 12 12 12 16 16 16 24

CODICE CODE MOCG1S MOCG3 MOCG3 MOCG3 MOCG4 MOCG4 MOCG36 MOCG36 MOCG4

0240G0037B1 Giunto Omocinetico/ Universal Joint/ Junta

homocinetico N. PEZZI N. PCS 1 1 1 1 1 1 1 1 1 2

52

CODICE CODE MOA18 MOA18 MOA18

0223G0004

6L1

MOA19

MOA20 MOA20 MOA21 0223G016

1L1 Alberi di Mescolazione/ Mixing Shafts/ Eje de mezcla

N. PEZZI N. PCS 2 2 2 2 2 2 2 2 2

CODICE CODE

R00SSM1BGH R00SSM3BGH R00SSM3BGH R00SSM3BGH R00SSM4BG

H R00SSM4BGH

R00SSM4BGH

R00SSM4BGH R00SSM4BGH R00SSM4B

GH Pareti usura (KIT COMPLETO)/ Walls wearing tiles

(COMPLETE KIT)// Baldosas de desgaste en fundicin paredes (set complete)

N. PEZZI N. PCS 1 1 1 1 1 1 1 1 1 1

CODICE CODE MORP1 MORP2 MORP2 MORP2 MORP3 MORP3 MORP6 MORP6 MORP9 MORP12

Piastrelle fondo (KIT COMPLETO) / Bottom tiles (COMPLETE KIT) / Baldosas de desgaste en fundicin

piso (set completo) N. PEZZI N. PCS 1 1 (112 p.) 1 (112 p.) 1 (112 p.) 1 (176 p.) 1 (176 p.) 1 (208 p.) 1 (208 p.) 1 (240 P.) 1 (320 p)

CODICE CODE MIMOA1A1M

MIMOA2A2M

MIMOA2A2M

MIMOA2A2M MIMOA2A2

M MIMOA2A2M

MIMOA2A2M

MIMOA2A2M

MIMOA2A2M (*)

MIMOA2A2M (*)

Tenute alberi (KIT N. 4 TENUTE) / Shafts seals (KIT WITH N. 4 SEALS) / Eje estanqueidad (set de 4

soportes) N. PEZZI N. PCS 1 1 1 1 1 1 1 1 1 1

CODICE CODE CR052 CR052 CR052 CR052 CR052 CR052 CR052 CR052 CR052

Cuscinetti alberi/ Shaft Bearings/ Eje cojinettes N. PEZZI N. PCS 4 4 4 4 4 4 4 4 4

Impianto di lubrificazione (KIT COMPLETO) / Lubricating system (COMPLETE KIT) / Grupo de

lubricacion (set complete)

CODICE CODE 60PGL1

60PGL1D

60PGL1

60PGL1D

60PGL1

60PGL1D

60PGL1

60PGL1D

60PGL1

60PGL1D

60PGL1

60PGL1D

60PGL1

60PGL1D

60PGL1

60PGL1D

60PGL1

60PGL1D

60PGL1

60PGL1D

N. PEZZI N. PCS 1 1 1 1 1 1 1 1 1

CODICE CODE CE010ASE CE034ASE CE034ASE CE034ASE CE042ASE CE042ASE CE042ASE CE042ASE CE042ASE CE072A Centralina oleodinamica

Hydraulic Power Pack/ Centralina Hidraulica N. PEZZI N. PCS 1 1 1 1 1 1 1 1 1 1

CODICE CODE CI010 CI010 CI010 CI010 CI010 CI010 CI010 CI010

0804G0008B1 Cilindro portella/ Discharge door cylinder/ Cilindro

compuerta N. PEZZI N. PCS 1 1 1 2 2 2 2 2 2

CODICE CODE ASFC1MOL ASFC1MOL ASFC1MOL ASFC1MOL

ASFC1MOL

ASFC1MOL ASFC1MOL ASFC1MOL ASFC1MOL ASFC1MO

L Serratura di sicurezza carter coperture High top cover safety lock/ Cerradura de suguridad N. PEZZI

N. PCS 1 1 1 1 1 1 1 1 1 1

CODICE CODE 15FCP AFIMA3A AFIMA3A AFIMA3A AFIMA3A AFIMA3A AFIMA3A AFIMA3A AFIMA3A AFIMA3A

Finecorsa portella di scarico (KIT COMPLETO) Discharge door limit switches (COMPLETE KIT) / Final

de carrera compuerta (set complete) N. PEZZI N. PCS 1 1 1 1 1 1 1 1 1 1

CODICE CODE MOGT0 MOGT1 MOGT1 MOGT1 MOGT5 MOGT5 MOGT6 MOGT6 MOGT9 MOGT12

Guarnizioni portella di scarico (KIT COMPLETO) / Discharge door rubber seals (COMPLETE KIT) /

Guarnicin compuerta (set complete) N. PEZZI N. PCS 1 1 1 1 1 1 1 1 1 1

CODICE CODE SU017 SU017