INSTRUCTIONS FOR USE

Truckmixer

All rights reserved Copyright by INTERMIX GmbH Grntenstrae 1 D-87751 Heimertingen Telephone: 08335 / 9828-0 Telefax: 08335 / 9828-30 Printed in Germany, 12.1999 This instructions for use and even parts of it may only be reprinted or copied in any way with the explicit and written authorisation by Messrs. INTERMIX. Any kind of copying, distribution or storage on data carriers that has not been authorised by INTERMIX is to be considered an offence against the existing copyright law and will be sued legally. Editor responsible for the contents: INTERMIX GmbH, Grntenstrae 1, D-87751 Heimertingen Edition: text und bild Redaktion, -tl-, Elly-Staegmeyr-Strae 15, 80999 Mnchen Layout, printing: text und bild Redaktion, Elly-Staegmeyr-Strae 15, 80999 Mnchen

Table of Contents
0 0.1 1 1.1 1.1.1 1.1.2 1.2 1.2.1 1.2.2 1.3 1.4 1.5 1.5.1 1.5.2 1.5.3 1.5.3 2 2.1 2.2 3 3.1 3.2 3.3 4 4.1 4.1.1 4.2 4.2.1 4.2.1.1 4.2.1.2 4.2.1.3 4.2.1.4 4.2.1.5 4.2.1.6 4.2.2 4.2.3 4.2.4 4.2.5 4.2.6 4.3 4.3.1 4.3.2 Preliminaries .................................................................................................... General Information and type plate ................................................................... Safety ................................................................................................................. General Information ........................................................................................... Obligations of the entrepreneur .......................................................................... General symbols and information ...................................................................... Safety and prevention of accidents .................................................................... Use and range of operation ................................................................................ Requirements to the operating and maintaining personnel ................................ How to act in case of accidents .......................................................................... How to dispose of scrap parts, operating materials and auxiliary materials ...... Remaining risks and protection .......................................................................... Risks caused by mechanical influence ............................................................... Risks by operating materials .............................................................................. Hazards caused by the hydraulic system ............................................................ Hazards by noise ................................................................................................ Overall illustration and technical data .......................................................... Overall illustration ............................................................................................. Technical data of serial models ..........................................................................13 General description .......................................................................................... Function .............................................................................................................. Scope of delivery ................................................................................................ Available accessories ......................................................................................... Operation .......................................................................................................... Initial installation phase ..................................................................................... Maintenance of varnish ...................................................................................... Normal operation ............................................................................................... Daily initial installation of the mixer ................................................................. Before starting work .......................................................................................... Water system with pressure water tank ............................................................. Water system with water pump .......................................................................... Operation the mixing drum ................................................................................ Discharging of mixing drum .............................................................................. Admixture container .......................................................................................... Cleaning of mixer .............................................................................................. At the end of work ............................................................................................. Winter operation ................................................................................................ Shutting down operation for a longer period of time ......................................... Reinstallation after a longer period of non-operation ........................................ Options ........................................................................................................ ....... Separate engine .................................................................................................. Hydraulically operated half flap ........................................................................ 5 5 6 6 6 6 6 8 8 8 8 8 9 9 10 11 12 12 14 14 14 14 16 16 16 17 18 18 19 21 22 26 27 28 28 28 29 30 30 30 30

4.3.3 4.3.4 5 5.1 5.2 5.3 5.4 5.4.1 5.5. 5.6 5.6.1 5.6.2 5.6.3 5.7 5.7.1 5.7.1.1 5.7.1.2 5.7.1.3 5.8 5.9 5.9.1 5.9.1.1 5.9.2 A

Fixture for plaster bucket ................................................................................... Chute for flowing concrete ................................................................................ Maintenance and service ................................................................................ Interfaces mixer superstructure mixer auxiliary frame vehicle ................... Change systems ................................................................................................. Interface truck auxiliary drive / mixer drive ................................................... Hydraulic system ............................................................................................... Hydraulic scheme .............................................................................................. Maintenance and service of pneumatic system and pressure vessels ................ Maintenance of water system ............................................................................ Dirt traps ............................................................................................................ Water meter ....................................................................................................... Water pump ....................................................................................................... Maintenance regulations for gearbox ................................................................ Special instructions of manufacturers of gearboxes .......................................... Gearbox PLM 7 / PLM 9 ................................................................................... Gearbox ZF ........................................................................................................ Gearbox Sauer HPM 51.2/HPM 61.2 / HPM 71.2 ............................................ Electrical circuit diagram .................................................................................. Lubrication positions and torque ....................................................................... Lubrication positions ......................................................................................... Lubricant / Lubricating positions table .............................................................. Tightening torque for bolts ................................................................................ Annex ................................................................................................................ Plan for maintenance of truck-mixer ................................................................. Confirmation of maintenance ............................................................................ Certificate of proficiency of operating and maintaining personnel ...................

31 31 32 32 32 33 33 35 37 38 38 38 39 39 40 40 42 43 44 47 47 48 49 51 51 53 54

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0.1

Preliminaries
General information and type plate
This instructions for use explicitly refer only to the mixer superstructure with respect to parts as manufactured by INTERMIX. For any additional attachments, e.g. conveyor belts, interchangeable systems for superstructures, concrete pumps, auxiliary engines etc. the instructions for use of the respective manufacturer are binding. The manufacturers of the respective additional power units are as well responsible for handing over of the espective instructions for use, spare parts lists etc. in full scope and in correct condition.

As INTERMIX constantly has the aim to adapt the mixer superstructures according to the customers requests there might be slight variations between illustrations and the actually supplied superstructure.
For the vehicle the instruction of use of the manufacturer of the vehicle are binding. The type plate (1) of the mixer superstructure is situated at the right side in driving direction of the gearbox supporting frame.

Safety
The truck concrete mixers as described in these instructions for use were manufactured according to present state-of-the-art technology and their safety has been tested by the manufacturer. For operation within the EC respectively the EEC the CE-mark has been approved. Any alterations on the concrete mixers as described in these instructions for use may only be made with the explicit authorisation of the manufacturer, otherwise the warranty of the manufacturer becomes void. This also refers to any additional attachments. The instructions for use must be strictly complied with. The manufacturer is not liable for any damage caused by improper handling or use or faulty installation by the customer. Upon operation of the truck concrete mixers it must be made sure that the mixer is only used in technically perfect condition, hazard-conscious and as directed.

1.1. General Information

1.1.1 Obligations of the Entrepreneur

The entrepreneur using the equipment respectively his authorised representative are obliged to strictly comply with the regional and national safety provisions. Furthermore he is obliged to grant instruction for use of the machine respectively safe contact with the machine for the operating personnel before initial operation of the machine.

1.1.2 General Symbols and Information

The following symbols are used in this instruction for safety information. They warn you of possible damage to persons or material or give you information to make work easier.

Danger! This symbol warns you of the danger of fatal accidents or serious injuries. This danger might occur, if the instructions for use or operation are not followed or are not followed exactly.
Danger

Attention

Attention! This symbol warns you, if imprecise execution or non-compliance of instructions for use or operation may cause injury of persons or damage may occuron the machine or if other serious damage may be caused. The non-observance of this information may lead to loss of warranty claims.

Note! This symbol draws your attention to special features. This is to facilitate your work.
Note

1.2.

Safety and Prevention of Accidents

To reduce the risk of persons being injured or material being damaged the respective and valid regulations for prevention of accidents and safety provisions have to be strictly complied with.

For safety reasons any person working on a truck concrete mixer must have read these

instructions for use and must have understood them. Furthermore he has to be made familiar with the relevant safety provisions and regulations for prevention of accidents. For safe operation of the truck concrete mixers as described in this instruction all relevant regulations for prevention of accidents, all relevant legal safety provisions as well as the local regulations for road operation have to be adhered to beside these instructions for use. Upon operation of ignition engines in closed rooms high quantities of oxygen are consumed, at the same time toxic gases are produced. This results in grave danger to life. When operating truck concrete mixers in closed rooms, tunnels, drifts or deep ditches it has to be made sure that there is sufficient air for breathing. For underground construction works only mixers with diesel engines are admissible. Toxic exhaust fumes have to be removed by suction with adequate measures. Before making a break and at the end of work the driver of the concrete mixer has to shut down the mixer properly and to secure it against unauthorised use. The efficiency of operating and setting parts may not be influence or removed. Refilling of fuel has to be effected in a way to prevent fuel getting into the soil or getting in touch with hot engine parts. Maintenance works have to be effected in compliance with these instructions for use and in compliance with the generally valid regulations of technology and work safety provisions. After repair works are finished all protective devices have to be remounted and must be tested by a responsible person with respect to safety and function. Should the result of this testing be that there are safety devices missing or that these are not fully reliable, the mixer may not be operated. Before start of every work shift the driver has to check the operational safety and traffic safety of the truck concrete mixer. Furthermore the efficiency of all operation and safety equipment as well as correct installation and effectiveness of all protective devices has to be checked. During operation the driver has to survey the fail-safe condition of his truck concrete mixer. Should any defects on the safety devices or other defects be noticed which endanger the safe operation of the truck concrete mixer, the responsible person respectively the operator of the truck concrete mixer has to be informed immediately. In case of any defects endangering persons the operation of the truck concrete mixer has to be stopped immediately. At the end of the shift the truck concrete mixer has to be shut down and secured in a way to exclude improper use by unauthorised persons. Especially the ladder of the rear platform has to be secured to make it impossible for unauthorised persons to climb it. When shutting down please make sure that the truck mixer is not below or in immediate reach of electrical overhead lines.

1.2.1 Use and range of operation

The truck concrete mixers as described in these instructions for use are machinery developed for the production and the distribution of ready-mixed concrete and ready-mixed plaster.

1.2.2 Requirements to the operating and maintaining personnel

The independent operation and maintenance of truck concrete mixers is only allowed for persons: 1. In possession of the required drivers licence, 2. who are at least 18 years of age, 3. who are physically and mentally in a position to do so, 4. who have been instructed to operate and maintain a truck concrete mixer and have proved their ability to the entrepreneur, 5. who can be expected to fulfil the tasks given to them in a reliable way, 6. who have been instructed by the entrepreneur to do so. Furthermore truck concrete mixers may only be operated by persons who have read these instructions for use completely and who have as well understood the instructions. All maintenance works that are not explicitly allowed for the operator may only be executed by instructed maintenance staff and by experts. Attention: A form to certify the proficiency of operating and maintaining personnel is enclosed in the annex of these instructions. Please copy this certificate if necessary before filling it in.

1.3

How to act in case of accidents

In case of accident with any harm to persons the vehicle respectively mixer has to be stopped immediately. If necessary the place of accident has to be secured and then immediately first aid measures have to be taken. Possibly the next available chief has to be informed.

1.4

How to dispose of scrap parts, operating material and auxiliary material

When having contact with operating and auxiliary material the respective persons always have to wear suitable protective clothes to prevent or reduce skin contact with these materials. Defective, replaced scrap parts have to be collected separately and have to be made available for correct recycling. Rests of oils, greases, solvents or cleaning agents have to be collected in suitable receivers and to be stored and disposed of in non-polluting way in accordance with local regulations.

1.5

Remaining risks and protection

Remaining risks are especially any hazards in contact with truck concrete mixers that cannot be prevented despite construction in accordance with safety regulations. These remaining risks are not easy to be traced and may be the source of a possible injury or endangering of health (see Euro-Standard EN 292/1, paragraph 4). Should any unexpected remaining risk occur, the operation of the machine has to be stopped immediately and the relevant chief has to be informed immediately. He make the necessary decisions to remove the danger occurred. If necessary the manufacturer has to be informed.

1.5.1 Risks by mechanical influence

_______________________________________________________________________ Attention! Fainting and injuries might be caused by: bumps, contusions, slipping, sliding, stumbling, falling. _______________________________________________________________________
Attention

Causes
Operating errors, inattention, non-existing, defective or improper clothes.

Protective measures
Wear only suitable and admitted leather protection gloves, wear only tightly fitting protective clothes, wear suitable protective shoes, wear face and eye protection as well as protective headgear.

1.5.2 Risks by operating material

Oil, grease and fuel may cause the following damage: Intoxication by respiration of fuel gases. Allergies by skin contact with fuel, oils, greases. Danger of serious and partially fatal diseases by direct skin contact or taking in fuel, oils or greases (e.g. swallowing, contact with mucous membrane). Danger of fire and explosions by smoking or use of fire or light when having contact with fuel.

Protective measures
When having contact with fuel, oil, greases smoking and the use of open fire and light is strictly prohibited. Oils, greases and fuels may only be stored in containers that are suitable and appropriately marked. Utmost caution is a must when having to do with fuel. The relevant safety regulations have to be observed strictly. Suitable protection clothes (gloves etc) is indispensable. Avoid any skin contact with oils, greases and fuels. Undress immediately if clothes are soaked with fuel and air them at a suitable place. Any rags soaked with fuel, oil or grease have to be stored in containers in accordance with regulations and must be disposed of in a non-polluting way. For filling of fuel or oil into different containers always use suited funnels. _______________________________________________________________________ Danger! Danger for health! In contact with fuel serious damage to health may occur! Inhalation of fuel gases and taking in of fuel into the body and contact with the skin must in any case be avoided. _______________________________________________________________________

Danger

________________________________________________________________________ Attention! Danger of environmental damage caused by leaking of fuel, oil or Grease! Danger of pollution of soil or water! ________________________________________________________________________

Precautions Wear protective clothes. Careful closing of containers with fuel, oils, greases. Do not expose fuel containers to direct sun. Store fuel container in the shadow only. Disposal or empty containers according to regulations in a non-polluting way. Keep suitable binders in stock for immediate use if necessary.

1.5.3 Hazards caused by the hydraulic system

________________________________________________________________________ Danger! During operation there is very high pressure in the hydraulic systems. In case of any damage on the system (e.g. hose bursting) hydraulic fluid gets out under high pressure. If persons are hit by the jet there may be serious injuries by hydraulic fluid, which may penetrate the skin into the body. Therefore any works on the hydraulic system may only be executed by experts. Before doing any work on the hydraulic system the pressure has to be removed. During operation of hydraulic systems make sure to have sufficient safety distance. Hydraulic hoses are marked with a date of manufacturing. Depending on the wear and locally valid safety regulations these hoses have to be exchanged in regular intervals against new hoses. Should any damage (abrasion etc.) be noticed on a hydraulic hose it has to be replaced immediately. ________________________________________________________________________

Danger

Precautionary steps Check hydraulic system regularly. Maintain hydraulic system regularly. Check regularly whether there is any damage on hydraulic hoses. Replace hydraulic hoses in regular intervals.

Protective measures All works to be executed on the hydraulic system may only be executed by experts. During operation keep sufficient distance to the hydraulic hoses.

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1.5.4 Hazards by noise

________________________________________________________________________ Attention! Noise may cause loss of hearing (deafness), defective hearing, damage to health like disturbance of equilibrium, disturbance of consciousness, disturbance of cardiac and circulation system. ________________________________________________________________________

Attention

Causes Impulsion noise (< 0,2 s; > 90 dB(A)) Machine noise higher than 90 dB(A) Machines without noise sealing

Methods for protection Avoid additional noise. Wear hearing protection (cotton wool, ear plugs, ear flaps or noise preventing helmet) when doing any works that may cause noise (e.g. cleaning works, repair works at the mixer or at the mixing drum).

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Overall illustration and technical data

2.1 Overall illustrations
1 2 3 4

13 12 11 10

8
1 2 3 4 5 6 7 Suspension Mixing drum Water tank Hydraulic engine Gearbox Gearbox mounting Auxiliary frame 8 9 10 11 12 13

6
14 15 16 17 18 19

5
Water tank supporting frame Ladder with pedestal Rear under-run guard Mud guard Side under-run guard Oil cooler

Extension chute Discharge chute supporting frame Swivelling chute Carrying roller Discharge container Feed hopper

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15

16

19

18

17

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2.2

Technical data serial models

In case of special executions only technical data as agreed upon in the respective confirmation of order are valid.

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General Description
3.1 Function
The complete mixer unit is mounted on an auxiliary frame. It consists of drive, drum, water supply, discharge chute and feed hopper. Depending on the model type additional attachments can be mounted to the auxiliary frame. The swivelling chute can be adjusted in height via a chute support. For better stability it is mounted with a reinforced double arm to the discharge chute supporting frame and has an elliptic profile. Additional extension chutes make it easy to increase the length of the swivelling chute. Gearbox and drum suspension are mounted on a stable supporting frame. This unit is connected to the auxiliary frame with stable frame connections. In the discharge chute supporting frame two carrying rollers form suspension of the mixing drum. Water pump, hydraulic engine and mixing drum are flanged directly to the gearbox. The drive of the mixer is effected by a separate diesel engine or by the auxiliary drive of the vehicle engine via a hydrostatic axial piston pump. The speed of the mixing drum is continuously adjustable in both directions from 0 12 min-1. The diesel engine to drive the mixing drum is operated via the control board. In addition the optional equipment operating hour meter is situated here. The essential elements of hydraulic (oil cooler, hydraulic oil filter, hydraulic pump, hydraulic engine, hydraulic lines) have generous dimensions. Leakage and flush oil of the hydraulic cycle are led back by hydraulic engine and hydraulic pump to the oil cooler. All valves of this closed cycle are either in the hydraulic pump or in the hydraulic engine. In chapter 5 maintenance and service you will find a detailed hydraulic plan.

3.2

Scope of delivery
Basically the scope of delivery depends on the individual order. Chassis of the vehicle with drivers cabin (only upon explicit request of customer) Mixer superstructure Instructions for use Spare parts list

3.3

Available accessories
A list of all available accessories is included in the spare parts list. In addition it is up to the customer to increase the function of the mixer superstructure by further attachments in his own responsibility. On principle the customer however has to observe the regulations by the manufacturer of the vehicle, the locally valid safety regulations respectively in the area of the European Community the EC guideline in its relevant and valid version as well as all legal regulations. If requested INTERMIX will of course provide all necessary information as far as it is in our possession that you or your supplier needs for additional attachments and superstructures.

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For the sake of completeness we want to point out that the responsibility for productive safety for all additional mounting and changes is to be born be the person executing these modifications. Under certain conditions retrofitting may have negative effects for the safety of the complete mixer superstructure. The person executing these works or ordering the works to be executed has the responsibility for this effect.

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Operation
4.1 Initial installation phase
Before initial installation additional checking respectively maintenance works are necessary. These measures are described precisely in the following. For your own sake these works and checks must be executed thoroughly. For the initial operation and running in of the vehicle the regulation of the manufacturer of the vehicle are of exclusive validity. These must be observed strictly. Should a separate diesel engine be available for the mixer drive, the initial installation and operation of this engine is only permitted according to the enclosed instructions for use of the engine. For possible attachments that have not been supplied by INTERMIX or that have been fitted afterwards by third companies the respective instructions for use are valid. Our instructions for use do not contain any respective information. The mixer superstructure has been manufactured at INTERMIX carefully and was tested on safe function of all parts, before leaving our works. Before first operating the mixer superstructure test all items as stated on the following checklist thoroughly item by item and execute the works stated therein. _____________________________________________________________________________ Note! For checking the oil levels the vehicle has to standing on even ground. All power units have to be shut down. After waiting approx. 5 minutes you can check the oil levels, as it takes some time for the oil in circulation to lower. _____________________________________________________________________________ Check oil level in gearbox, if necessary, refill gear oil (see chapter 5, maintenance and service). Check oil level diesel engine drum drive (separate engine), if necessary refill oil ( only if existing see separate instructions of engine manufacturer). Check oil level of hydraulic oil in hydraulic oil cooler, if necessary refill oil (see maintenance and service). Check tight fit and no-play of clamping flange between cardan shaft and hydraulic pump shaft. If necessary refill water tank (see chapter 5 maintenance and service). Start operation of mixer (see paragraph 4.2 normal operation) and operate all functions. Make sure all functions are working perfectly.

Note

4.1.1 Maintenance of varnish

The varnish of your new concrete mixer has not yet quite hardened at the date of delivery. Depending on the kind of varnish this might take several weeks. During this time you can of course use your concrete mixer. To ensure a long lifetime of the varnish you should observe the following instructions during the first four weeks: Clean the varnish with pure water and a mild cleaning agent only. Do not use any cleaning agents that are very aggressive or contain acid (e.g. agents to remove concrete). Do not use a high pressure cleaner clean with ordinary water pressure only. The water temperature must not exceed 40 C.

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4.2 Normal operation

Safety instructions _____________________________________________________________________________ Danger! Danger of serious injuries. Never put your hand into the rotating mixing drum, not even with a tool. You might be caught by the spiral sheets inside the drum and be injured seriously. Never put you head or other parts of your body close to the rim of the rotating drum. Never climb on the rails of the platform at the feed hopper. If you have to make visual inspections of the interior of the drum, always shut down drum and secure it against unauthorised starting (e.g. remove starter key and carry it with you). For cleaning and repairs in the mixing drum the drum has to be shut down and to be secured safely against unauthorised starting (e.g. take off ignition respectively starting key and carry it with you). When doing repair works inside the drum, lighting, welding or drive of electrical machines may only done with protective extra-low voltage according to relevant regulation of electronics (in Germany according to VDE). For welding works to be done in the drum the locally valid safety provisions for working in limited space have to be observed. For all works inside the mixer drum there is danger of life for the person inside the drum by suffocation. Therefore the respective person has to be secured in a reliable way from outside (safety line). Furthermore you always have to make sure that there is sufficient air in the drum. Used respiration air must be sucked off with suitable gadgets. When doing welding in the drum toxic gases may develop. Furthermore welding consumes a lot of oxygen. Sufficient supply of fresh air that contains sufficient oxygen must be provided. Possibly developing health hazardous gases have to be sucked off. Always wear suitable protective clothes and respiratory protection. _____________________________________________________________________________

Danger

Important information regarding driving

Please bear in mind that a truck with mixer superstructure has other driving features than a truck with a normal superstructure. When loading and discharging always make sure that trucks stand solidly. Inexperienced drivers should be made familiar with the driving features of the vehicle slowly and if necessary be instructed by an experienced driver. Avoid any overload of the mixing drum. Beside legal consequences this might lead to a loss of warranty. Consider overall height of vehicle! It has happened often to drivers to seriously damage mixing drum or feed hopper in too low passages. Especially for discharging it is important to note the safety instructions of the manufacturers of possible attachment (e.g. conveyors, concrete pumps etc.). Additional supporting measures on the vehicle might become necessary.

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When driving on incline and descent roads, please make sure that the mixing drum is not filled too much. Depending on inclination of the vehicle and degree of filling of drum this may unintentionally cause at least partial discharging of the drum. You can prevent this by driving such routes with rotating drum (speed of rotation approx. 1 2 min-1). You however have to observe correct rotating direction of the drum. As every material shows different flow behaviour, no statements regarding filling level of the drum in relation to gradient can be made. Before starting your trip always make sure that the swivelling chute is swivelled to the side and fixed safely. Make sure at any time before starting, whether the switching mechanism of drum is in neutral position and safely fixed. (Exception: transport of material that has to be mixed continuously during the trip). Make sure before every trip that possibly existing extension chutes are safely fixed in their respective fixtures. Always wear the suitable and demanded protective clothes. ______________________________________________________________________ Danger of life! When discharging you always must have sufficient safety distance to concrete bombs, plaster buckets and similar containers. If these containers start to swing you might be crushed, if you are between the mixer and the swinging container. There is no chance to stop such a container by force of muscles. ______________________________________________________________________

Danger

4.2.1

Daily installation of mixer

4.2.1.1 Before starting work

Every day before starting work the following works and checks have to be made: (Exact and detailed information to be taken from the maintenance sheets resp. the lubrication schedule and our service voucher booklet.) Check oil level in hydraulic oil cooler. Put operating lever for pump and speed adjustment to zero position. Fill water system (at least partially) or shut down water pump. Test tight fit and absolute absence of play (heavy shaking) of clamping flange between cardan shaft and hydraulic pump shaft. Should there be only the slightest clearance, retighten clamping bolts. If this retightening does not remove the clearance, the clamping flange has to be replaced immediately. Lubricate lubrication positions according to lubricating table. For mixers with separate engine the instructions in the instructions for use of this engine must be observed. Put mixer into operation and test all function. Remnants of water in the drum (rain water etc.) have to be removed completely.

4.2.1.2

Water system with pressure water tank

The water tank system must only be filled with pure and clean water. Recycled water

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that still contains any residues of dirt must not be filled into the water system, as this might cause grave damage. Depending on the model type the mixer superstructures of INTERMIX are equipped with a pressurised water system or with a non-pressure water tank and water pump. ______________________________________________________________________ Attention! Danger of injuries! For safety reasons the pressurised water system must not be under pressure while filling the tank and while driving on roads. For filling the tank the pressure has to be removed first. The pressurised water tank may only be filled with water. The filling with other fluids is strictly prohibited and may cause serious damage on the mixture superstructure. Any pressure tank must be presented at an authorised board for inspection according to the locally valid safety regulations. These inspections have to be documented in an inspection booklet. Filling in the booklet and presenting the equipment in time for the inspections is solely within the range of responsibility of the party operating the tank. ______________________________________________________________________ Pressure for the pressurised water system is generated by an existing compressed air system. A pressure relief valve in the tank fittings makes sure that a pressure of 4,5 bar is not exceeded. This adjustment is stipulated by the manufacturer and may under no conditions be altered. In addition there is an excess pressure valve which is adjusted to 5 bar. ______________________________________________________________________ Note! Overflow valve (ex pressure vessel) and pressure relief valve are tested safety components. This parts may under no conditions be altered or be replaced by other parts that have no explicit approval from INTERMIX. The adjustments as made in our works may under no conditions be altered. Depending on the local regulations the pressure tank has to be inspected in regular intervals. The observance of this instructions is exclusively within the range of responsibility of the operator. ______________________________________________________________________ For filling and while driving the lever (1) must always be set on airing (down). For discharge of water this lever has to be set on pressure in water tank (to point in driving direction). Before starting to drive always set lever on airing.

Attention

Note

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2 3 1

Attach water hose to house coupling (1) (C-house-coupling). Open water locking valve (hydrant etc.). Open ball cock (2). The water tank is filled via C-coupling (1), the dirt trap (3) and the ball cock. Observe filling level indicator (4). As soon as the display shows that the tank is filled with the desired quantity of water, lock ball cock.

- Lock shut-off valve. ________________________________________________________________________ Note! Hose is under pressure. Open ball cock shortly and lock it. Disengage hose and put it aside in a way nobody can be endangered. ________________________________________________________________________ Water discharge At the rear of the vehicle beside the swivelling chute there is the fixture for the water hose. Before starting any trip the operator has to make sure that the water hose is securely mounted in its fixture and therefore cannot get loose independently. To build up pressure in the water tank the vehicle engine must be running. Put lever (1) at the pressure tank fitting on pressure in water tank. Wait, until there is sufficient pressure in the tank. The manometer (4) shows the air pressure provided by the truck. Open shut-off cock for wash-down hose or ball cock of water batching, if the water has to be directed straight into the mixing drum.

Note

2 4 1 3

___________________________________________________________________________

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Attention

Attention! The compressed air system has to be checked every day for tightness (audio testing). A whistling or hissing sound indicated that compressed gets out. Such damage has to be repaired immediately, as otherwise there may be massive disturbance of operation. ___________________________________________________________________________ In case the compressed air system is equipped with a water meter, it is indispensable to make sure that the water meter is always filled with water. If the water meter is operated without water, e.g. kickback of compressed air, the water meter is destroyed inevitably.

4.2.1.3 Water system with water pump

Depending on the model type mixer superstructures of INTERMIX are available either with a pressurised water system (with pressurised water tank) or with water tank and water pump. The water pump is flanged to the gearbox directly. On mixers with separate engine the water pump can be operated either directly via v-belt by the separate engine or via a separate hydraulic engine. The water pump is always in operation, if the respective drive is in operation. A separate switching of the water pump is nether required nor possible.

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______________________________________________________________________ Attention! The water pump must never run dry. If the water pump is operated without water filling, this will inevitably destroy the pump. ______________________________________________________________________
Attention

Connect water hose to hose coupling (C-hose-coupling). Open water locking valve (hydrant etc.) Open ball cock. The water tank is filled via C-coupling, dirt trap and the ball cock. Observe filling level indicator. As soon as the display shows that the tank is filled with the desired quantity of water lock ball cock. Lock water locking valve.

4.2.1.4 Operation of mixing drum

Mixer superstructures of INTERMIX are supplied with different operating elements depending on the type of vehicle. Therefore all available variations are described.

Mixer with separate engine

The operation of the mixing drum is effected via a double rack gear mechanism.

5 3 4 2 6

1 Hydraulic pump adjustment 2 Truck accelerator adjustment 3 Arresting lever 4 Operating hours meter 5 Oil pressure indicator 6 Voltage control lamp 7 Shut-down button 8 Starting switch

Set lever (1) to adjust the hydraulic pump to position zero

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Set lever (2) to adjust the speed of engine on low speed. Start separate engine with starting key (8). Approx. 10 seconds after starting of the engine the control lamp (6) should go out. If this is not the case, shut down engine and remove defect (see instructions for use of manufacturer of the engine). By means of shut-down button (7) the separate engine is stopped. If the control lamp for oil pressure light up, the separate engine has to be shut down immediately. You will find further information in the instructions for use of the separate engin.

Adjustment of lever (1) and lever (2) can be fixed with lever (3) (arresting lever). Should your mixer superstructure be equipped with a separate engine, please find the details regarding operation, maintenance and service of this power unit in the enclosed instructions for use of this unit. As soon as oil pressure lamp lights up, the oil level of the separate engine has to be checked (see instructions for use of the separate engine). The fuel supply is effected depending on individual condition and customers request from the fuel tank of carrying vehicle or via a separate diesel tank which is mounted on the mixer auxiliary frame. Location and capacity of this tank is agreed upon with the customer within the range of the legal regulations. If requested by the customer, the separate engine can be equipped with its own starter battery. Serially the carrying vehicle supplies power for the separate engine. If the separate engine is supplied with its own starter battery, this battery is loaded via the dynamo of separate engine. Details regarding maintenance and service of this starter battery are included in instructions for use of the separate engine.

For all other mixers

Depending on vehicle chassis or requested model type your mixer may be equipped with a single rack gear mechanism and electrical operating elements or with a double rack gear mechanism.

1 Hydraulic pump adjustment 2 Truck accelerator adjustment 3 Arresting lever 1 Double rack gear mechanism

23

In case of rack gear mechanism the speed of the truck engine as well as speed and sense of rotation of the mixing drum are adjustable. Via the lever (2) the speed of the truck engine and thus the capacity of the pump can be modified. The neutral position of lever (1) is easy to adjust. As soon as the operator moves the lever (1) from neutral position in any direction, the hydraulic pump audibly starts operation. At the same time the mixing drum rotates in proportion to the moving of lever quicker. If you want to lower the speed of the mixing drum, you must simply swivel back the lever (1). The adjustments of lever (1) and lever (2) can be locked by lever (3) (arresting lever). Switching with lever (1) has to be done very slowly. ________________________________________________________________________ Attention! To avoid damage of the drive of the mixing drum the speed of the diesel engine has to be increased via lever (2), before adjusting the pump from neutral in direction mixing or discharge.
Attention

To lower the speed of the drum or to stop the mixing drum first set lever (1) at neutral position and then lower engine speed of diesel engine. Do not directly switch the direction of rotation of the mixing drum from forward to backward (and vice versa). Wait at least one second with lever in neutral position, before starting the drum in the opposite direction. The immediate switching from one direction to the other may lead to grave damage of the gearbox. ________________________________________________________________________ Depending on model type the truck engine can be started via the start switch (4) and be stopped via the stop switch (5) (Optional equipment, if the start/stop function is not already existing from the manufacturer of the truck). ________________________________________________________________________ Note! For safety reasons the engine of the truck can only be started via start/stop-switch at rear, if in the standing vehicle no gear is engaged and the vehicle is secured by parking brake (handbrake). ________________________________________________________________________

Note

Simple gear rack mechanism with 4-step-switch

On electronically controlled vehicle engine the speed of the engine is selected via 4-step-switch (6). The following speeds are available:

24

Position of switch:

1= 2= 3= 4=

idle speed 950 min-1 1150 min-1 1450 min-1

Do always operate the 4-step-switch very cautiously and in a sensible way. Do not use any violence. The use of the 4-step-switch demands smooth touch. Never point the jet unit of the high pressure cleaner directly on the 4-step-switch, as this may cause a defect of the electronics. Speed and sense of direction of the mixer drum can be adjusted with lever (7). You have reached neutral position, if the lever (7) is in centre position. Lever (7) can be fixed with lever (8). As soon as the operator moves the lever (7) from neutral to any direction, the hydraulic pump audibly starts to work. At the same time the mixing drum moves faster. If you want to lower the speed of the mixing drum you simply have to swivel back the lever (7) a little. ________________________________________________________________________ Attention! To avoid any damage of the drive of the mixing drum, the engine speed of the diesel engine must be increased, before adjusting the pump from neutral in direction mixing or discharge. When lowering the drum speed or stopping the drum first set the lever (7) to neutral position and then reduce the engine speed of the diesel engine. ________________________________________________________________________

Attention

25

4.2.1.5 Discharging of mixing drum

Discharging is effected via a discharge chute. Either your vehicle is equipped with a chute with mechanical manual crank support or with a chute whose angle of inclination can be adjusted via a manually operated hydraulic pump. If the chute is to be lifted with the hydraulic system, first close the hydraulic valve at the manual pump. By moving the pump lever up and down the chute is lifted. When opening the hydraulic valve cautiously the chute lowers again. The contents of the mixing drum can be forwarded to a certain direction via the rear discharge chute of the vehicle. The chute can be extended with up to three discharge chutes. If you intend to connect even more chutes, sufficient support for the fourth and further chutes must be provided, otherwise the weight of the loaded chutes will lead to serious damage of the chute support. During driving the discharge chute must be fixed as a principle and must be secured to avoid unintentional swivelling movements. A possibly existing foldable discharge chute has to be folded up and secured with the existing rapid locks. Additional chutes have to be removed and stowed in their fixtures on the mudguards.

1 Chute support 2 Clamping lever for discharge chute

26

4.2.1.6 Admixture container

Depending on the model type the mixer superstructure can be equipped with a container for fluid concrete admixtures. The filled admixture can be batched pneumatically directly in the mixing drum. The mounting of the admixture container is usually on the left side bottom (seen from driving direction). Upon request of the customer this container can be mounted at other locations as well, if it is possible from a technical point of view. ______________________________________________________________________ Attention! Danger of injuries and danger of damage to the system. For safety reasons the admixture container must be without pressure before filling the tank and during road operation. The admixture container must not be filled with anything but fluid admixtures. The filling with pulverised admixtures is prohibited and may cause serious interruptions of operation or even destruction of the admixture system. ______________________________________________________________________

Attention

1 2 3 3.1 4 5 6 7 8 9 10 11 12 13

Container Filling hole with cover Discharge Drain cock Filling level indicator Scale Pressure relief valve 2 bar Rapid air drain pet-cock Pressure controller with manometer Manometer for container pressure Compressed air connection Fixing bow Hose Pipe nozzle

27

______________________________________________________________________ Note! We expressively inform you that the admixture container may under no circumstances be filled with flammable fluids or with any substances that are injurious to health. Before filling the admixture container always observe the relevant valid regulation and laws for transport of chemicals or hazardous goods on roads. The manufacturer of the mixer superstructure is not liable for any damage created by the fact that non-suited substances or toxic substances or goods were filled into the admixture container or were transported in the admixture container. ______________________________________________________________________ As an optional equipment delivery of a fixture for the admixture tank without pneumatic batching device at the rail of the pedestal at vehicle rear can be mounted. In accordance with the customer the admixture mostly consists of a special plastics container with a simple drain device to be opened and closed via a cock fitting.

Note

4.2.2

Cleaning of mixer
To clean the mixer INTERMIX recommends water. In case of grave soiling a concrete dissolving agent mixed with water can be used. It is indispensable to observe the instructions for use of the manufacturer of the concrete dissolving agent. After emptying the mixture fill 150 - 200 l water into the drum and run drum for 5 10 minutes on highest speed in mixing operation. ______________________________________________________________________ Note! It is indispensable to observe the local environmental regulations to dispose of the cleaning water. ______________________________________________________________________ Discharge mixing drum afterwards.

Note

4.2.3

At the end of work

Fill mixer superstructure with sufficient water , make it run for 5 10 minutes on highest speed in position mixing. Subsequently discharge all water without remnants. If existing: check admixture container, possibly fill or discharge it. Please observe the instructions for use of the respective manufacturer of the admixture.

Shut down mixer and secure it against unauthorised operation (Remove any engine starter keys and store at a safe place). If existing, remove battery switch and store it a safe place as well. ______________________________________________________________________ Danger! Always shut down the mixer in a way that no unauthorised person has access to the mixer. Avoid to place the mixer somewhere near or under active electrical transmission lines or plants. ______________________________________________________________________

Danger

4.2.4

Winter operation
Winter operation demands additional measures to prevent damage to the water system of the mixer superstructure. The instructions for use of the respective manufacturers will inform you if and which additional measures are required on the separate engine, the vehicle or possible attachments.

28

In danger of frost the following has to be observed before operating the mixer and at the end of work: Before starting work check, whether the water pump is free of ice. Even after supposedly complete discharge of the water system there can still be dampness in the water pump to result in freezing. In case of doubt defrost the water pump with suitable means. ______________________________________________________________________ Attention! Danger of damage of material. The starting of a frozen water pump may lead to destruction of the pump. ______________________________________________________________________ Should despite all carefulness the water pump be frozen and a damage occur on starting it, there is a coupling sleeve made of plastic between gearbox and water pump. This coupling sleeve is executed to form a breaking point. In case of damage mostly only this sleeve has to be replaced. ______________________________________________________________________ Attention! We expressively warn you to replace this plastic sleeve by an element of a foreign supplier, as the safety function of this element can then not be granted any more. In this case any claim for warranty to INTERMIX becomes invalid. ______________________________________________________________________ Instructions for replacement of the coupling sleeve are to be found in the paragraph 5.6 maintenance of the water system. Depending on conditions of environment and operation the complete water system a the mixer has to be emptied when finishing work by the latest. Please note that for pressurised water systems the same procedure has to be applied, but in this case there is no water pump. All steps referring to the water pump are not applicable. To empty the water system please proceed as follows: Empty water tank completely. Open all ball cocks and leave them open. Open drain cock of water pipe and leave it opened. Open drain cock of water pump and leave it opened. Operate water pump without water and opened cock for a short period of time (max. 10 seconds).

Attention

Attention

______________________________________________________________________ Note! Depending on conditions of environment and operation it may be required to run the mixer with emptied water system during daytime and to fill the system immediately before use and empty it immediately after use. ______________________________________________________________________

Note

4.2.5

Shutting down for a longer period of time

If the mixer superstructure will be out of operation for more than four calendar weeks, the complete superstructure must be cleaned thoroughly. The water system must be emptied completely. All drain cocks must be left open (see paragraph 4.2.4, operation in winter). If a separate engine is mounted, this engine must be preserved according to recommendations by the manufacturer (see instructions for use by manufacturer). The same applies to possible additional attachments.

29

4.2.6

Reinstallation after a longer period of non-operation

For reinstallation after a period of non-operation of more than 4 week the same procedure as for the initial installation is required (see paragraph 4.1, initial installation).

4.3 4.3.1

Options Separate engine

As an option mixing drum can be driven by a separate diesel engine an not via the vehicle engine. Should your mixer superstructure be equipped with a separate engine, please find all details regarding use, maintenance and service of this unit in the enclosed instructions for use of this unit. Fuel supply is effected, depending on the individual conditions and customers request, either from the fuel tank of the carrying vehicle or via an own diesel tank fixed on the mixer auxiliary frame. Location and volume of this tank are determined within the scope of legal regulations and in agreement with the customer. On customer request the separat engine can be operated by a separate battery. In the standard the electrical supply is coming from the truck. If the separate engine is supplied with its own starter battery, charging of this battery can be effected either via dynamo of the carrying vehicle or via the dynamo of the separate engine. Details regarding maintenance and service of this starter battery are included in instructions for use of the separate engine.

4.3.2

Hydraulically operated half flap

Depending on model type your mixing drum can be closed partially with a half flap. Retrofitting of this half flap is possible at any time without problems. INTERMIX urgently requests you to have the installation done by an expert workshop or by INTERMIX.

30

4.3.3

Fixture for plaster buckets

As an option your mixer superstructure can be equipped with special fixtures for plaster buckets. In these fixtures up to 10 cleaned plaster buckets can be transported safety.

4.3.4

Chute for flowing concrete

The chute for flowing concrete is installed at the discharge chute and serves as an intermediate element for connection to existing pipes and hoses.

31

Maintenance and Service 5.1 Interfaces

Mixer superstructure mixer auxiliary frame vehicle The mixer superstructure is fixed to the vehicle frame via screwing sheets respectively bolted connections. Once a week the state of these fixtures has to be checked. Special attention must be drawn to the tight fit of the nuts. If necessary the nuts must be readjusted to the prescribed torque with a torque wrench. The correct torque is stated in paragraph 5.9.2 tightening torque for bolts.

Frame connections of discharge chute supporting frame

Frame connections of gearbox supporting frame

All other parts of fixtures have to checked for detection of possible damage (e.g. capillary cracks, rust deposit). Rust deposit must be removed immediately, in case of any other damage the respective part must be replaced immediately.

5.2

Change Systems
Regarding change systems please observe the instructions for use of the respective manufacturer. In case of change systems INTERMIX supplies the complete mixer superstructure to the manufacturer of the change system. The supplier of the change system is responsible for adjustment of the individual interfaces (hose connections, cable connections etc.). Information regarding use, maintenance and service are to be found in the instructions for use of the respective manufacturer

32

5.3

Interface truck auxiliary drive / mixer drive

________________________________________________________________________ Attention! Maintenance and service of the cardan shaft are of utmost importance. If this shaft is not lubricated sufficiently, very expensive repairs may occur. ________________________________________________________________________

Attention

If your mixing drum is driven directly via the auxiliary drive of the truck a torsion coupling is situated at the auxiliary drive of the truck gearbox. This torsion coupling must be maintained according to the information by the supplier. If these maintenance works are not effected or if they are not effected correctly, grave damage to the gearbox of the truck or to the cardan shaft of the mixer drive may be the result.

5.4

Hydraulic system
For all works on the hydraulic system expert knowledge in the field of hydraulic systems is required. For safety reasons only persons with the respective expert knowledge are allowed to execute works on the hydraulic system. When working on the hydraulic system utmost cleanness is a must. Even the smallest foreign substance may cause serious damage on the hydraulic system. ________________________________________________________________________ Note! For information regarding the approved hydraulic oils and filling levels please refer to the lubricant table, paragraph 5.6.21. ________________________________________________________________________ Hydraulic oils may not be mixed. Always top up hydraulic oil of the same make and same specification. Should you decide to change the make of the oil, e.g. from ATF to HPL, the complete hydraulic cycle must be emptied. Subsequently the whole system including tank has to be flushed with the new oil. The oil used for flushing - as well as the old oil - must be disposed of respectively recycled according to the locally valid environmental regulations. Basically no hydraulic oils must be used that are not expressively approved by the manufacturer of the system. If other oils are used, any claim for warranty towards INTERMIX becomes void.

Note

________________________________________________________________________ Attention! Danger of environmental damage. Hydraulic oil must under no circumstances get into the ground or into water, as this may cause serious environmental damage. When
Attention

33

working on the hydraulic system and with hydraulic oil please observe the valid regulations regarding environment protection. ________________________________________________________________________ Before starting operation of the mixer always check, whether there is sufficient oil in the hydraulic system. For this purpose the mixer must stand horizontally. If the oil level has sunk under the middle of the gage glass (1), oil has to be refilled, until level is above middle of the gage glass.

Oil change must only be effected with hydraulic system run warm, as warm oil discharges easier. If the hydraulic system must be discharged completely, the hydraulic pump must be opened at the lowest point and must be left open, until oil has discharged completely. Before opening a suitable receiver of sufficient size must be put below this position. On occasion of every oil change the filter cartridge of the hydraulic filter must be replaced by a new one. The filter is a one-way product. Any effort to clean it leads to destruction of the filter. As soon as oil has been discharged, the oil drain screw has to be fixed with a new copper seal. Please care for utmost cleanness. After filling the oil cooler with new hydraulic oil the hydraulic system must be operated at low speed. While doing so watch the oil level constantly and refill hydraulic oil until the oil level does no longer sink below the middle of the gage glass. Make sure that the hydraulic cycle is absolutely tight and that there is no leakage at any spot. Use new sealing material for every change of components and for every maintenance. For oil change intervals and oil types refer to paragraph 5.6.1.1, Lubricant / lubricating positions table.

34

5.4.1 Hydraulic scheme

Hydraulic switching scheme, conventional standard execution

Hydraulic scheme: Sauer hydraulic pump in combination with Sauer hydraulic engine and epicyclic gear

35

Scheme: Admixture container

4 3

5 7

1 2 3 4 5 6 7 8

4-cycle protective valve Overflow valve Three-way-cock with pressure relief and manometer Safety valve and manometer Scale Additional discharge Container 50 l Lead to mixing drum

36

5.5

Maintenance and service of pneumatic system and of pressure vessels

The pneumatic system of the carrying vehicle is subject to the legal survey according to the locally valid regulation of the Road Traffic Authorities. The pressure vessels of the mixer superstructure must be tested according to the locally valid regulations for pressure containers in the prescribed intervals by experts respectively by specialists. Due to the fact that these regulations differ locally and nationally, no generally valid intervals can be stated. It is within the responsibility of the operator of the mixer that these tests and examinations are executed in the prescribed intervals by the authorised persons and organisations, respectively that application is made in time for the respective tests of the pressure vessels. If the truck concrete mixer is equipped with pressure containers that are subject to survey, the operator has been handed over all necessary and prescribed documents for the installed pressure container. These documents include all information regarding the respective pressure container and the necessary regular tests. Otherwise the pneumatic system and pressure container do not have to be maintained. Only during the frost period it has to be made sure that on vehicles standing outdoors all pipes and containers carrying water are completely discharged. Scheme pneumatic water system

Pressurised water tank

Three-way-cock with pressure relief, safety valve and manometer

Overflow valve without flowback

4-cycle protective valve

37

5.6 Maintenance of water system 5.6.1 Dirt traps

1 2

After every 500 operating hours the dirt trap must be cleaned. For this purpose remove locking bolt (1). Clean strainer (2) and mount it. Every 1000 operating hours the strainer must be replaced by a new one.

5.6.2

Water meter
Water meter (1) and strainer (2) must be flushed with pure water sufficiently. ______________________________________________________________________ Attention! The water meter is a very sensitive metering instrument. It may only be flushed with water. For cleaning no other substances or compressed air may be used. This would destroy the water meter immediately. ______________________________________________________________________

Attention

38

5.6.3

Water pump

1 2

3 ______________________________________________________________________ Attention! The water pump may not be running without water! ______________________________________________________________________
Attention

Shutting down of water pump: Remove three hexagon bolts (1). Remove pump. Take out plastic coupling sleeve (2) and replace it. Remount pump accordingly in the reverse order.

The drain cock (3) on the water pump serves to drain remaining water from the pump housing. The plastic coupling sleeve serves as an overload protection and will break, if the pump is blocked.

5.7

Maintenance regulations for the gearbox

Before every start of operation of the mixer it must be made sure that there is sufficient oil in the gearbox. For this purpose the mixer must stand as horizontal as possible. Remove oil filling bolt. Check oil level. If the oil level does not reach the lower edge of the oil filler opening, transmission oil has to be filled, until the oil level reaches the lower edge of the oil filler opening. Oil change has to be effected with the oil being warm, as warm oil drains better. For this purpose the drain plug have to be removed. After oil has drained off, remount the drain plug. Fill new transmission oil, until the oil level reaches the lower edge of the oil filler opening. Remount oil filling bolt, use new sealing and make sure that it is absolutely tight.

39

5.7.1

Special instructions of manufacturers of gearbox

5.7.1.1 Gearbox PLM7 / PLM9

The following intervals of maintenance are recommendations and can be adjusted to the maintenance intervals of the vehicle. Change of oil and filter element: After 500 operating hours. After 2000 operating hours. Every 2000 operating hours or once a year, regardless of the respective operating hours. Check oil level after every change of oil and filter element with engine being shut down. Quality of oil see lubricant table. Change oil with system being warm. Leakage test: After every change of oil and filter. Checking of oil lever: Once a month! Important information Function of the fan has to be check by visual testing on a weekly basis. Check oil cooler regularly regarding cleanness to ensure heat emission. Check tightness of all gearbox bolts from time to time regarding the prescribed torque (first time after 50 operating hours). In case of removal of gearbox strict attention must be laid on the fact that no dirt gets into any free openings. Therefore all openings have to be closed immediately with blind plugs or other appropriate material.

Hydraulic scheme: Sauer hydraulic pump in combination with PLM gearbox

40

Hydraulic scheme: Hydromatic hydraulic pump in combination with PLM gearbox

Gearbox scheme PLM 7

Gearbox scheme PLM 9

p.t.o.

5.7.1.2 Gearbox ZF
Required quantity of oil:

p.t.o.

41

P 3301: approx. 7,5 l P 5300: approx. 11,5 l Use only EP transmission oils according to API GL-5 in SAE classes 90. Check before starting operation: Check oil level in oil cooler and gearbox.

Lubricants for ZF gearboxes Execution Truck mixer drive Common oil system gearbox and hydrostatics P23201 PLM7, PLM 9 Truck mixer drive Separate oil system gearbox and P3301, P4300, P5300, P6300 Admissible lubricants for the service filling Engine oil - API CD/CE / CF /SF / SG - MIL-L-2104C/-D/-E - MIL-L-46152C/-D/-E - SAE 5W-40/10W-40/15W-40 Transmission oil - API GL-5 - MIL-L-2105D - SAE 80W-85W/ 80W-90/ 85W-90/85W-140/ 90 Alternative recommendation Super tractor oil (STOU) - SAE 10W-30/10W-40/15W30/15W-40

Engine oil - API CD / CE / CF / SF / SG - MIL-L-2104C/-D/-E - MIL-L-46152C/-D/-E - SAE 10W-40/15W40

Temperature range: Class of viscosity

Operation at ambient, Temperatures, Load gearbox (3) --20C a +40C -15C a +40C -10C a +40C 0C a +50C

- SAE 5W-40 - SAE 10W-30, 10W-40 - SAE 15W-30, 15W-40 - SAE 20W-20 - SAE 30

Operation at ambient, Temperatures, Truck mixer drive (3) -15C a +50C -12C a +50C - 8C a +50C ---

(1) To reach optimum operation viscosity quickly, we recommend viscosity category SAE 10W-40. (2) To reach the minimum oil temperature for start of drive unit (lowest threshold value of temperature range) an even pre-warming is required. At temperatures of -5C a warming-up phase of at least 10 minutes is required, independent of the used category of viscosity. At lubricant positions a multiple-purpose grease, lithium-soaped Cat. NLGI 2 has to be used Note: For truck mixers all products may be used, if they meet the following specifications: API CD / CE / CF / SF / SG e MIL-L-2104C / -D / -E e MIL-L 46152C / -D/ E e SAE 5W-40 / 10W-40 / 15W-40

5.7.1.3 Gearbox Sauer TMG 51.2 / TMG 61.2 / TMG 71.2

42

1 Oil drain plug 2 Oil filling bolt

Required quantity of oil:

TMG 51.2: TMG 61.2: TMG 71.2: approx. 12 l approx. 16 l approx. 16 l

Use exclusively EP transmission oil according to API GL-5 in SAE category 90. For higher temperatures we alternatively recommend EP transmission oils of the SAE viscosity category 140. Check before starting operation: Check oil level in oil cooler and gearbox. Measures for maintenance and service: Check level of hydraulic oil. The level of the lubricating fluid has to be checked every day with the dipstick. When loosing hydraulic oil repair leakage and refill hydraulic oil. Clean gearbox on the outside regularly and check, if any bolts need tightening. ______________________________________________________________________ Attention! When cleaning the gearbox with a high pressure cleaner make sure that the jet is not pointed directly on the radial shaft sealing, as thus dirt might get under the sealing lips. This may cause premature wear and defect of the radial shaft sealing. ______________________________________________________________________

Attention

5.8

Electronic circuit diagrams

43

Circuit diagram IM truck mixer with separate engine 24 V

30 15 S1 P1
0 1 2 15 15x 50

30 15

S38 G1

L1

B1

G1 G2 S1 M1 L1 B1

= = = = = =

Battery Generator Ignition lock Starter Control lamp Operating hours meter
31

B+ G 3 B

D+

50

30

M
W

G2 P1

M1

15a

31

P1

T1

31

Fan Control

F1 M1 S1 A1 K1

= = = = =

16 A 6x25 blue Fan oil cooler T. Behr, thermo switch 160.4 Fan control Relay Bosch 24V 0332 019 203

44

Engine START STOP speed adjustment 4-step

Engine START STOP speed adjustment 4-step type MB Actros

45

Electronic circuit diagram control panel - separate engine

50: magnet switch 31: earth 30: starter

15: plus to starter switch 30: plus from battery (starter) 50: to magnet switch

46

5.9 Lubricating positions and torque

Generally the mixer superstructure must be maintained according to the maintenance plan (see annex). The maintenance plan is available in the form of a check list. We recommend you to copy this checklist and to enter the respective data after each maintenance. INTERMIX points out that granting of any warranty claim depends on the correct execution of the prescribed maintenance works within the period prescribed. Documentation of these maintenance works is effected by complete presentation of correctly filled-in maintenance reports. ______________________________________________________________________ Note! We expressively point out that all described maintenance works may only be executed persons who are familiar with similar works and who have the required expert and specialist knowledge. This maintenance plan contains only maintenance works and maintenance intervals for the mixer superstructure. Information regarding additional power units and additional attachment are exclusively included in the instructions for use of the respective manufacturer. ______________________________________________________________________ Lubricating positions

Note

5.9.1

clamping lever

Gear ring

Cardan shaft

Carrying roller

left / right

For lubrication of the mixer superstructure only the lubricant types as stated below must be used.

47

5.9.1.1

Table of lubricants and lubrication positions SAE respectively Specification FZG damage force NLGI-category Stage < 12 DIN 51354 Approx.Oil consumption

Lubricating Position

Type of lubricant

Gearbox - HPM 51.2 - HPM 61.2 - HPM 71.2 - P3301 - P5300 - PLM 7 - PLM 9 Hydraulic system Gear ring Carrying roller left / right 4-off Swivelling arm Clamping lever Cardan shaft 2-off EP transmission oil EP transmission oil EP transmission oil EP transmission oil EP transmission oil Super tractor oil Super tractor oil Hydraulic fluid Graphite lubricant Grease Grease Grease Grease, lithium-soaped API GL 5 API GL 5 API GL 5 API GL 5 API GL 5 10 W 30 10 W 30 ATF Tipo A ----DIN51502 K2K DIN51502 K2K DIN51502 K2K Penetration 2 DIN 51804 Suffix A ----NLGI category 2 NLGI category 2 NLGI category 2 NLGI category 2 SAE 90 SAE 90 SAE 90 SAE 90 SAE 90 12 16 16 l l l

7,5 l 11,5 l 12 18 18 l l l

5.9.2

Tightening torque for bolts

To retighten bolts and nuts generally the proved and tested methods of technology have to be observed. This means that bolts and nuts must not be tightened too much. Certain fixing elements on the mixer superstructure are of special significance. These bolts and nuts must on principle be tightened according to the below table with a precise torque wrench to the stipulated torque. According the maintenance regulations all bolts and frame connections on the mixer superstructure must be checked on tight fit and if necessary must be retightened. The following checking intervals are applicable: 1. Inspection after 50 operating hours. 2. Inspection after 1000 operating hours. Further inspections accordingly after every 1000 operating hours. INTERMIX recommends to check screwed connections that are exposed to changing load at least once a week (visual inspection and inspection by touch).

48

Mixer Size m 4-12 4-7 8-10 12

Torque in Nm Position 1 420* 300 750 360 Position 2 Position 3 Position 4

* only applicable for clearance bolts ______________________________________________________________________ Attention: For screw connections 2, 3 and 4: put HV washer DIN 6916 under bolt head and nut (also applicable for frame connections). For screw connections 1: put washer DIN 7349 under bolt head. ______________________________________________________________________

Attention

Position 1 Screw connection Gear flange Position 2 Water tank supporting frame Screw connection gear flange Frame connections Frame connection

Position 4 Screw connection gear flange Mixer size m 4-7 8 8-12 Quantit fori 12 12 24 Torque (Nm) 280 280 280

Position 3

Bolts Type 10.9 10.9 10.9

49

Maintenance Schedule
Item Works to be done after operating hours Inspection 8h 1 Check level of transmission oil and hydraulic oil. If necessary, refill oil 2 Change oil and filter of hydraulic system Change oil on gearbox 3 Check respectively clean cooling fins resp. cooling elements 4 Lubricate drum gear with graphite grease 5 Lubricate cardan shaft, check tight fit of pump and cardan shaft flange, retighten nuts 6 Check all remote control cables and rack gear mechanisms on function and grease them 7 Clean and grease 5th wheel plate and king pin 8 Lubricate all lubricating positions 9 Check tightness and possible abrasions of hydraulic lines and hose connections 10 Check function of fan blades 11 Check v-belt and v-belt tension 12 Clean dirt flaps in water system, if necessary replace strainer, check tightness 13 Check pneumatic water batching, safety valve and pressure relief valve 14 Check electrical system 15 Check all bolts, frame connections, straps, retighten, if necessary. 16 Check if carrying rollers are in alignment with gear ring and clearance of bearings 17 Check, if there are bends, damage or wear on the mixing drum 18 Check mixing spirals and wear protection 19 Check feed and discharge hopper, swivelling chute, if necessary, replace wear sheet 20 Visual testing of cracking and deformation Used oil: Hydraulic: .............................. Transmission: .............................. X X X X X X X X X X X X X X X X X X X X X 50h 200h 8h X X X X X X Following inspections after hours 50h 200h 500h 1000h X X X 2000h

X X

X X X Please copy this sheet before filling it in.

-----------------------------Place, date

-----------------------------Stamp, signature customer

-----------------------------Mechanic

50

Information regarding maintenance table

Regarding item 2 Change transmission oil and hydraulic oil only with power unit being in warm condition. For complete drainage of the oil the oil must be discharged at the lowest point of the unit. Always care for utmost cleanness when changing oil or checking oil level. Attention hydraulic system: After filling with fresh oil set pump to zero-position and operate it at low speed. Refill oil, until oil has reached the prescribed level. After a short test run check level again. Make sure that the sealing is tight. Use new seals for every filter change and every oil change. Regarding item 6 The cable for pump adjustment has to be fixed to click into position exactly in the centre of the possible adjusting range. The speed adjustment of the drive engine has to be effected in a way that with hydraulic pump swivelled outside a maximum speed of 12 min-1 respectively 14 min-1 is not exceeded. Regarding item 9 Possible leakage has to be removed by retightening of bolts, replacement of o-rings or cutting rings. Regarding item 11 Check V-belt tension and alignment. Replace damaged v-belt immediately. Regarding item 13 In case of pneumatic water batching please make sure that the safety valve reacts at 5 bar (see confirmation of TV Technical Survey Board). Regarding item 16 To check alignment of carrying rollers a ruler is put on the carrying rollers. If the ruler is in a distance of 8 10 mm parallel to the gear ring, the adjustment is correct. Regarding item 17 Damage on the drum cover has to be removed immediately. Regarding item 18 Check general condition and standing height of mixing spirals. Weld wear protection in time and re-weld spirals to drum cover if necessary. Regarding item 20 Cracks and deformations have to be removed immediately.

51

Confirmation of Maintenance

Maintenance after Other maintenance works: operating hours

completely effected on: executed by: Signature: _______________________________________

Maintenance after Other maintenance works:

operating hours

completely effected on: executed by: Signature: _______________________________________

Maintenance after Other maintenance works:

operating hours

completely effected on: executed by:

Signature:

_______________________________________

52

Please copy this sheet before filling it in.

Certificate of Proficiency of Operating and Maintaining Personnel

Mrs./Mr.

................................................................................ born ... (Surname and first name) in operation*) in maintenance*)

was instructed on ...............................

of the mixer superstructure...................................

of Messrs. INTERMIX.

Instruction was effected by.......................................................... (Surname and first name)

The required knowledge for operation* maintenance* of the mixer superstructure has been proved by presentation of the following documents:

....................................................................................... dated ............................................ (Certificate) (Date)

I have received, read and understood the instructions for use:

.................................................. (Place and date)

.................................................. (Signature of entrepreneur)

................................................................... (Signature of operator/mechanic)

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