OPERATING INSTR U CTION

UCTION

CERTIFIED
 MAI® INTERNATIONAL
GmbH

LIST OF CONTENTS
List of contents .................................................................................................................................................... 2
Foreword............................................................................................................................................................ 3
User-friendly ....................................................................................................................................................... 3
Operating instructions ......................................................................................................................................... 3
Potential hazards................................................................................................................................................. 3
Warranty and liability........................................................................................................................................... 4
Prescribed use of the machine .............................................................................................................................. 4
Improper use ...................................................................................................................................................... 4
Personal safety.................................................................................................................................................... 4
Safety devices ..................................................................................................................................................... 5
General safety instructions ................................................................................................................................... 5
Copyright ........................................................................................................................................................... 5
General ............................................................................................................................................................. 6
Training the operating personnel .......................................................................................................................... 6
Training record ................................................................................................................................................... 7
Safety instructions for manual operation ................................................................................................................ 7
Hazards of electricity ........................................................................................................................................... 7
General safety regulations ................................................................................................................................... 8
Machine views .................................................................................................................................................... 9
Operating panel and indicators.......................................................................................................................... 10
Plug-in connections ........................................................................................................................................... 10
Main dimensions............................................................................................................................................... 11
Technical data .................................................................................................................................................. 11
Technical Descripton ......................................................................................................................................... 12
Filter parts ........................................................................................................................................................ 13
Initial settings .................................................................................................................................................... 13
Transport weight & dimensions ........................................................................................................................... 14
Controls ........................................................................................................................................................... 15
Directions before start-up................................................................................................................................... 15
Connections before start-up ............................................................................................................................... 16
Start-up ............................................................................................................................................................ 16
Start-up for manual operation ............................................................................................................................ 19
Start-up with remote control ............................................................................................................................... 19
Interruptions and downtime................................................................................................................................ 20
Termination of work and cleaning ...................................................................................................................... 20
Machine maintenance ....................................................................................................................................... 21
Procedure in the event of frost ............................................................................................................................ 21
Transport.......................................................................................................................................................... 22
Checklist for remedying faults............................................................................................................................. 23
Main and control system circuit .......................................................................................................................... 24
Replacement parts m400NT Grout pump assembly.............................................................................................. 25

© Copyright 2004 V10/08/04 Page 2


FOREWORD
Dear MAI customer!
We wish to congratulate you on your purchase of the
MAI m400NT mortar mixing pump. The MAI pump
m400NT is a fully automatic mortar mixing pump for
continuous processing of all kinds of machine-
processable anchor mortar and building site cement.
The pump is driven by one motor only. A rubber screw
in the mixer transports the dry anchor mortar to the
mixing chamber where it is continually mixed with wa-
ter.
The water can either be supplied direct if the pressure
is high enough or an optional water pump can be
fitted, if required.
Once the material is thoroughly mixed, the entire
amount is then drawn in and pumped away by the
clampless, maintenance-free screw pump.
The most important features of the MAI pump m400NT
are the high quality of the components used, the user-
friendly layout of the controls and the rugged design
which proves its worth, day in and day out on demand-
ing building site applications.
User-friendly
o Simple to service and dismantle thanks to the
modular design.
o Clearly structured operating elements.
o Economical.
o The patented MAI mixing and pumping technology
guarantees continuous blending of dry material,
uniform mixing ratio, constant mixing quality and
therefore adequate processing.
© Copyright 2004 V10/08/04
MAI® INTERNATIONAL
GmbH
OPERATING INSTRUCTIONS
These operating instructions contain the most impor-
tant directions for a safe operation of the machine. The
manual should therefore always be kept in the tool box
so that it is at hand when required.
Please read the operating instructions carefully before
starting the machine to familiarize yourself with its han-
dling and trouble-free operation of the machine.
A working knowledge of the basic safety regulations
and instructions is the prerequisite for safe handling
and trouble-free operation of the machine.
Every single person working with the machine must not
only observe the operating instructions and the safety
regulations in particular, but also the applicable rules
and regulations governing accident prevention at the
location.
POTENTIAL HAZARDS
The MAI pump m400NT is built to the state of the art
and in accordance with recognized safety regulations.
If not used properly, the machine can
! however constitute a danger to life
and limb for the operator or third
parties, or adversely affect the ma-
DANGER chine or other material resources
The machine may only be operated for the prescribed
use and if it is in perfect condition conforming to the
safety regulations. Faults that could affect safety must
be remedied immediately.
Page 3

WARRANTY AND LIABILITY
Our General Terms and
Conditions of Sale apply to
warranty and liability. The
purchaser will have received a
copy on conclusion of the
contract at the latest.
Warranty and liability claims in
the event of personal injury or
material damage shall be
excluded if they are caused by
one or more of the following reasons:
Operation of the machine for any other than the pre-
scribed use:
o Improper assembly, start-up, operation and main-
tenance of the machine.
o Operation of the machine with defective safety
devices or incorrectly fitted or non-functioning
safety and protective devices.
o Non-observance of the directions in the operating
instructions regarding transport, storage assembly,
start-up, running, maintenance and set up of the
machine.
o Unauthorized alterations to the motor (e. g. power
or speed), mixing shaft, rubber screw, mixing
chamber, controls etc.
o Inadequate monitoring of machine parts that are
subject to wear and tear (e. g. mixing shaft, rubber
screw or worm pump).
o Unauthorized structural changes to the machine.
o Improperly carried out repairs.
o Unforeseen disasters as a result of external influ-
ence or force major.
Please note that the manufacturer s warranty shall
expire if your machine is not operated and serviced in
accordance with these operating instructions.
© Copyright 2004 V10/08/04
MAI® INTERNATIONAL
GmbH
MAI® International GmbH shall cancel all obligations
entered into by MAI International GmbH and/ or its
dealers, such as guarantees, service agreements etc.,
without notice if any other than original MAI Pump or
MAI® International spare parts are used for operation,
maintenance or repairs.
PRESCRIBED USE OF THE MA-
CHINE
The prescribed use of the MAI pump m400NT is for
mixing and pumping commercially pre-mixed, machine
processable dry mortar such as cement or anchor mor-
tar with a max. grain size of 4 mm.
Please note that the MAI pump m400NT can only
function properly if the mortar or cement used is in-
deed machine-processable material (e. g. verified with
a manufacturer s certificate).
IMPROPER USE
Any uses for the MAI pump m400NT, other than those
prescribed above are prohibited. The MAI pump
m400NT is not intended for mixing non-machine proc-
essable dry mortar or other materials, such as inflam-
mable or potentially explosive substances or from
asbestos existing materials used in the chemical indus-
try.
In the event of improper use, the operator runs the risk
of jeopardizing life and limb, damaging the machine
and other property, having an unforeseeable impact
on the environment, and impairing efficient operation
of the machine.
PERSONAL SAFETY
The machine purchaser must provide the necessary
personal safety equipment.
All the existing safety devices on the machine must be
inspected at regular intervals and checked to ensure
that they are functioning properly.
Page 4

SAFETY DEVICES
Before starting the machine, ensure that all the safety
devices are fitted correctly and functioning properly.
Safety devices may only be removed:
o after a standstill and
o if the machine is prevented from being re-
started (e.g. padlock on master switch).
When components are replaced, the purchaser must
ensure that the safety devices are fitted again properly.
GENERAL SAFETY INSTRUC-
TIONS
The operating instructions must always be kept on the
machine.
In addition to the operating instructions, the general
and local regulations on accident prevention and envi-
ronmental protection must be made available to the
operator and observed.
All safety regulations and warnings on the machine
must be legible and replaced as required.
© Copyright 2004 V10/08/04
MAI® INTERNATIONAL
GmbH
COPYRIGHT
All parts of this documentation are subject to copyright
(© ).
Photocopying or circulating the documentation, in part
or in whole, is prohibited.
No part of this documentation may be reproduced,
stored in a retrieval system, transmitted or translated in
any form or by any means without the prior written
permission of MAI® International GmbH.
Copies of individual parts may be made and passed
onto third parties if they are required for locating faults.
© Copyright 2004, MAI® International GmbH. All
rights reserved.
MAI® International GmbH
Werkstrasse 17
A-9710 Feistritz/Drau
Company Register No. 191388d
Klagenfurt Provincial Court
We reserve the right to alter any technical details of the
machine compared with the specifications and illustra-
tions in the present manual.
No claims against the manufacturer, especially regard-
ing design and structure of the machine may be de-
rived from statements made in the operating instruc-
tions.
MAI® und MAI-PUMP® are registered trademarks of
MAI® International GmbH.
Page 5

GENERAL
In the operating instructions we have listed the most
important directions for correct operation and mainte-
nance of the MAI m400NT mortar mixing pump.
The prerequisite for the use of the machine is a thor-
ough knowledge of the technical documentation and
observation of the instructions and directions, espe-
cially the safety regulations.
The operating, safety and work instructions are bind-
ing. The special symbols illustrated below indicate
important instructions which affect machine and per-
sonal safety:
DANGER: This symbol means immi-
! nent danger to the life and health of
people.
DANGER
Non-observance of these directions will cause serious
damage to health and even lethal injuries.
WARNING: this symbol means a
potential risk to the life and health of
! people.
WARNING
Non-observance of these directions can cause serious
damage to health and even lethal injuries.
CAUTION: this symbol means a
! potentially dangerous situation.
CAUTION
Non-observance of these directions can cause slight
injury or damage to property.
IMPORTANT: this symbol indicates
important information for correct
handling of the machine.
© Copyright 2004 V10/08/04
MAI® INTERNATIONAL
GmbH
Non-observance of these directions can cause faults
on the machine or in the work environment.
NOTE: indicates directions for pre-
venting faults or tips for economical
use of the machine.
NOTE
In addition, the manual contains useful information to
help you to make the most of your machine.
TRAINING THE OPERATING PER-
SONNEL
1. The qualification required by the machine operator
are physical and mental aptitude, a sense of re-
sponsibility and reliability in carrying out the tasks
assigned, proof of the necessary skills and a decla-
ration to the company that training regarding op-
eration, maintenance and repair of the machine
has been received. The minimum age for machine
operators is 18 years.
2. In accordance with use as prescribed, the machine
may only be started if the manufacturer s operating
instructions are observed.
3. Only trained and instructed personnel may work
with the machine. The responsibilities for set-up,
operation and maintenance must be clearly de-
fined.
4. Trainee personnel may only work on the machine
under the supervision of an experienced person.
5. The machine controls may only be operated by
trained personnel.
6. Training on the machine must, without exception,
be confirmed in writing.
Page 6
 MAI® INTERNATIONAL
GmbH

TRAINING RECORD HAZARDS OF ELECTRICITY

PERSON 1. Work on the electrical supply may only be carried
out by authorized electricians. Inspect the ma-
Person Person Elec- Superior chine s electrical system regularly. Obvious de-
trained with trician with fects, such as loose connections, singed cables
techni- technical etc. must be rectified immediately.
ACTIVITY
cal compe-
qualifi- tence Repairs to the electrical system, es-

Start-up
cations
! pecially installation, connection and
opening of control cabinets which
are fed by the power supply system,
DANGER may only be carried out by author-
Operation ized personnel.

Trouble- 2. In accordance with use as prescribed, the machine

shooting may only be started if the manufacturer s operating
instructions are observed.
Remedying
mechanical 3. All safety instruction labels and warnings, and all
faults devices attached to the machine for safety and ac-
cident prevention must always be legible, and may
Remedying not be altered or removed.
electrical
faults 4. Check that the machine is safe for operation be-
fore every start-up. If any faults occur, proceed as
Maintenance follows:

Repair Minor faults that do not affect safety:

Shut down the machine at once, remedy the fault and

SAFETY INSTRUCTIONS FOR notify the supervisor if necessary.
MANUAL OPERATION Faults that affect safety:
The machine may only be operated if all the safety
devices are functioning properly. Stop operation of the machine immediately, notify the
supervisor and have the faults rectified by authorized
Before switching on the machine, ensure that nobody is personnel.
at risk when it starts.

Inspect the machine for visible damage and check that

the safety devices are in proper service condition at
least once a day.

© Copyright 2004 V10/08/04 Page 7

 MAI® INTERNATIONAL
GmbH

6. Before cleaning the machine with water, close all

GENERAL SAFETY REGULATIONS openings where water penetrating could have a
detrimental effect on function or safety (electric
1. Any alterations, additions and conversions to the motors, control cabinet and plug-in connectors).
machine require prior written permission from the After cleaning, remove the caps and covers again.
manufacturer. Failing this, any warranty and liabil-
ity claims shall expire. We also wish to point out The MAI m400NT mortar mixing
that only original MAI spare parts may be used in
the machine. ! pump conforms to Protection Class
IP44 in accordance with DIN 40050
and may not be cleaned with water
2. The machine may DANGER jets.
only be operated by
qualified, reliable 7. If work has to be carried out on live parts, a sec-
personnel selected ond person must be at hand to break the circuit in
by the company, case of an emergency.
trained in and
familiar with the 8. Disconnect the power supply before changing the
operation, mainte- location of the machine. Check that it is connected
nance and working to the mains again correctly before starting opera-
of the machine. tion again.

3. Trainee personnel 9. The machine must be connected to a proper

may only be power source, e.g. construction site distribution
instructed in the board with r.c.c.b. (rated fault current I=30mA)
handling of the
machine by an 10. Set up the machine horizontally with safety lights in
already qualified, place and safeguarded against accidental move-
experienced ment.
operator.
11. Ensure that the mortar hoses are laid without kinks
4. Follow the operating and not rubbing on any sharp edges to prevent
instructions with them from being damaged. Where there is a
regard to indicators change of direction, the bending radius must not
and procedures for be less than six times the outside hose diameter.
switching on and off
the machine. Screw pumps are high pressure
pumps only use steel-reinforced
5. The machine must be prevented from accidental ! hoses.
restarting during any maintenance and repair
WARNING
work. To do this, immobilize the master switch with
a padlock. You can also apply a warning sign to
the master switch.

© Copyright 2004 V10/08/04 Page 8

 MAI® INTERNATIONAL
GmbH
20. When you fill the dry mortar in the hopper it can
12. Before starting the machine, ensure that machine-
come to strong dust formation. It can be necesaary
processable, easily workable mortar is being used,
to wear a protective mask.
the hose is not leaking anywhere, especially at the
unions, and the inside of the hose has been suffi-
21. The machine may not do in the environment with
ciently lubricated.
danger of explosion which by types of dust, steams
or gases can develop are used.

13. Before undoing the unions and the pump outlet

MACHINE VIEWS
flange, ensure that they are depressurized by start
the main motor in REVERSE direction. To prevent
eye injuries protective goggles is to be used.

14. Wear protective goggles when removing obstruc-

tions. The person carrying out the task must be in
a position where he cannot be hit by any material
that may be discharged. Other people must be
kept out of the immediate vicinity.

15. The machine must be inspected by a qualified

person at least once a year.

16. The control cabinet may only be opened if the

machine is disconnected from the power supply.

1. Safety screen with bag opener

2. Water system
3. Control cabinet
17. The safety screen must not be removed while the 4. Water injection unit
machine is in operation. 5. Mixing chamber
6. Worm pump
7. Pump outlet
Disconnect the machine from the 8. PU lining tube
9. Vibrator
power supply before removing the
! screen or carrying out any cleaning
10.
11.
12.
Water pump
Main motor
Charge hopper
and repair work
WARNING

18. The cover on the flange of the mixer motor and the
flange of the pump outlet must not be opened
while the machine is in operation.

19. The mixer motor must not be switched on when it

is tilted.

© Copyright 2004 V10/08/04 Page 9

 MAI® INTERNATIONAL
GmbH
Mode switch:
REMOTE C HAND INJECTIO N
OPERATING PANEL AND INDICA- Manual operation (setting HAND ) is the nor-
TORS mal operation mode of the machine.
Red button When on REMO TE C the machine can be
STOPS or shuts-off the machine when running operated with the remote control.
or ready for operation When on INJECTION the machine can be
operated with the Mai Injection pressure switch

Mode switch vibrator: 0FF ON

Green button
STARTS the main motor in forward direction or
for establishing readiness for operation.
The vibrator, located on the mixing chamber of
the mortar mixing pump, prevents the dry mortar
from bridging.

Mode switch water pump (optional)

ON OFF-AUTO
Setting ON the Water pump is continuous
Yellow button running
Starts the main motor in REVERSE direction for Setting AUTO water pump running with main
depressurizing the hoses before opening the motor
quick-change-coupling (when needed).

Hour meter
Red indicator or fault display Indicates how long the main motor has been
When illuminated, indicates a FAULT caused running.
by motor overload.

White button Water injection PLUG-IN CONNECTIONS

Water can be injected into the mixing chamber
by pressing the white button.
When illuminated, indicates that enough water
pressure is available.

Main switch EMERGENY OFF

System power O N-OFF, lockable with safety
disconnection and short circuit function.

1... Socket for remote control or injection pressure switch

2... Socket for main motor 400V 5x16A 200V 4x32A
3... Main power plug ~3x400V/50Hz/32A/5-poles
Main power plug ~3x200-220V/50-60Hz/32A/5-poles

© Copyright 2004 V10/08/04 Page 10

 MAI® INTERNATIONAL
GmbH

MAIN DIMENSIONS TECHNICAL DATA

Model Mortar mixing and m400NT
injection pump

Drive Mixer motor ~3x400V/50Hz/

6.0kW 12,1A

~3x220V/60Hz/
6.0kW 23A

Connection Electricity ~3x400V/50Hz

~3x220V/60Hz

Protection Board distribution with min. 3x32A

r.c.c.b. only

Cable diameter Power supply min. 4x4 mm²

Nominal power Overall system 6,2 kW

A... ca. 173 cm B... ca. 96 cm
C... ca. 57 cm D... ca. 12 cm Ext. power unit Minimum size 16 kVA

Water connection Hose min.3/ 4 at least 2,5 bar

(dynamic)

O perating pres- If the hose is chocked, approx. 40 bar*1

sure*1 the pressure can rise to
100 bar).*1

O perating dis- with hose NW 25 approx. 40-60 m*2

tance*1
with hose NW 35 max. 200*3

Mortar hose All the figures quoted Steel reinforced hose

here refer to MAI prod- NW 25 and NW 35.
ucts and MAI hoses only. Burst pressure = 160
bar *4

Water pump*5 No self priming pump ~3x400V/50Hz/

0,53kW/1,7A
A... ca. 173 cm B... ca. 96 cm
~3x220V/60Hz/
C... ca. 57 cm D... ca. 12 cm
0,53kW/3A

1. In addition to other factors, the operating pressure and pumping distance

depends on the mortar speed, material quality, consistency, maximum grain

and the nominal width of the pump outlet.

2. Prerequisite for reaching the listed figures is the use of machine processable

dry materials.

3. These figures can only be reached in exceptional cases with special materi-

als.

4. Only use steel-reinforced hoses.

5. The water pump is not included in the standard scope of delivery (i. e.

available as an optional extra).

A... ca. 173 cm B... ca. 92 cm
C... ca. 57 cm D... ca. 9 cm

© Copyright 2004 V10/08/04 Page 11


TECHNICAL DESCRIPTON
The compact MAI m400NT mortar mixing pump uses
patented, proven MAI mixing and conveying technol-
ogy to process various types of machine-processable
anchor mortar and cement.
Function
Only one main motor is required to mix the material in
one pass and to pump the quantity which is required
without any problems.
The volume to be mixed and pumped can be varied by
using different types of worm pumps.
For particularly large volumes the MAI pump m400NT
can also be fitted with the MP 12 conversion kit.
The MAI pump m400NT is successfully in use all over
the world in tunneling, engineering and mining ap-
plications, and for securing pits and slopes. The proven
mixing and pumping technology is especially suitable
for:
o injection work
o grouting
o filling in bore holes
o backfillings
© Copyright 2004 V10/08/04
MAI® INTERNATIONAL
GmbH
Thanks to careful component selection and combina-
tion, the MAI system provides optimum problem solu-
tions:
MAI Pump, MAI anchor mortar and MAI injection hol-
low core anchors guarantee unique product and appli-
cation advantages.
All MAI International GmbH products feature diverse
application options and MAI s renowned quality, mak-
ing the MAI pump m400NT cost-effective to purchase
and economical to use.
Long service life, minimal susceptibility to faults, low
maintenance and running costs keep your expenses
down and ensure that you benefit from these efficient,
economical solutions.
Pumping volume, distance, pressure
and wear depend on the material
(type, consistency, grain and grading
curve) and worm pump used.
NOTE
Page 12
 MAI® INTERNATIONAL
GmbH

FILTER PARTS

Pressure reducing valve water system

Filter for mud
Setting range: 1 2 bar
Max. water flow at 1 bar approx. 800 l/h
INITIAL SETTINGS Max. water flow at 2 bar approx.1300 l/h

Pressure sensor water system Thermal relay main motor

Automatic adaptation to the setting of pressure reducing valve Relay setting 400V 6kW: 12,1 A
Relay setting 220V 6kW: 23 A

© Copyright 2004 V10/08/04 Page 13

 MAI® INTERNATIONAL
GmbH

TRANSPORT WEIGHT & DIMEN-

SIONS Pump unit

D... approx. 500 mm

E... approx. 320 mm
A... approx. 1040 mm
Weight of components approx. 27 kg
B... approx. 570 mm
C... approx. 955 mm
Weight of components approx. 120 kg

Drive unit

F... approx. 600 mm

G... approx. 200 mm
Weight of components approx. 55 kg
A... approx. 1040 mm
B... approx. 570 mm
C... approx. 955 mm
Weight of components approx. 130 kg Safety screen with bag opener

H... approx. 660 mm

I... approx. 575 mm
Weight of components approx. 5 kg

A... approx. 1040 mm

Weight of m400NT approx. 213 kg
B... approx. 570 mm
C... approx. 920 mm
Weight of components approx. 125 kg

© Copyright 2004 V10/08/04 Page 14

 MAI® INTERNATIONAL
GmbH

CONTROLS

Check that all the cables and safety devices are func-
tioning correctly.

1... Plug for remote control

2... Vibrator switch
3... Switch for Remote Control Hand Injection
4... Hour meter
5... Phase reversal plug for power supply
6... Plug for main motor Ensure that the machine is horizontal and standing
7... Fault indicator safely.
8... Switch for water pump ON OFF AUTO
(Optional)
9... Main switch
10... Button and indicator for water injection
11... START button
12... STOP button
13... REVERSE button

DIRECTIONS BEFORE START-UP

Check that all the components have been mounted
properly.

To guarantee trouble-free start-up, ensure that all the

components have been cleaned properly and are in
perfect condition. Check that the machine is horizontal
and stable so that it cannot slip if moved accidentally.

© Copyright 2004 V10/08/04 Page 15

 MAI® INTERNATIONAL
GmbH

CONNECTIONS BEFORE START-

UP
Connect the main power plug on the control cabinet
with the cable to the construction site distribution
board.

Plug the drive motor into the socket on the control

cabinet.

Connect the water supply hose (use a minimum diame-

ter of ¾ ) to the coupling in the water system.

Switch on the machine by turning the master switch to

START-UP
Close all the water supply and drain valves.
Connect the water supply hose (minimum diameter ¾
for 4 bar min. dynamic water pressure). Slowly open
the water supply cock.
position I .
The machine may only be connected
! to a construction site distribution
board fitted with a residual current-
operated circuit breaker. Electrical
DANGER protection: 3x25 A distribution board,
rated fault current I=30mA

Connect the ~ 3X400V/ 50Hz ~ 3X220V/ 60Hz power

supply with the electricity cable (use only 5x4 mm²
H07RN cable).

Press the white WATER INJECTION button and set

the required water volume by turning the knob on the
needle valve.

The water pressure must be at least approximately 2,5

bar when the valve is open (dynamic). If this is not the
case, the machine cannot be started or stops auto-
matically if already in operation.
Set the mode switch REMOTE C HAND - INJEC-
TION to the HAND position. (All controls, such as
switches, indicators, alarms and buttons are illustrated
on page 11 and 16).

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 MAI® INTERNATIONAL
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Turn the mode switch REMOTE-HAND-INJECTION
to position HAND . The vibrator switch must be set on
ON to prevent the dry material from bridging at the
bottom of the material hopper.

Undo the eccentric clamp on the mixing chamber.

Open the pump outlet by turning it to the side to drain
the water which was just sprayed into the mixing
chamber.
Place machine processable dry material in the hopper.

Close the pump outlet again and lock the eccentric

The safety screen must not be re-
clamp.
moved when the machine is running
! or ready for operation.

WARNING

Press the white WATER INJECTION button for

approx. 3 seconds to let a defined water volume into
the mixing chamber of the mortar mixing pump. This is
to prevent the eccentric worm pump from running dry
when the machine starts.
Start the machine by pressing the green START but-
ton. Let the mortar mixing pump run until water starts
to come out of the front of the pump outlet.

The mixer motor must not be opened

! or tilted when the machine is running

or ready for operation (as long as the
power supply is connected and/ or
DANGER the master switch is set to ON ).

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 MAI® INTERNATIONAL
GmbH

While the machine is running, open the slide gate,

Switch of the machine by pressing the red STOP
located above the motor, slowly and in stages until it
button.
locks into the guide rod notch.
To prevent chocking, we recommend wetting the inside
1.)
2.) walls of the hose with water or preferably lime or ce-
ment slurry.
3.)
During the wetting process with water
it is absolutely necessary that any
excess water is completely drained
from the hose otherwise grains could
be washed out when the machine is
started, especially in the case of
After 10 15 seconds the mortar consistency should coarse grain materials, such as an-
have adjusted to the value pre-set on the water flow chor mortar with 4 mm maximum
meter and be coming out of the coupling on the pump grain. This could cause the hose to
outlet pulsating slightly but uniformly. The consistency choke.
of the mortar can be adjusted to the required applica-
tion by changing the water flow rate. Lay the mortar hose so that it can be easily connected
before the machine is started.
If you are working with unknown
materials, experience has proved that
it is better to start with a relatively
fluid consistency and then slowly
NOTE reduce the water volume with the
machine running until the required
consistency is reached (unknown
materials: water flow meter setting:
approx. 600 litre/hour).
Connect the quick release coupling on the mortar hose
to the male union on the pump outlet.

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 MAI® INTERNATIONAL
GmbH

Start-up for manual operation Start-up with remote control

Proceed as described in the previous section Start- Proceed as described in the previous section Start-
up . up .

Make sure that the mode switch REMOTE C HAND Make sure that the mode switch REMOTE C HAND
- INJECTION is set to HAND . - INJECTION is set to REMOTE C .

Start the machine by pressing the green START but- Press the green START button. The machine is now
ton. ready for operation with the remote control

Start the machine by turning the switch on the remote

To switch off the machine at any time, press the control.(Switch shines green)
STOP button.
You can stop the machine at any time by turning the
green switch on the remote control.

© Copyright 2004 V10/08/04 Page 19

 MAI® INTERNATIONAL
GmbH

During the operation of the machine

with the remote control not instructed TERMINATION OF WORK AND
! persons in the direct danger area of
CLEANING
the machine may not be!
WARNING After work is completed or in the event of longer inter-
ruptions, run the machine until the material hopper is
empty and then clean it thoroughly.
INTERRUPTIONS AND DOWN-
TIME
Interruptions at work that last longer than 30 minutes
should be avoided at all costs because this material in
the mortar hose and injector can start to harden and
even set under certain circumstances.

Starting the machine in this case would cause a break-

down and a considerable amount of cleaning.

For material hardening and setting times, see the in-
structions and guidelines issued by the manufacturer.
Every time the injection procedure is interrupted, there
will be slight variations in the consistency after the
machine is started again.
Depressurize the mortar hose before uncoupling them
(press the yellow REVERSE button). Check the pres-
sure on the pressure gauge on the pump outlet to
ensure that they are no longer under pressure.

These variations are caused by material setting in the

hose, but are no cause for concern. They usually only
last until the hardened material in the hose passes
through the nozzle.

At this stage the pressure in the hose may rise consid-

erably. If slight fluctuations in the consistency occur After disconnecting the mortar hoses, leave the ma-
after work is restarted again, there is no need to alter chine running until water comes out of the material
the water setting right away. discharge opening on the pump outlet.

If interruptions or downtimes last longer, clean the Ensure that the machine does not run
machine thoroughly, following the instructions in the dry during this process.
section Termination of work and cleaning described
below.

When only water comes out of the worm pump, the

machine can be turned of by pressing the red STOP
button.

Place the hose cleaning ball in the mortar hose and

pump water through at least twice.

© Copyright 2004 V10/08/04 Page 20


Stop the machine by pressing the red STOP button
on the control cabinet, and turn the main switch to 0
to prevent the system from being started accidentally.
Undo the eccentric clamp on the mixing chamber so
you can move the motor and pump parts away to the
side.
Remove the pump part from the machine and disman-
tle it into its main components of pump flange, pump
outlet, rotor, stator and pump cleaner.
Remove the mixer and the safety screen from the ma-
chine. Clean all soiled parts carefully with water.
Danger of jamming fingers when
! tilting (opening) and closing the mo-
tor flange.
CAUTION
The MAI pump m400NT complies
! with the provisions of Protection
Class IP44 in accordance with DIN
40050 and must therefore not be
DANGER cleaned with water jets.
If the machine is not required for a
longer period, dismantle the rotor
and stator from the eccentric worm
pump and lubricate them with MAI
silicone grease or MAI silicone spray.
Reassemble the components and
replace the machine.
© Copyright 2004 V10/08/04
MAI® INTERNATIONAL
GmbH
MACHINE MAINTENANCE
Ensure that the motor housing surface and fan cowl
guards are always kept clean so that dust and dirt do
not impair the motor output.
If the motor has become wet, dry it before starting and
have the insulation checked by a technician.
Change the lubrication on the main drive motor gears
after six months.
Mixer motor: grease, Shell S 420 F
Regularly check that the wearing parts, such as PU-
screw, mixer and worm pump, are in good condition
and dimensionally true, as the function of the machine,
the actual delivery rate and the attainable maximum
pressure all depend on the condition of these compo-
nents.
Carry out the following maintenance work daily:
o lubricate all threads and keep them clean
o spray pump lubricant on rotor and stator
The mechanical and electrical condition of the ma-
chine must be inspected by qualified personnel at least
once a year.
PROCEDURE IN THE EVENT OF
FROST
If frost is expected always clean the entire machine first
and then follow the procedures described below.
Disconnect the water supply and remove the mixer
from the mixing chamber in the mortar mixing pump.
Disconnect the water supply from the water system.
Open the water drainage valve and drain cocks on the
machine.
Connect the power supply and turn the main switch to
pos. 1 .
Page 21

Press the water injection button until all water has run
out of the valves and fittings.
We recommend purging the water
system with compressed air.
Turn the main switch to pos. 0 and unplug the elec-
tricity cable.
Drain any residual water from the mortar hoses and all
other components.
Assemble the machine again.
Drain any residual water from the water supply hose.
Water freezing in the measuring pipe
could destroy it.
The machine is now completely drained except from a
small amount of water in the eccentric pump. When
you turn on the machine the next time, start it carefully
as there may be some ice left which will mix with the
mortar. This problem only occurs however if the ma-
chine is subject to very low temperature for a longer
period.
© Copyright 2004 V10/08/04
MAI® INTERNATIONAL
GmbH
TRANSPORT
Observe the following whenever you move the ma-
chine.
Danger of toppling while loading
! and unloading the complete ma-
chine.
CAUTION
Transport checklist:
o disconnect all electrical connections
o lock the pump motor eccentric clamp
o Check that all parts and components are
mounted, screwed in or assembled properly and
that all the safety devices are in place
There are no lifting pins on the MAI
! pump m400NT for transporting by
crane. If it has to be lifted by crane,
ensure that it is placed in a suitable
CAUTION
container.
The machine must always be carried horizontally dur-
ing transport.
Page 22

CHECKLIST FOR REMEDYING FAULTS
FAULT: Machine will not start
Contactor defective or does not pick up prop-
erly.
Rotor is stuck in stator.
Water pressure sensor defective
Machine will not start although power and properly or removed or proximity switch defec-
water supplies are in order.
Water system filter soiled.
FAULT: mixing motor, vibrator or remote control
not functioning.
FAULT: mortar flow too thick or thin
FAULT: mortar only intermittent
FAULT: mixing motor overloaded
© Copyright 2004 V10/08/04
MAI® INTERNATIONAL
GmbH
Possible causes Fault remedy
Dirt in control cabinet; power cable too long or Have contactor replaced by a qualified electri-
cable diameter too small; stand-by generator cian; only use cable with diameter of at least
has not enough power. 5x4 mm².
Unsuitable material, not enough water, eccen- Dismantle pump, clean, lubricate, reassemble,
tric pump not lubricated. replace rotor and stator if necessary.
Water dirty. Replace water pressure sensor.
Fit safety screen with bag opener, check prox-
Safety screen with bag opener not mounted
imity switch for damage and replace, if neces-
sary; check that water pressure sensor is func-
tive; water pressure sensor defective
tioning (white light is illuminated sensor is ok)
and replace, if necessary.
Water dirty; water drawn from river or con- Clean or replace water supply filter and/ or
tainer. reversible flow filter screen.
Components not plugged in or circuit breaker Switch on circuit breaker in control cabinet.
tripped because overloaded. A connected Check each individual component for proper
component is defective (e.g. short circuit) function.
Unsuitable material; not enough water; mixer
Use machine-processable material; replace
worn out; pressure reducing valve not set prop-
mixer or motor coupling; clean mixing cham-
erly; soiled or defective stator and/ or rotor worn
ber; find cause and rectify fault.
or defective; pump outlet blocked.
Use machine-processable material; replace
Unsuitable material; poor mixing; mixer or
mixer or motor coupling; clean mixing cham-
motor coupling defective or worn.
ber; find cause and rectify fault.
Rectify fault, if possible. Machine can be re-
Hose too long; worm pump blocked; because started once the red FAULT indicator has
material to dry; defect moisture in motor coil. gone off. Check or replace mixing motor if
necessary.
Page 23
 MAI® INTERNATIONAL
GmbH

MAIN AND CONTROL SYSTEM CIRCUIT

L1
L2
L3 2 4 6

1,6A

1 3 5

1 3 5 1 3 5 1 3 5 1 3 5

2 4 6 2 4 6 2 4 6 2 4 6

97 95 97 95

2 4 6 98 96 2 4 6 98 96 42V

T1
2 4 6
0V 0V
1 3 5

X0

MAI
INTERNATIONAL Ersteller Zeichnungs-Nr. Blatt 1
von 1

1 2

M400 Steuerstrom
2. Prototyp
1

© Copyright 2004 V10/08/04 Page 24

 MAI® INTERNATIONAL
GmbH

REPLACEMENT PARTS M400NT GROUT PUMP ASSEMBLY

Pos. P/N Description

1 9899152805 Safety screen w/ bag opener
1.01 not shown 9899153443 Screw M8
2 9899152728 Hopper
2.01 not shown 9899153223 Handle
2.02 not shown 9899152763 Proximity sensor with cable
3 9899100014 Gear motor 6.0kW, 400 V, 50 Hz -200 rpm
3 9899151840 Gear motor 6.0kW, 400 V, 60 Hz -200 rpm
3 9899150217 Gear motor 7.5 kW 200/220 V, 50/60 Hz
3 9899153364 Gear motor 6.0kW; 220/200V, 50/60Hz, 200/240rpm
4 9899153250 Motor coupling compl.
5 9899152796 Mounting flange
6 9899152774 Gasket
7 9899152662 MAI-Auger
8 9899100033 Universal mixer
9 9899153227 Gasket pump outlet large
9 9899153495 Gasket pump outlet medium
10 9899153224 Pump flange complete large
10 9899153490 Pump flange complete medium
11 9899100834 MAI-Stator MP 8 large orange
11 9899100832 MAI-Stator MP 8 Medium orange
11 9899100818 MAI-Stator MP 3 large silver
11 9899100816 MAI-Stator MP 3 medium silver
11 9899100570 MAI-Stator MP 4 large green
12 9899150550 MAI-Rotor MP 3 large single
12 9899100685 MAI-Rotor MP 3 medium single
12 9899150449 MAI-Rotor MP 4 large single

© Copyright 2004 V10/08/04 Page 25

 MAI® INTERNATIONAL
GmbH
12 9899153664 MAI-Rotor MP 8 large single
12 9899102553 MAI-Rotor MP 8 medium single
13 9899153228 Pump outlet complete large
13 9899153489 Pump outlet complet medium
14 9899152620 Vibrator 220 V/400 V with cable
15 9899153376 Attachment parts Japan complete
16 9899102960 Wheel 250x80
16 9899153313 Wheels set
17 9899153578 Attachment parts runner comp.
18 9899152783 El-control system 6KW, 440-460V, 50Hz/60Hz
18 9899153396 El control system 6KW, 200/220V, 50/60Hz
18 9899153658 El control system 6KW, 440-460V, 50Hz
19 9899153386 Cover plate digital water control system, front
19 9899153235 Cover plate flow meter water control system, front
20 9899153222 Cover plate, side
21 9899153221 Toolbox
22 9899100074 Water pump PK65, 400 V, 50 Hz
22 9899104295 Water pump PK 65, 220 V, 60 Hz
23 9899153220 Cover plate, top
24 9899152720 Digital water control system
24 9899153340 Flow meter water control system
25 not shown 9899101361 Mortar hose "Injection" NW25L=20 m stole PN60 SYS-M

© Copyright 2004 V10/08/04 Page 26


Replacement parts
Pos. P/N
1 9899102826
1 9899102737
1.01 not shown 9899151549
1.02 not shown 9899100018
2 9899103555
2.01 not shown 9899151548
3 9899151287
3 9899151308
4 9899151306
4 9899150378
5 9899100020
5 9899151305
5.01 not shown 9899151286
6 9899100019
6 9899151304
7 9899100021
© Copyright 2004 V10/08/04
MAI® INTERNATIONAL
GmbH
Gear motor
Description
Gear set FG132, 20/61
Gear set G132, 23/58
Gear set 2. level FG132 200 min-¹, Z14/67
Gear set FG132
Gear set G132, 19/45
Gear set 1. level FG132 200 min-¹, Z23/41
Mounting flange
Mounting flange 7.5kW
Terminal box, for 7.5 kW motor
Terminal box, 6.0 kW motor
Fan for gear motor 2.2 - 3.3 kW, 6 kW
Fan 7.5 kW
Motor bearing for both sides
Fan cover for gear motor 2.2 - 3.3 kW, 6 kW
Fan cover for motor 7.5 kW
Air seal for gear FG132
Page 27
 MAI® INTERNATIONAL
GmbH
Replacement parts Motor flange

Pos. P/N Description

1 9899152796 Mounting flange
2 9899152798 Friction bearing
3 9899152774 Gasket
4 9899152650 Eccentric tentioner w/o base plate

© Copyright 2004 V10/08/04 Page 28

 MAI® INTERNATIONAL
GmbH
Replacement parts Mixer

Pos. P/N Description

1 9899152752 Mixing tube liner
2 9899152784 Mixing-tube
3 9899152792 Nozzle plate comp.
4 9899152771 Nozzles
5 9899152764 Nozzle housing
6 9899153545 End plate w/ 1/2" nipple
7 9899100247 Nipple 1/2"
7 9899101213 Elbow 1/2"
8 9899153304 Hopper liner
9 9899152794 Auger housing
10 9899152790 Slide rod
11 9899152717 Gate
11.01 not shown 9899153674 Gate wiper brush

© Copyright 2004 V10/08/04 Page 29

 MAI® INTERNATIONAL
GmbH
Replacement parts Pump flange assy.

Pos. P/N Description

1 9899153227
1 9899153495
2 9899152650
3 9899153225
3 9899153491
4 9899103191
5 9899153408
6 9899153335
7 9899153348
8 9899103190
9 9899152798
Gasket pump outlet large
Gasket pump outlet medium
Eccentric tentioner w/o base plate
Pump flange large
Pump flange medium
Set screw M16x120 galvanized
Hex flange nut M16
Washer HV M16
Hex nut M16
Pin for cocking screw
Friction bearing

© Copyright 2004 V10/08/04 Page 30

 MAI® INTERNATIONAL
GmbH
Replacement parts Pump outlet assy.

Pos. P/N Description

1 9899103159 Guard
2 9899100275 Gauge 100 bar
3 9899101411 Reducer 1/2"- 1/4"
4 9899100254 Washer M20
5 9899153233 Flanged adaptor
6 9899102820 Diaphragm ø35
7 9899153229 Pump outlet large
7 9899153492 Pump outlet medium
8 9899153516 MAI-Quick coupling 1½"
8 9899151097 Kamlok coupling
8 9899100231 MAI-Quick coupling NW35 1½"
9 9899153640 Pump outlet medium (Japan)

© Copyright 2004 V10/08/04 Page 31

 MAI® INTERNATIONAL
GmbH

Replacement parts Flow meter water system

Pos. P/N Description

1 9899100252 Gauge 6 bar
2 9899153606 Flow meter
3 9899153810 Solenoid valve 1/2"
3.01 not shown 9899153761 Solenoid valve w/ cable 1/2"
4 9899100391 Water valve 3/4"
4.01 not shown 9899100269 Knob for valve 1/2"
5 9899151124 Drain cock 3/8"
6 9899100134 Claw coupling 3/4"
7 9899151000 Filter 3/4" brass
7.01 not shown 9899151300 Filter mesh insert
8 9899153645 Proximity switch
8.01 not shown 9899153760 Proximity switch w/ cable
9 9899152787 Pressure reducing valve 1/2" w/ proximity switch
9.01 not shown 9899151206 Sealing ø18.5 - ø23.5 x 2 mm
9.02 not shown 9899151069 Plastic cap 1/4"
9.03 not shown 9899102746 O-ring
10 9899103122 Nipple 3/4"
11 9899153824 Rubber hose 3/4" black
12 9899100223 Claw coupling 3/4"
12.01 not shown 9899103122 Nipple 3/4"
13 9899102915 Flow meter spacer
14 9899100389 Flow meter flange
15 9899150883 Sealing for water flow meter ø28x3.5
16 9899153607 Measuring tube
17 9899153600 Rotameter

© Copyright 2004 V10/08/04 Page 32

 MAI® INTERNATIONAL
GmbH

Replacement parts Digital water system

Pos. P/N Description

1 9899100252 Gauge 6 bar
2 9899153610 Water flowmeter 1/2"
3 9899153810 Solenoid valve 1/2"
3.01 not shown 9899153761 Solenoid valve w/ cable 1/2"
4 9899100391 Water valve 3/4"
4.01 not shown 9899100269 Knob for valve 1/2"
5 9899151124 Drain cock 3/8"
6 9899100134 Claw coupling 3/4"
7 9899151000 Filter 3/4" brass
7.01 not shown 9899151300 Filter mesh insert
8 9899153645 Proximity switch
9 9899152787 Pressure reducing valve 1/2" w/ proximity switch
9.01 not shown 9899102746 O-ring
9.02 not shown 9899151069 Plastic cap 1/4"
9.03 not shown 9899151206 Sealing ø18.5 - ø23.5 x 2 mm
10 9899103122 Nipple 3/4"
11 9899153824 Rubber hose 3/4" black
12 9899100223 Claw coupling 3/4"
12.01 not shown 9899103122 Nipple 3/4"

© Copyright 2004 V10/08/04 Page 33

 MAI® INTERNATIONAL
GmbH

Replacement parts Fixed water connection

Pos. P/N Description

1 9899101489 Ball valve 1/2"
2 9899151302 Handle for ball valve
3 9899100181 Claw 1/2"
4 9899153517 MAI-Quick coupling 1/2"

© Copyright 2004 V10/08/04 Page 34

 MAI® INTERNATIONAL
GmbH

Replacement parts El cabnette

Pos. P/N Description

1 9899151066 Connector angular 32A 5 poles 400V
2 9899100025 Socket 16 A 5poles 400V
2.01 not shown 9899101188 Socket 32A 4pole 400V
3 9899151728 Indicator light lens assembly M22-L-R red
4 9899151594 Selector switch 3 Stellungen M22-WRK3
5 9899150961 Main switch P1-32/EA/SVB 32A
5.01 not shown 9899153262 Main switch P3-63/EA/SVB 6-7,5kW Japan
6 9899151593 Protection cap M22-T-D
6 9899152051 Illuminated pressure switch white M22-DL-W
7 9899151593 Protection cap M22-T-D
7 9899152293 Illuminated push button M22-DL-G
8 9899151593 Protection cap M22-T-D
8 9899151591 Push button red M22-D-R
9 9899151593 Protection cap M22-T-D
9 9899151592 Push button yellow M22-D-Y
10 9899151698 Selector switch M22-WRK
11 9899100472 Socket 16A 3 poles 50V
12 9899101572 Hour meter BA632,2 42V / 50 Hz
13 9899152756 Switch cabinet
14 9899152521 Cover for switch cabinet
15 9899154242 Lock for switch cabinet

© Copyright 2004 V10/08/04 Page 35


Replacement parts
Pos. P/N
1 9899150961
1.01 not shown 9899153262
2 9899152356
2 9899151597
3 9899151599
3 9899151597
4 9899101572
5 9899151598
5 9899151597
6 9899151597
6 9899151600
© Copyright 2004 V10/08/04
MAI® INTERNATIONAL
GmbH
El cabnette, front panel (back side)
Description
Main switch P1-32/EA/SVB 32A
Main switch P3-63/EA/SVB 6-7,5kW Japan
LED-Element red M22-LED-R 18-30V
Fixed adaptor M22-A
Contact element 1Ö M22-K01
Fixed adaptor M22-A
Hour meter BA632,2 42V / 50 Hz
Contact element 1S M22-K10
Fixed adaptor M22-A
Fixed adaptor M22-A
LED-Element green M22-LED-G 18-30 V
Page 36
 MAI® INTERNATIONAL
GmbH
Replacement parts El cabnette 400V

Pos. P/N Description

1 9899152756 Switch cabinet
2 9899150739 Auxiliary contactor 400V/50-60Hz
3 9899152759 Motor protection switch PKM0-16
4 9899104044 Motor protection relay PKZM 0-1,6, 1-1,6A
5 9899102126 Phase sequence relay RM4TG20
6 9899151762 Auxiliary contactor 42 V/50 Hz
7 9899151147 Clamp 4mm²
8 9899151739 Power Contactor Vanne LC1D18D7 7,5 kW 42V 50-60 Hz
8.01 not shown 9899152232 bond bridge for reverse contactor combination LAD-9R1
9 9899152377 Motor protection relay 9-13A LRD-16
10 9899100490 Transformer ET 0,1 400/ 42 V
11 9899102281 Control relay CA2KN31E7
12 9899152730 Motor protection relay 1,2-1,8A
13 9899152729 Reversing contact 42VAC, 9A

© Copyright 2004 V10/08/04 Page 37

 MAI® INTERNATIONAL
GmbH

Replacement parts El cabnette 220V

Pos. P/N Description

1 9899152756
2 9899153263
3 9899153255
4 9899104044
5 9899102126
6 9899151762
7 9899151147
8 9899151741
9 9899153257
10 9899101693
11 9899102281
12 9899153407
13 9899152729
Switch cabinet
Auxiliary contactor 220V/50-60Hz
Motor protection switch 32A
Motor protection relay PKZM 0-1,6, 1-1,6A
Phase sequence relay RM4TG20
Auxiliary contactor 42 V/50 Hz
Clamp 4mm²
Power Relay LC1D32D7 15 kW 42V 50-60 Hz
Motor protection relay 23-32A LRD-32
Transformer 42 V
Control relay CA2KN31E7
Motor protection relay 2,6-3,7A
Reversing contact 42VAC, 9A

© Copyright 2004 V10/08/04 Page 38


Replacement parts
Pos. P/N
1 9899100381
2 9899100368
3 9899152145
4 9899153542
5 9899100379
6 9899100377
7 9899100357
8 9899100914
8 9899100220
9 9899100383
© Copyright 2004 V10/08/04
MAI® INTERNATIONAL
GmbH
Accessories
Description
Brush round ø160mm
Hose blockage remover L=10m
Flat Spanner SW24 galvanized
Flat Spanner SW10x13 galvanized
Brush
Rubber ball NW25 ø30mm
Rubber sealing NW25
Cleaning hose 1/2" with 1 coupling
GEKA coupling 1/2" with nozzle
CEE coupling 32 A, 5poles 400V
Page 39

Replacement parts
Pos. P/N
1 9899150543
2 9899104008
3 9899150544
4 9899150545
5 9899150552
6 9899100185
7 9899101047
7 9899102549
7 9899102516
7 9899151388
8 9899101191
9 9899100373
10 9899100279
11 9899153861
11 9899150925
11 9899153860
11 9899153910
© Copyright 2004 V10/08/04
MAI® INTERNATIONAL
GmbH
Injection pressure switch
Description
Body pressure indicator NW25
Sleeve NW25 non-abrasive
Clamp for pressure indicator
Box nut 1 1/2"
Safety handle for pressure switch
Hex nut 1/2" brass SW28/S6
Contact gauge 0-16 bar
Contact gauge 0-25 bar
Contact gauge 0-40 bar
Contact gauge 0-60 bar
CEE-plug 16A, 2poles
MAI-Quick coupling NW25 1" IT "female"
MAI-Quick coupling NW25 1" "male"
MAI-Injection pressure switch 0 - 16 bar with 2 couplings
MAI-Injection pressure switch 0 - 25 bar with 2 couplings
MAI-Injection pressure switch 0 - 40 bar with 2 couplings
MAI-Injection pressure switch 0 - 60 bar with 2 couplings
Page 40