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UNI EN 29001
SO 9001
INSTRUCTIONS MANUAL
Planetary Mixer
type P 1250
MACHINE TYPE: PLANETARY MIXER TYPE P1250
SERIAL N°: 9510
YEAR: 2006
PROGRESSIVE INDEX
4) ELECTRICAL CONNECTIONS
4.1 - Electrical connections
4.2 - Control panel
4.3 - Junction box
4.4 - General system characteristics
4.5 - Electrical supply connections and earthing
7.1 - Mixer
7.1.1 - Loading phase
7.1.2 -- Mixing phase
7.1.3 -- Loading phase from conveyor belt
7.1.4 - Unloading phase
7.1.5 - Cleaning
7.2 - Skip
7.2.1 - Loading phase
7.2.2 - Ascent
7.2.3 - Unloading phase
7.2.4 - Descent
9) DISASSEMBLY INSTRUCTIONS
10 ) MAINTENANCE INSTRUCTIONS
10.1 - Maintenance of the planetary mixer
10.1.1 - Changing the lubricating oil
10.1.2 - Changing the hydraulic oil in the hydraulic system
10.1.3 - Greasing
10.1.4 - Verify bolt tightening
10.1.5 - Checking parts subject to wear
10.1.6 - Adjusting the mixing and scraper arms
10.1.7 - Adjusting the mixing arms
10.1.8 - Adjusting the scraper arms
10.1.9 - Replacing the oil seal and resetting the preloading on the planetary gear outlet shaft bearings
10.1.10 - Resetting the preloading on the reduction-gear outlet shaft bearings
10.1.11 - Fixing oil leaks between the fixed reduction-gear box and the cover of the rotating planetary gear
10.1.12 - Dismounting the mixing reduction-gear unit
10.1.13 - Reassembling the mixing reduction-gear unit
10.1.14 - Adjusting and resetting the seal on the discharge opening
10.2 - Maintenance of loading skip
10.2.1 - Changing the lubricating oil
10.2.2 - Cable lubrication
10.2.3 - When to replace the cable
10.2.4 - Checking the cable
10.2.5 - Typical causes for breakage of the cable strands
10.2.6 - Examples of cable deterioration
10.2.7 - Greasing
10.2.8 - Adjusting the descent limit switch on the spool shaft (if supplied)
10.2.8.1 - Adjusting the descent limit switch on skip rails (if supplied) (tav. SDM/09/128)
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11 ) TROUBLE-SHOOTING INSTRUCTIONS
11.1 - Faults or malfunctions that may occur
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PREFACE
The present document contains information about the equipment and procedures for proper
installation as well as information about its use, maintenance and repair.
The present MANUAL has been compiled in compliance with the provisions of MACHINERY
DIRECTIVE 89/392 CE and its amendments 91/368-93/44-93/68, with particular reference to Article
1.7.4 of Annex I.
In any case, it is important to emphasize that optimum operation of the machinery can be ensured only
through adequate experience gained by machine operators, together with specific knowledge of the
contents of this manual.
Any additional technical information that is not listed in this manual is part of the technical file that has
been drawn up by S.I.CO.MA: (Società Italiana Costruzione Macchine) and this file is available at
company headquarters.
The name of the manufacturer (Società Italiana Costruzione Macchine)) will be abbreviated as
S.I.CO.MA. throughout the manual.
As part of its ongoing effort to improve its products, the S.I.CO.MA. Company reserves the right to
modify the contents of this manual at any time and is not obliged to add any modifications and/or
updated information to previous instructions manuals for its machinery and/or installations.
The S.I.CO.MA. Company will assess how to advise its clients about any modifications as far as
installation SAFETY is concerned.
The S.I.CO.MA. Company welcomes any suggestions that its clients may have about improving its
machinery and will be happy to assess how to implement these proposals.
Never perform any operation or maneuver unless you are absolutely sure of what you are doing.
If necessary, contact the manufacturer or your area representative.
The S.I.CO.MA. Company considers itself relieved of all responsibility for any damage that the
machine causes to people or property, or to the machine itself, in the following situations:
1. Incorrect use of the machinery
2. Failure to observe the regulations currently in force
3. Incorrect installation
4. Failure to observe this Manual
5. Failure to observe the maintenance plan
6. Modifications that have not been authorized by S.I.CO.MA.
7. Installation of non-original spare parts on the equipment or individual machines
8. Installation and use of the equipment for any purposes other than the ones for which it has
been designed and sold.
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\\\\\\\\\\\\\\\
P1250
9510
2006
MANUFACTURE:
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Important:
The machine can be hoisted using a bridge crane, a mobile crane, a fork lift or any other suitable
means with a capacity of at least twice the weight of the machine.
Anyone operating the hoisting equipment must stay a suitable distance away from the part being lifted.
He must also make sure that people and property are not exposed to any possible risk if the machine
should fall. Movements must be slow and constant in order to avoid breaking the cables, chains, etc.
The machine comes with specifically designed gripping points that are indicated with special plates or
symbols (see Fig. 2).
Illustrated in Fig. 1 is a dimensional drawing showing machine weights and measurements.
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Important:
Table 1
The loads given above are only a part of the factors to be taken into consideration when calculating
the strength of the support structures.
If the machine is supplied with a support structure, follow exactly the procedure shown in the assembly
diagram.
Important:
On receiving the machine and thus before starting it up, check the oil level in the mixing
units and hydraulic pump. If, for transport purposes, the machine arrives the upside-
down, neither the gearboxes nor the pump will contain oil. These reducers must be filled
before the installation (look at the table 10.1.1 and 10.1.2 on chapter 10).
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FIG.1
Note: THE ELECTRICAL MOTOR’S ELEMENTS ARE FOR ALL STANDARD TYPE
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Fig. 2
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4) ELECTRICAL CONNECTIONS
This section gives all the information necessary for making electrical connections during installation.
Important:
The electrical connection cable must comply with UNI 60309-1-2 regulations.
The voltage drop must also be checked and should comply with the formula:
DV = K*L*I < 4%
V
where:
K = cable coefficient
L = cable length
Vc = Contact voltage
Rt = Grounding plate resistance
Is = Differential switch sensitivity current
If national laws or regulations impose more restrictive values for Rt, then these must be respected.
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Important:
Important:
When the machine is supplied with an electrical panel, check the direction of rotation of
the motors.
The correct direction of rotation is indicated by the arrows on the rear part of the motors.
In any event, verify that the mixing arms rotate in a clockwise direction. If this is the case,
then all the mixer motors are synchronized.
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5) MACHINE USES
This section gives general information on the uses for the machine and describes its main functions
and restrictions as to its use.
5.3 - Operator
No special technical knowledge is required to use the machine.
A careful examination of this manual is sufficient. It should be borne in mind, however, that it is very
important to have both experience and a knowledge of the type of product being handled.
Special
applications: To handle oxides, a version with a stainless-steel lining must be used. A Polygirs-lined
version must be used for particularly sticky aggregates.
If liquids must be added, (water, additives, etc.),a tilting -type loading skip is used.
Aggregates with particle size over 70mm (150mm for mixers with shovel-shaped blades) amounting to
more than 10% of all aggregates.
Clay with a humidy level of 15% can only be mixed by a specific crusher with blades for clay.
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Important:
Since the aggregate hoisting unit (when furnished) has been designed for loading
materials with a maximum specific weight of 2000 Kg per cubic meter, the operator
is required to reduce the load volume in proportion to the difference in specific
weight per cubic meter.
Example: Model P1000 - allowable load by weight - 2000 Kg for a specific weight of
2000 Kg/cubic meter.
For materials with a specific weight of 3000 Kg per cubic meter, the same skip
must be loaded with only about 670 liters, even if in terms of volume, it can contain
a larger quantity that is equivalent to 2000 Kg in weight.
The allowable load by weight is 2000 Kg for the skip of a mixer P1000TN.
Using the machine outdoors poses no particular problems. Nevertheless, it is advisable to put a protective
cover over the electrical components.
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6) TECHNICAL DESCRIPTION
This section provides a technical description of the machine and how it works. It details everything the
operator and maintenance personnel need to know in order to understand the proper working of the
machine and to quickly identify possible faults and malfunctions.
The machine comprises two main components that are separate from each other:
A) Planetary mixer
B) Skip with normal discharge and tilting discharge
Planetary mixer
The planetary mixer is composed of:
• MIXING TANK: made of very thick steel sheets on a frame of U-type sections allowing several
discharges. The tank is protected by a metal sheet preventing powders from spilling while a
microswitch blocks the mixer should the front door open.
• TANK BOTTOM AND WALLS: made of very thick sheets of Fe 52 with 120 HB resistance, with
interchangeable and bolted sectors. On request a special antiwear lining of CR 321 with 300HB
resistance or, only for the bottom, of CR 6000 with 460 HB resistance.
• MIXING AND SCRAPER ARMS: made of steel rods. They can be adjusted in order to alter the
position the blades in relation to the tank base and walls.
• MIXING BLADES: made in Ny-Hard cast iron with a mean hardness of 630 HB. They are
particularly suitable for heavy-duty mixing work. The mixing blades can also be made in rubber.
• DISCHARGE: Circular sector opening made on the bottom of the tank ( three more optional
discharge oulets can be provided on request ) it can be opened by means of a handle with an
endless screw for easy manual operation, or can by hydraulic or air cylinder whose position is
controlled by a Ravasi limit switch (two positions: open and closed).For the discharge operated by
hydrasulic cylinder the operation features are hereon summoned: pressing the button related to the
opening operation the corresponding solenoid inside the electrovalve is activated and the pump is
stopped by the opening microswitch located on the rotation axis of the outlet door; pressing the
closing button the related solenoid inside the electrovalve is activated and the pump is stopped by
the opening pressure switch the microswitch connected to closing must be used only to indicate the
door position and to abilitate eventual automatic-operating devices. in case the machine is provided
without any eccentric device, rubber gasket, and stop pressure switch, the microswitch related to
closing also stops pump engine operation. The hydraulic control gear can be equipped with a
manual pump for emergency discharge ( such equipment is standard on P 1500 and P 2000
models. the outlet pipe is on request provided with an outlet convey pipe or with a container hopper
envisaging manually operated push discharge or an automatic discharge.
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• MIXING REDUCTION UNIT: has incorporated planetary gearing and is the heart of the machine.
It has been specially developed over the years to stand up to severe stress and tough working
conditions as well as for use during non-stop work shifts. The bolted-on reduction-gear housing is
supported by a frame, is easy to dismantle and is bridge-mounted on the mixing tank. The helical
gears, which are more resistant, are very quiet even at high rotation speeds and are of 18NCD5 case-
hardened steel. With thermal treatment, the resistance on the surface of the teeth has a hardness of
58-60 Rc. The torsion shafts are made from 39NCD3 tempered steel with an average resistance of 90
Kg/mm². The bearings all have tapered rollers to ensure greater static and dynamic loading and are
adjustable. The reduction gears operate in an oil bath (Engler EP150) ensuring maximum lubrication in
conditions of extreme pressure on the teeth. The reduction unit may be connected to the motor via a
hydraulic coupling. This facilitates starting the machine even with a full load.
• MIXER MOTOR: the power, voltage and frequency are variable. The motor is a class B type with
class F or H insulating material. It is suitable for tropical environments and has IP 55 protection.
• MIXER SUPPORT STRUCTURE: (if supplied by us) is a trellis-type, column or portal structure
that varies in height from 1 to 5 meters. It is designed to give maximum stability, including in areas of
high seismic risk.
• SERVICING PLATFORM: (if supplied by us) made of checkered sheet metal and is fitted around
the tank in order to facilitate maintenance work on the machine. The platform is accessed by stairs
equipped with a handrail and constructed in accordance with accident-prevention regulations.
Skip
The skip is composed of:
• HOISTING SELF-BRAKING GEARMOTOR: the hoisting unit is composed of a self-braking motor
and a reduction gear. The outgoing revolution speed of the reduction gear is further decreased by a
pinion/gear coupling.
• MOTOR:: This is a four-pole motor (a dual-speed 2/4 pole motor can be supplied on request).
Power, voltage and frequency are variable. The standard version is a class-B type and is made with
class F or H insulation and IP55 protection, and it is also tropicalized. A self-braking model with a dual-
circuit brake is mounted.
• REDUCTION GEAR: it is an epicycloidal model and is mounted horizontally. It is flanged to a
sheet-metal casing and is fastened to the sliding guides. Rotating inside the guides is a pinion
mounted on the shaft of the reduction unit, as well as a gear that is mounted on one of the cable-
winding reels.
• CABLE-WINDING REELS: The reels are splined to the same shaft, with rotates on bearings.
They are either cast or are made of metalwork and are fitted with a band that is only wide enough to
wind the cable on a single level, for a development that varies up to a total of 50 meters maximum,
which is equivalent to a track with a development of about 15 linear meters (upon request, reels with
wider bands can be made in order to wind longer cables).
• RUNWAYS: These are made of NPU-type sections. The upper end is fastened either to the
machine into which the material will be unloaded or to a specifically-designed structure. The section
going down to the lower loading level, either on ground level or in the pit, is subdivided into sections
that vary in length and can either be standard or it can be reinforced with a base, positioned on the
ground, with has been widened to ensure optimum stability. The fittings are flanged and bolted. The
runway can be tilted at an angle ranging from 45° to 75°, or it can be placed in a vertical position.
• MOBILE LOADING SKIP: Shaped as a truncated pyramid, for dry dust or aggregate loading, of
size suitable to containment of material, it transfers the aggregates to the mixing tank by means of a
hinged bottom avoiding outlet of dusts, and runs on four reels along rolling grooves pulled by a
double-lapped steel cable For the conveying of particularly adhesive or plastic pre-mixed aggragates,
the shape of the loading skip is tha t of a closed container with tilting discharge, sliding on vertical
guides.
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• CABLE: it is made of steel and the number of wires varies depending on the breaking load. The
various breaking loads are listed in Table 2 below.
Table 2
CABLES SKIP
P 50 Ø5 KG 1400 *
P 100 Ø8 KG 4000 *
P 250 Ø8 KG 4000 *
P 375 Ø 10 KG 6500 *
P 500RS Ø 10 KG 6500 *
P 500 Ø 8,75 KG 8060 **
P 750 Ø 12 KG 15000 **
P 1000 Ø 12 KG 15000 **
P 1250 Ø 12 KG 15000 **
P 1500 Ø 14 KG 20500 **
P 1500TN Ø 14 KG 20500 **
P 2000 Ø 18 KG 33000 **
P 3000 Ø 20 KG 41000 **
Important:
In order to determine the loads allowed for each type of cable, the data listed in the table
must be compared with the indications given in Chapter 5.5
The cable, which is anchored to one of the reels, passes through two cable guides and then goes
under the skip along the bottom, which is hinged in the truncated-pyramid model and closed in the tub-
type. It then hooks onto the other reel.
In the center of the skip bottom, a safety device is applied between the two cable guides. This
prevents the skip from falling if the cable breaks.
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3” 5”
7.5” 10”
Fig. 3
As the sequence shows, all parts of the mixing tank are covered by the motion of the arms. This uniform
movement, which only takes 10", keeps the components being mixed from getting separated and stratified, even
if they have different specific weights. It also ensures that the mixture is totally uniform.
• Mixer motor starts up (models P 1500 and P 2000 are equipped with 2 motors).
• Unloading door is closed.
• Granular and/or powder components are added.
• Dry mixing.
• Water, chemical additives and/or dyes are added (if required).
• Final mixing.
• Unloading of mixture.
• Tank and mixing parts are cleaned using a manual or automatic cleaning system (if fitted).
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• The ascent motor is activated at low speed (if a dual-speed motor is mounted, after the initial
movement at low speed for a stretch delimited by a microswitch, the motor switches automatically to
high speed).
• The skip ascends along the runway.
• It stops near the unloading point, which is performed by means of a hinge systems located on the
bottom of the skip.
• Transported material is transferred.
• The descent motor is activated at low speed (if a dual-speed motor is mounted, after the initial
movement at low speed for a stretch delimited by a microswitch, the motor switches automatically to
high speed).
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6.4.1 - Maximum pressure valve and pressure switch in the hydraulic system
The hydraulic circuit is equipped with a valve to protect against any undesired increase in pressure
that could damage system components. The circuit also has a pressure switch which stops the main
cylinder motor when the door is fully closed.
Located in the electrical circuit of the machine is a power isolating switch, which is to be used during
maintenance and cleaning operations in compliance with standard EN-60204-1 (if the client does not
which to have this system supplied as standard, he will be personally responsible for arranging to
install it inside the system).
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6.4.4.3 - Installation
If one limit switch has been installed by the client, the following regulations must be followed in order
to install it correctly:
1. The keylock contact element must be serially connected to the limit switch.
2. The keylock contact element must be set at a minimum distance in order to make it possible to
stop the machine completely (in order to determine this minimum distance, see UNI 8205
standards)-
3. Once installation has been completed, the only copy of the key inserted in the switch must be
available to workers.
Important :
The key of the safety device must always be under the control of the
operator working by the machine
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Leq = 70 dB ( A ) MIXER
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7.1 - MIXER
The main mixing phases (described in brief in the preceding section) are:
• loading phase
• mixing phase
• unloading phase
• cleaning
If the machine is equipped with conveyor for inert matter see information reported on paragraph 7.1.3.
Conveyor loading time counts as dry premix phase and cement can be introduced simultaneously
with the aggrgates. As soon as the cement scale display marks 0 (zero) water can be introduced.
Loading and pre-mixing time varies according to the capacity of the conveyor belt, therefore only
15” of final pre-mixing is sufficient to obtain perfect homogeneousness of mixture. Discharge and
outlet opening times are not changed.
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Discharge takes place through the outlet situated on the bottom of the tank, it is necessary to press
the related button.
Important notice:
in case the mixer is equipped with more than one outlet and if only one of
them is currently used, it is possible that the others tend to rotate towards
the opening position under the pressure exerted by the mixing and side
arms at ever turn over such outlett doors it is wise to carry out a complete
opening and closing for every hour of operation in order to restore correct
sealing of the rubber gaskets, or to perform correct repositioning of the end-
switch for the out lets not provided with gaskets.
the discharge time is 20” for repeated cycles , or of 40” to obtain full discharge of the tank
Outlet closing requires goes from 2” for the pneumatic-operated model to an average of 4” for the
hydraulic-operated model.
For more highlights see the mixing cycle diagram Tab. 3, only for example, hereon shown
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Tab. 3
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7.1.5 - Cleaning
To remove traces of mixture, clean the machine at the end of the work cycle either by using the
automatic system provided or else manually.
Important:
7.2 - SKIP
The main operating phases of the mobile skip are as follows:
7.2.2- Ascent
After the skip-loading phase has been completed, a manual control with push-buttons or an automatic
control will drive the self-braking motor of the hoisting unit.
The ascent starts out at a speed of about 15 meters/minute (see technical characteristics). On
request, the skip can ascend at twice this speed, or 30 meters/minute.
The speed-exchange is controlled by a microswitch located about 50 cm after the starting point.
When the skip reaches its unloading position, a microswitch located near the aggregate loading mouth
on the mixer will stop the motor. The motor brake, which is positive, ensures proper unloading position
for a time that varies from 5” to 15”.
When working with dual ascent speed, a microswitch located about 50 cm before the unloading point
controls the switch-over to low speed.
Important:
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7.2.4 - Descent
Following the descent phase, the skip remains in position for a period ranging from 5” to 15”. At this
point, it then begins its descent to the unloading point to start a new cycle. Here, it is stopped by a
position microswitch, which can be regulated in order to keep the cables taut between the cable-
winder reels and the skip.
Upon request, a dual-speed motor can be supplied in order to achieve a descent speed of 30
meters/minute.
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1. Loosen the lock-nut on the control screw (with hexagonal recess) situated on the electric valve unit.
2. Turn the screw clockwise one full revolution.
3. Check to be sure that the pressure gauge shows a rise in pressure.
4. Turn the screw back to the original position and tighten the nut.
Important:
If the pressure shown on the pressure gauge does not vary, replace the
valve.
Important:
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8.2 SKIP
The mobile skip is equipped with the following safety devices:
A) When the brake is powered, the electromagnet (43) overcomes the force exerted by the spring
(38), attracting the plunger (37). It releases the brake disk(s) (36) and allows the drive shaft to turn
freely.
B) When the electromagnet (43) is not supplied, the plunger, pushed by the spring (38) acts by
pressing on the brake disk(s) (36), blocking the rotation of the drive shaft.
8.2.2 - Microswitch
The ascent, emergency ascent and descent microswitches on the skip are electromechanical and are
driven by a cam that, when regulated, anticipates or delays the run of the skip. When the switch goes
past the ascent limit switch, the microswitch acts as an emergency device.
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Important:
The worker is required to check the cable every six months of operation. He
must place a flat metal bar on top of each cable and slide it up and down in
order to raise any cut strands.
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9) DISMANTLING INSTRUCTIONS
To dismantle the machine, disconnect the electricity power cables entering the control panel.
If the machine is equipped with a support, a diagram is supplied giving dismantling instructions.
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When performing any type of intervention, the following safety standards must be followed:
• Machine cleaning and maintenance (mixer and skip) must be done while the electrical power is
off (using the isolator switch on the control panel), as well as the pneumatic and hydraulic
supplies.
• Before starting any type of maintenance, set out placards indicating MACHINE MAINTENANCE.
Place the signs in clearly visible areas.
• Keep unauthorized personnel away from the work area.
• Wear suitable work garments (overalls, gloves, boots) without any loose ends.
• The electrical control panel must be opened only after the machine is off and once a sufficient
amount of time has elapsed for the electrical equipment to cool.
• Do not use solvents, inflammable materials or water to clean and maintain the electrical panel.
• Do not smoke or use open flames around inflammable materials such as rubber, oil, plastic,
etc.
• Do not modify, alter or tamper with the hydraulic circuit in any way, nor with the electrical
parts, moving parts, cables, safety devices or electrical wiring.
• Avoid coming into contact with hydraulic fluids and dispose of them properly, especially
during filling, recuperation and repair operations. In case any leaks should occur, be sure to
wear rubber gloves when changing the oil.
• At the end of maintenance, repair or cleaning operations, restore the refasten all the guarding
and protective casings that may have been opened or removed.
• Used oil must be disposed of in closed containers and redelivered to your usual supplier or to
competent public agencies so that can be disposed of as provided for by law.
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Change the oil in the reduction gearboxes EVERY 4000 HOURS or at least EVERY 2 YEARS.
Important:
Table 5
P P P P P P P P P P P P
QUANTITY OF 50 100 250 375 500 500 750 1000 1250 1500 1500 2000
OIL litters RS TN
REDUCTION 1.5 2.2 12.5 22 22 34 55 82 82 87 135 157
GEAR
PLANETARY 1.5 2.5 3 8 8 12 12 21 33 22 47 80
GEAR
Change the hydraulic oil in the main hydraulic cylinder (part. 16 table 0000/06/188) EVERY 2000 HOURS or at
least EVERY 2 YEARS. When changing the hydraulic oil, completely drain the system, including pipes and
cylinder (or cylinders, depending on equipment).
Important:
Table 6
QUANTITY OF P50 P100 P250 P375 P500 P500 P750 P1000 P1250 P1500 P1500TN P2000
OIL litters RS
HYDRAULIC 3 3 8 8 8 8 8 8 8 8 8 8
UNIT
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10.1.3 - Greasing
Regularly grease parts fitted with greasing nipples.
Important:
Check the tightness of the bolts securing the arms and blades of both the mixer and the scraper arms
every 500 hours of use and after replacement or adjustment.
A torque wrench is recommended for this work to ensure that bolts are tightened to the correct
torques, as listed in Table 7 below.
Table 7
A torque wrench, set to the torques given in Table 7 (point 10.1.4), is recommended for this work. To
adjust the position of the arms and blades, see point 10.1.6.
The mixing and scraper arms need periodical adjustment to ensure that the machine is operating at
full efficiency. If such adjustment is not carried out, problems may arise.
Lack of adjustment causes rapid wear to the bottom of the tank and to the blades: grit caught between
the blades and the bottom gets crushed and causes abrasions. If there is too much space between the
iron blades and the bottom, larger and harder stones can get caught, bending the arms and probably
breaking the cast-iron blades.
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Important:
10.1.9 - Replacing the oil seal and resetting the preloading on the planetary gear outlet shaft
bearings
The conical roller bearings ensure that there is no play in the rotating spider shaft. Stresses on the
mixing arms (from flexing, knocks etc.) can cause these bearings to lose their assembly preloading
due to oil loss from the planetary box. The planetary gear box seal consists of two rubber rings (part. 6
diagram 10TN/09/063). To restore to full efficiency, proceed as follows:
1. Dismantle the spider (part. 01 diagram 9999/05/0001/0001).
2. Drain the oil in the planetary gear box (part. 07 diagram 10TN/09/063) by removing the oil drain
plugs.
3. Loosen the screws (part. 03 diagram 10TN/09/063) that secure the cover.
4. Remove the bearing support cover (part. 5 diagram 10TN/09/063) in which the two oil seals are
held.
5. Extract the old oil seals.
6. Increase the size of the bearing pressure ring on the adjustable support by removing (using a lathe)
approximately 1 mm from the surface (with holes) of this support.
7. Place 2 (new) oil seals in the support.
8. Using an emery cloth, smooth the planetary shaft where it meets on the surfaces of the shaft oil
seals.
9. Apply liquid sealant to the surface around the holes in the planetary box.
10. Refit the support and check that the planetary shaft is properly firm.
11. Refill with oil - the type and quantity are given in Table 5, point 10.1.1
12. Refit the spider and secure it with the nut .
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Società Italiana Costruzione Macchine a R.L.
Important:
Important:
10.1.11 - Fixing oil leaks between the fixed reduction-gear box and the cover of the rotating
planetary gear box.
The presence of oil on the planetary box cover can be due the water that goes inside the planetary
box through the shaft dust seal (part. 09-10 diagram 10TN/09/064) fitted to this cover and is not due
to leaking seals on the fixed reduction-gear box.
Water has a higher specific weight than oil and when water enters the planetary box, it raises the level
to a point where a leak occurs.
To prevent this problem, proceed as follows:
1. Drain the planetary box by removing the oil drain plugs.
2. Replace the oil drain plugs.
3. Fill the planetary box with diesel or detergent oil several times and activate the planetary box so as
to flush the internal parts.
4. Refill with oil - the type and quantity are given in Table 5, point 10.1.1.
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Società Italiana Costruzione Macchine a R.L.
If, in addition to water, cement dust and aggregates are also found inside the planetary box, it is
necessary to open it up and thoroughly clean the internal parts as follows:
• Loosen the screws (part. 03 diagram 10TN/09/063).
• Loosen the spider nut (part. 01 diagram 10TN/09/064).
• Extract the spider (part. 01 diagram 9999/05/0001/0001).
• Remove the oil seal support cover (part. 05 diagram 10TN/09/063).
• Loosen the nut (part. 16 diagram 10TN/09/064) securing the planetary box to the reduction-gear
shaft (part. 01 diagram 10TN/09/044/E).
• Extract the planetary box from the reducer shaft hub by using a 2-hole extractor provided for this
hub. To ease extraction, use 2 levers positioned between the box and the cover on the 2 shorter
sides of the box.
Important:
Do not try to extract the planetary box by applying pressure to its cover
since it is blocked by the fixed gear (part. 14 diagram 10TN/09/064).
• Thoroughly clean the parts inside the planetary box and the box itself.
• Reassemble, following the above steps in reverse order. When fitting the oil seal flange, take care
to carry out the preloading work on the roller bearings as described in point 10..1.9.
Important:
Before re-sealing the planetary box, lubricate the upper bearing of the
planetary shaft using approximately 1 Kg of grease of the type given in point
10.1.3.
Important:
If any internal parts should break, we recommend that you replace the
lubricating oil. Used oil or impure oil should be collected in special containers
and disposedof properly.For disposal, contact specialized companies.
3. Remove bridge cover casings (part. 12 diagram 10TN/09/041 or 10TN/09/042), removing the
screws (part 11 diagram 10TN/09/041 or 10TN/09/042).
4. Remove the front casing (part. 07 diagram 10TN/09/041 or 10TN709/042).
5. Remove the 6 screws blocking the reduction unit to the fixed beam of the bridge.
6. Remove the 4 screw (part. 40 diagram 10TN/09/041 or part. 33 diagram 10TN/09/042) located to
the left and right of the mobile beam.
7. Lift the mixer reduction gear complete with the mixing and scraper arms, using the mobile beam.
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Società Italiana Costruzione Macchine a R.L.
FIG. 5
3) Raise the reduction unit and place in the opening of the bridge beams.
4) Fasten the reduction unit to the fixed beam, using the 6 screws.
5) Mount the mobile beam in the front position, blocking it with the 4 screws (part. 40 diagram 10TN/09/041 or
part. 33 diagram 10TN/09/042) and connect it to the reduction unit with the 6 screws.
Important:
Before tightening the redyction unit completely, check to be sure it is
centered with respect to the mixing tank. Check to be sure it is level with
respect to the bottom of the tank, sliding it by a few millimeters in the slots
of the two beams of the reduction bridge.
6) Reassemble the mixing arms in the spider as well as the scraper arms, with the arm-holders, adjusting as
indicated in points 10.1.6, 10.1.7 and 10.1.8.
7) Fill the fixed gear box and the planetary box with oil as indicated in point 10.1.1, Table 5.
8) Mount the mixing motor(s) complete with the first reduction pinion. Connect the power supply mains and
check to be sure that blade rotation occurs in a clockwise direction.
9) After several mixes, check screw tightness as indicated in point 10.1.4.
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Società Italiana Costruzione Macchine a R.L.
Change the oil in the reduction gearboxes EVERY 4000 HOURS or at least EVERY 2 YEARS (12° E
at 50° C).
Important:
Table 8
SKIP P P P P P P P
REDUCTION 50 100 250 375 500RS 500’ 750
GEAR
QUANTITY OF 0.75 0.75 1.5 0.7 0.7 1.0 2.0
OIL litters
SKIP P P P P P P
REDUCTION 1000 1250 1500 1500TN 2000 3000
GEAR
QUANTITY OF 2.0 2.1 2.4 2.4 2.4+2.4 2.5+2.5
OIL litters
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Società Italiana Costruzione Macchine a R.L.
The steel cables are usually have an initial greasing, which is applied during operation, that covers
the outer surface and every interstice inside the cable. This protects the strands from corrosion and
lubricates the internal and external areas of the cable while it is in motion.
If done properly, the initial greasing has an extended duration, especially in cables with a textile
core, where the flexing movement helps the grease-impregnated core gradually gives off the
lubricant to the strands.
Nevertheless, lubrication must be repeated during use. The frequency of this operation as well as
the type of lubricate depend on the working conditions.
Listed below are several indications:
1) Cables that normally work in contact only with the pulley and the winch drum: lubricants that
can penetrate the gaps in the cable deeply. Products with a viscosity of about 30 SA are generally
suitable.
2) Cables subject to heavy wear: lubricants with a good adherence that can resist against being
removed by mechanical agents. Very viscous oils or light greases with adhesive additives, graphite
or molybdenum disulfide.
3) Cables that come into contact with loose abrasive materials (sand and the like): in these
cases, external greasing of the cable could drag the abrasive particles with it, thus obviously
damaging the strands and the pulleys. Therefore, it is preferable to keep the outside of the cable
dry, accepting the ensuing risk of corrosion.
4) Cables that work in corrosive environments: lubricants that are not very viscous and that
contain solvents if required and that can easily penetrate the cable and spread rapidly into the
points where the pressure of the cable on the pulleys and the drum leave the surface of the steel
wires unprotected.
5) Cables that work in static conditions: products that will protect the cable from corrosion above
all. Examples include petrolated products with the corrosion-proofing additives if required.
6) Cables drawn by drive pulleys: lubricants that will not compromise adherence between the cable
and the pulley. Indicate this problem when ordering.
In addition:
• Don’t forget to lubricate cables mounted on machines that are left idle for long periods of time,
especially if outdoors. In these cases, protection from corrosion is even more important that it
is on machinery that is kept in operation.
• Do not use corrosive products (for example, tar-based products)
• Do not use products that are incompatible with the type applied by the cable manufacturer).
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Società Italiana Costruzione Macchine a R.L.
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Società Italiana Costruzione Macchine a R.L.
BROKEN STRANDS - The recommendations that follow are contented in the ISO 4309 standards
(with the exception of the data in the table, which has been adapted for the type of cable being
used and that we recommend based on our own experience). These recommendations are valid
solely for the cables being used on hoisting equipment that complies with Presidential Decree n°
547 dated 27 April 1955 and that are wound on steel or cast-iron pulleys that are not covered with
synthetic materials.
You should count the wires broken on the outside of the cable on the section that is most worn.
In the table above, we have indicated the number of broken strands that can be tolerated in a cable
length that is equivalent to 6 diameters and to 30 diameters of the cable itself, based on cable type
and lay. The strands should be counted on both of these lengths and the cable should be replaced
if breakage exceeds the minimum in even just one of these two cases.
For cables other than the ones listed in the chart, the total number of external strands that is
broken along a length of 6 diameters must not exceed 10% of the wires comprising the external
strands for ordinary-lay cables and 4% for parallel-lay cables.
You should bear in mind that breakage is often difficult to identify, because the end of the broken
wire stays in its original position and do not come to the surface of the cable.
To see this type of breakage, you need to remove the grease that covers the cable. To do this, you
can rub the cable with a piece of softwood and, if possible, bend the cable by hand so that you can
force the ends of the wires to stick out visibly.
WEAR - Pronounced wear of the wires indicates upcoming breakage and when you have a passed
a certain limit, the worn wire must be considered as if it were broken. Thus, at this point, you must
apply the replacement criteria shown in the preceding table.
This limit has been reached when the diameter of the wire looks like it has worn to have of its
original diameter.
In any case, if there is advanced wear of the wires, it is advisable to conduct more frequent regular
checks of the cables.
CORROSION - Like wear, corrosion also leads to breakage of the wire, but when the wire diameter
is reduced to a similar extent, corrosion must be considered a more serious type of deterioration
than wear.
Therefore, the indications listed in the paragraph above are also valid for corrosion, but these
criteria should be applied with greater caution.
Internal corrosion of the cable can be detected by noting a decrease in the overall diameter of the
cable.
We recommend that you check the inner part of the cable regularly so that you can detect any
deterioration due to corrosion.
OTHER SIGNS OF DECAY - In addition to the above-mentioned assessments, the cable must be
replaced in the following cases:
• When the overall cable diameter has decreased by 10% with respect to the original diameter,
even if only on one point.
• When a strand is broken internally or when it has undergone damage that will reduce some
point of the effective section by 40% .
• When the cable appears dented, twisted or bent permanently due to damage or because it
has been set on sharp edges.
• When the core comes out of the cable.
• When one or more strands seem to be loose and stick out of the cable, even when it is taut.
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Società Italiana Costruzione Macchine a R.L.
• Tracction Fatigue
• Bending • Traction •
corrosion
• Wear
• Wire breakage due to Wire breakage in the • Inner wires sticking out
• Wire breakage at the •
of the strands, due to
flexion fatigue. metal core due to
contact point between repeated “tugging”
strands or between the excessive traction
(note the cuts in strand stress
strands and the metal
core wires)
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Società Italiana Costruzione Macchine a R.L.
10.2.7 - Greasing
Regularly grease parts fitted with greasing nipples.
Important:
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Società Italiana Costruzione Macchine a R.L.
10.2.8 - Adjusting the descent limit switch on the spool shaft (if supplied)
After about 200 hours of operation, the skip cables can become stretched.
The operator is required to adjust the descent limit microswitch in order to restore proper cable
tension. Failure to observe this regulation can damage the cable during the initial “jerking” phase
when the skip starts its ascent.
To adjust the microswitch, proceed as follows:
loosen the nut (part. 7a diagram 10TN/09/068), turn the cam (pos. 8 diagram 10TN/09/068)
clockwise by a few degrees. Tighten the nut again. Repeat this procedure until the initial cable
tension has been restored.
10.2.8.1 – Adjusting the descent limit switch on skip rails (if supplied) (tav. SDM/09/128)
After about 200 hours of operation, the skip cables can become stretched.
The operator is required to adjust the descent limit switch in order to restore proper cable tension.
Failure to observe this regulation can damage the cable during the initial “jerking” phase when the
skip starts its ascent.
To anticipate or to delay the contact with the clamp which put on the descent limit switch on the
rails, turn up or down the lever of the limit switch, as indicated on the plan Z here below
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Società Italiana Costruzione Macchine a R.L.
10.2.8.3 - Diagram for placement of the limit switches: ascent limit switch, ascent emergency
limit switch, stand-by limit switch and limit switch on skip rails.
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Società Italiana Costruzione Macchine a R.L.
The magnet gap (9), or in other words, the distance between the electromagnet (8) and the plunger
(4) must be 4 tenths of a millimeter for each type of brake.
It is advisable to check the magnet gap on a regular basis, since it tends to increase due to wear
on the brake disk seals.
Turn the nuts to adjust the gap to its initial values.
The braking torque is proportional to the compression of the springs (5) and is adjusted by turning
the self-locking nuts (6). The more compressed the springs are, then the greater the braking.
Fig.6
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Società Italiana Costruzione Macchine a R.L.
10.2.12 - Replacing the reduction unit or the pinion and gear on the skip
To replace the reduction unit or the pinion and gear on the skip, proceed as follows:
bring the skip to the bottom of the pit as indicated in section 10.2.10. Set in on the mechanical
block pins in order to loosen the cable.
Dismount the reduction unit (part 24/25/26 diagram 10TN/09/068) on whose shaft the pinion (part
15 diagram 10TN/09/068) is mounted.
Dismantle the casing (part. 17 diagram 10TN/09/041) and the cover of the belt guard.
Remove the tension washer (part 21 diagram 10TN/09/068) and withdraw the cable wheel (part 11
diagram 10TN/09/068) that holds the gear on (part 10 diagram 10TN/09/068) and that is fastened
to it by the screws (part 9 diagram 10TN/09/068).
Check all the parts for wear and mount any pins that need to be replacing, working in reverse
order.
After the skip gear-unit has been reassembled, grease it as described in section 10.1.3. and put the
cover of the belt guard back on the skip guarding (part. 17 diagram 10TN/09/041).
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Società Italiana Costruzione Macchine a R.L.
Fig. 7
Remove the screws that hold the closing plate on the section.
Exert upward pressure using leverage so that the rollers can come out of the NPU section.
Using short impulses, bring the skip down until the two skip rollers to be replaced are outside of the
cut section.
Replace the rollers and send them back into the NPU section. Remount the closing plate and
tighten it with the screws.
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Società Italiana Costruzione Macchine a R.L.
Mixture deposits on the tank bottom and side Adjust mixing arms to compensate for mixture
walls. residue on the tank bottom and scraper arms for
residue on the side walls (See point 10.1.6).
Oil leaks from the planetary gear outlet shaft. Carry out servicing as in point 10.1.9.
Oil leak between the reduction-gear box and Carry out servicing as in point 10.1.11.
the cover on the rotating planetary gear
Loss of material through the seal on the Carry out servicing as in point 10.1.14.
unloading opening
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Società Italiana Costruzione Macchine a R.L.
Important:
Discard lubricating and hydraulic oil with care. Use specialized firms to
dispose of used lubricating and hydraulic oil.
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Società Italiana Costruzione Macchine a R.L.
We also advise against using non-original spares and their use will compromise the WARRANTY
terms (if still under warranty). In this case, the manufacturer’s can no longer be held responsible for
use of the machinery or any damage to persons or property.
Important:
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Società Italiana Costruzione Macchine a R.L.
MATRICOLA / N° DE FABRICACION / SÉRIE TIPO / TIPO / TYPE / TYPE ANNO / AÑO DE FABRICACION
SERIAL N° / AUFTRAG TYPE ANNÉE / YEAR / BAUJAHR
INDIRIZZARE LA MERCE A
REMITIR LA MERCANCIA A
ADRESSER LES MARCHANDISES A’
DELIVER THE GOODS TO
WARENLIEFERADRESSE
Tempi consegna richiesti / Tiempos de entrega solicitados / Délai de livraison / Delivery required / Liefertermin
_______________________________________
Mezzo di spedizione / Medio de expedición / Mode d’expédition / Transport / Versandart
_______________________________________
Richiesta Tecnico / Necesidad de un Técnico / Demande technique / Technician required / Techniker benötigt
DATA / FECHA / DATE / DATE / DATUM FIRMA / FIRMA / SIGNATURE / SIGNATURE / UNTERSCHRIFT
_____________________ _____________________________________________________
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Società Italiana Costruzione Macchine a R.L.
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7
6
2
2 8 3 5
4
3
TAV. 10TN/09/053
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A
B
C
D
A SCREW
E B
B EDGE
C SHIMS
C
D NUT
TO REMOVE THE ROUND
E WEAR SECTOR FOR DISCHARGE DOOR SHIMS (DETAIL C )
INSTRUCTIONS:
WHEN THE FLOOR WEAR SECTOR TANK BOTTOM THICKNESS DECREASES IT IS NECESSARY
TO REGULATE THE CORRECT DISTANCE BETWEEN THE MIXING SHOVELS AND THE TANK BOTTOM
(BETWEEN 3 AND 5 mm).
THE SUPERIOR PLAN OF THE EDGE (DETAIL B) MUST CORRESPOND TO THE SUPERIOR PLAN OF THE
TANK BOTTOM WEAR SECTOR (DETAIL E). THE REGULATION OF THE EDGE (DETAIL B) CAN BE MADE
REMOVING A PROPORTIONAL NUMBER OF SHIMS (DETAIL C) TO THE SUPERIOR PLAN OFTHE TANK BOTTOM
(DETAIL E)
Drawing SDM_09_099
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Società Italiana Costruzione Macchine a R.L.
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22 23 27
21
20
19X 19Z
18 19Y
17 25 28
15 24 29
14 26 30
10 31
13
12
11
8 16
32
33
10
14
9
34
8 29 28
7 6
36 A Vedi anche
Voir aussi
See
37 B Veer
Sehen
5 TAV. SDM/09/099
38 C
4
3 28 D
2
1 SDM/09/184
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TAV. N° 0000/06/188
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10
16
17
18
13
15
14
20
16
12
13
15
14
7
9
7
11
19
10
3
9
3
6
4
11
10
16
17
18
13
15
14
20
16
12
13
15
14
7
9
7
11
10
3
9
3
6
TAV. N° 0000/06/189
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VALVES GROUP
(Drawing N° 0000/06/189)
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HYDRAULIC CYLINDER
(Drawing N° 0000/08/074)
* THE PARTICULARS INDICATED WITH ASTERISK ARE SUPPLIED IN ONE UNIQUE SET
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