ALTRAD MK-145/B Gravity Concrete Mixer Owner’s Manual

POLAND
BETONIARKI
ZAGESZCZARKI
PRZECINARKI
TACZKI
INSTRUKCJA ORYGINALNA
BETONIARKA WOLNOSPADOWA
GRAVITY CONCRETE MIXER
145l: MK-145/B
165l: MK-165/B, MK-165/BK
180l: MK-180/B, MK-180/BK
OPERATION MANUAL
2021r

Reading the present manual carefully and strict observance of the operation and maintenance guidelines contained herein will to a large degree extend the life cycle of the concrete mixer and contribute to user’s satisfaction of the concrete mixer’s operation.
The present manual is an integral part of the concrete mixer.

GENERAL

1. Type and parameters of the concrete mixer are indicated on the nameplate. It is fixed to a drive cover.

2. Power concrete mixer is subject to the European Directive no. 2012/19/UE on waste electric and electronic equipment, therefore:
   • it is marked in accordance with the above directive on waste electric and electronic equipment (WEEE) (crossed bin) on a nameplate.
   • before throwing it out (scraping), remove electric motor and switch with cables, which are subject to segregated collection of waste electric and electronic equipment and send them for disposal.
   Motor with cables must not be placed together with other municipal waste. The place of their collection shall be defined by municipal or commune authorities.
   • remaining elements of concrete mixer are subject to regular waste collection, mainly as steel scrap.
   • do not destroy or detach a crossed bin plate.

3. The present manual is an integral part of the concrete mixer. In order to ensure safe and failurefree operation of the concrete mixer, read carefully the manual, particularly the assembly, connection of power supply and operation instructions.

4. After the purchase of a concrete mixer, check its completeness comparing it with the list contained in paragraph 12 of the present manual and check whether a warranty card contains the date of purchase.

5. Concrete mixers are produced as class II power tools. Electric shock safety is ensured through durable and continuous insulating housing. Electric shock safety does not depend on the conditions of installation and mains connection.

6. Main switch installed for switching the concrete mixer on trips automatically in case of power failure. Switch it on again to restart the concrete mixer.

7. For power supply connection the machine requires OWY or OPL 3 x 2.5 mm2 extension cable ended with 2p plug-in socket. Recommended length of the extension cable is 10 m.

8. Recommended ambient temperature for masonry works ranges from +5 to 40°C.

9. In your comments, orders of spare parts or complaints always state the type, production date and serial number of the machine.

10. In case of any doubts or troubles with connecting or using the machine, contact:
    • Producer – address and telephone numbers are presented in a title page
    • Seller – distributor of the concrete mixer.

11. During operation, the concrete mixer should stand on hard and flat ground. The acceptable roughness of the ground is approx. 2°.

12. The manufacturer reserves the right to modifications which shall not cause any deterioration of the machine parameters which were not contained in the present manual; basic features of the product, however, remain unchanged.

13. Never operate the concrete mixer with drive cover open.

INTENDED USE

Power driven gravity drum concrete mixer is intended for production of concrete mixtures of liquid, semiliquid and workable consistency as well as cement and cement-lime mortars. It can be used for dry materials.
Operating the concrete mixer for any other purpose shall be considered improper use

 TECHNICAL DATA

DESCRIPTION| UNIT| MK145/B| MK165B| MK165BK| MK180B| MK180BK
---|---|---|---|---|---|---
Drum capacity / Max operational drum capacity| dm3| 145 / 115| 165 / 130| 180 / 145
P1 power demand; Power supply| kW ;
V/Hz| 0,7 ;
230/50
0,9 ;| 230/50
Drum speed| min-1| 23+1
Dimensions: Length / Width / Height| mm| 1295/735/1405| 1295/735/1415| 1295/735/1440
Height of charging / discharging| mm| 900 / 600
Weight| kg| 62| 64| 66

TECHNICAL DESCRIPTION

Concrete mixer is composed of the following basic elements:

• In screwed version – on one side a leg is screwed to an upper fame welded from profile bars and a chassis frame with roadwheels on the second side.
  In welded version – completed frame is made of suitably welded profile bars.
  The remaining units are also screwed to the frame.

• Load bearing bow and a drum bearing-mounted on its axle, to which mixing blades and cast iron toothed rim.

• Tilting and positioning mechanism of the concrete mixer’s drum, composed of: tilting wheel, locking disc and pull rod with a spring.

• Drum drive, composed of 1-phase electric motor, belt transmission and gear transmission. Gear transmission is composed on:  -z12 driving gear and Z144 cast iron rim

• Electric system, composed of: electric motor, switch, cables, plus, housing.
  Concrete mixer operates in cycles, i.e. in the following work sequence: charging raw materials, mixing, discharging
  A drum shall be positioned at 22 ÷ 30 o to the level. Concrete mixer is switched on with push switch located on a drive cover.

ACOUSTIC PRESSURE LEVEL OPERATORS ARE EXPOSED TO

• Maximum, equivalent pressure level measured at the drive side during mixing – LpAeq,T=75.5 dB ±2.5dB
• equivalent pressure level measured at the loading side during loading, mixing and unloading – LpAeq,T=72.5 dB ±2.5dB

WORK SAFETY

6.1. Safety instructions
To ensure safe operation or maintenance conditions, follow the instructions below:

• read carefully the present manual before starting work with a concrete mixer

• concrete mixer must not be operated by children
  WARNING ! Never operate concrete mixers with drive cover dismantled.

• never carry out any repair or maintenance work on mixer in operation. Disconnect the plug from socket before removing the cover, periodical inspection, removal of any failures.

• when idle, remove the concrete mixer’s plug from a socket.

• check integrity of the power cord before connecting the mixer to mains.

• only qualified electrician is allowed to perform any operations on the motor and electric system.

• when producing lime mortars always observe general safety conditions, wear safety goggles and have clean water for eyes flushing at hand,

• for safety reasons, manual loading of concrete mixer onto the transportation means shall be performed by 2 – 3 people

• Always observe safety signs stuck to a drive cover.

1. read the operation manual
2.  keep children away
3. do not plug the machine in if the cable and socket are damaged
4. use proper electrical connectors (socket, plug, cable)
5. disconnect the machine from mains before starting any repairs

Protect all signs and inscriptions from damage and dirt.
Damaged and illegible signs and inscriptions should be replaced with new ones, available to be purchased from the manufacturer or retailer.
6.2. Residual danger and methods for its elimination
Concrete mixer was manufactured in accordance with the latest technical knowledge and applicable safety requirements.
ALTRAD POLAND S.A. is fully responsible for the concrete mixer’s manufacturing (structure and marking) and safe use if it is used in compliance with the manual.
Despite of that, there still remain some residual risks that may result from improper use or unforeseeable events.
Residual risks and methods of its elimination are presented in the table below:

• Manual and warning labels enclosed to the concrete mixer advice:
o never operate the concrete mixer with drive cover open
o never use damaged cord for connecting the concrete mixer
o disconnect power supply before opening the drive cover
o for repairs use original parts only
o repairs can be performed by qualified technicians only
2| Limbs and body injury| • Apply covers for rotating elements
• Switching device protects the mixer against automatic restart after a power failure
• The manual and warning labels enclosed to the concrete mixer inform:
o never insert hands or objects into rotating drum
o disconnect the mixer from the power source before any repairs or cleaning operations
3| Repair or maintenance hazards| • In accordance with the manual, any adjustments and repairs can be performed only when the machine is switched off and by authorized service or qualified workers
• For repairs use original parts only
• User must not implement any modifications into the concrete mixer.
4| Various hazards resulting from improper use of machine| • The manual informs in detail that:
o concrete mixer shall be used in compliance with its intended use only
o concrete mixer can be used by people of age, who read the manual and were trained for concrete mixer operation.
o never transport the concrete mixer while in operation or still connected to power supply.
o never implement any modifications into the concrete mixer’s design.
5| Loss of stability| • In accordance with the manual, concrete mixer shall be positioned for operation on dry, level and stable ground.
o acceptable roughness of the ground is up to 2 o .
6| Transport hazards| • Concrete mixer can be transported along hard and level ground, after prior disconnecting it from mains Machine can be handled by one person, firmly holding the grip welded to a concrete mixer’s leg or a tilting wheel.
• Loading (unloading) onto transportation means shall be performed by 2-3 people, one on which shall support the concrete mixer from the titling mechanism side, the other one from the drive side. Third person shall assist to maintain the concrete mixer’ stability during lifting.

TRANSPORT AND STORAGE

Concrete mixer can be transported by any means of transport. Be careful not to throw a concrete mixer box during loading and not to turn it upside down.
Completely assembled concrete mixer shall be manually loaded onto the transportation means by 2 – 3 people. Protect is against movement i.e. by fixing a leg to a floor and immobilising roadwheels.
During the storage protect the concrete mixer against mechanical damage and corrosion.
Concrete mixer is equipped with roadwheels and it can be transported by one person all around the construction site.

ASSEMBLY MANUAL

For the machine assembly you will need: two wrenches no. 13, wrench no. 10, screwdriver, hammer
MK-165/BK, MK-180/BK CONCRETE MIXER

1. Assembly of roadwheels
   Roadwheels shall be mounted onto a chassis axle. Using thassembly sleeve push on the 25 ZA stopper ring securing thwheels.

2. Assembly of frame.
   Join the upper frame with the leg and the chassis using M8x70 screws. Round washers shall be inserted on bolts from bothbolt head’s side and nut’s side. All screws shall be screwed tight using M8 self-locking nuts.

3. Assembly of pull rod.
   Insert the bottom pull rod through a support located on leg and screw to the upper pull rod using the M8x25 screw and M8 the self-locking nut, under which ø8.5 washer shall be inserted first.

4. Assembly of drum with bow
   Insert the**0**45/38×0.8 washer and plastic sleeve onto the journal from the drive shaft side with the longer recess towards the spring ring. Then, position the bow on assembled frame so as the drive shaft was at the chassis side. Screw the covers of drive journal and locking flange to the frame using M8x70 screws. Round washers shall be inserted on bolts from both bolt head’s side and nut’s side. All screws shall be screwed tight using M8 self-locking nuts.

5. Assembly of tilting wheel
   Screw the tilting wheel to the wheel support using two M8x20  screws and M8 self-locking nuts. Insert round ø8.5 washersunder the nuts.

6. Assembly of mixing blades to a bottom drum
   Two mixing blades shall be preliminary screwed to a bottom drum in the following sequence: M8x25 screw, bottom drum, ø8.5 aluminium washer, mixing blade, ø8.5 aluminium washer, M8 self-locking nut.

7. Assembly of upper drum
   Unscrew 4 screws M6x16 from the bottom drum and the ironcrown together with the washers Glue a gasket to a drum along the inner edge. Install upper drum aligning ø14 holes with M6 bolts (holes for screwing mixing blades in upper drum and bottom drum shall match eachother) and screw 4 M6 bolts in with ****6.5 washers. Loosen 4 pieces of M6 bolts fixing the toothed gear, insert washers and screw the bolts again,

8.  Assembly of mixing blades to the upper drum
   Bending slightly mixing blades align holes in the blades with holes in the upper drum.
   Two mixing blades shall be screwed to an upper drum in the following sequence: M6x25 screw, upper drum, ø8.5 aluminium  washer, mixing blade, ø6.5 aluminium washer, and tight ittogether with M6 toothed flange nut. Finally screw mixing blades to upper and bottom drum.

9. Assembly of drive
   Remove protective cap from a shaft.
   Drive unit shall be put on drive shaft aligning the notch on a shaft with the opening of a belt pulley hub located inside the drive unit. Then, screw the drive unit to a frame with two M8x70 and M8x80 screws using round **0** 8.5 washers under nuts and screws. After the assembly, check manually the rotational movement of a drum with a drive.

LIST OF SPARE PARTS

In the order for spare parts provide the name of the part, catalogue number and type of concrete mixer indicated in the warranty card. Spare parts can be ordered from retailers of concrete mixers or the producer.

PART NO.IN
DRG.| CODE| DESCRIPTION| MK-145/BMK-165/8| me/ss•mw| eiost•ow| me/on-mw
---|---|---|---|---|---|---
1| C8104| WELDED FRAME| | 1| | 1|
2| C8136| UPPER FRAME| | | 1| | 1
3| C8202| CHASSIS FRAME| | | 1| | 1
4| C8303| LEG| | | 1| | 1
5| (8407| BOW| 1| 1| 1| |
(8408| | | | 1| 1
6| (8453| WASHER 0 38.5| 1| 1| 1| 1| 1
7| C8461| BOW GUARD| 1| 1| 1| 1| 1
8| C8462| 1| 1| 1| 1| 1
9| C8491| TOOTHED GEAR COVER| 1| 1| 1| 1| 1
10| (8511| TILTING WHEEL| 1| 1| 1| |
(8513| | | | 1| 1
11| C8521| UPPER PULL ROD| | | 1| | 1
12| (8522| BOTTOM PULL ROO| | | 1| | 1
13| C8523| LONG PULL ROD| 1| 1| | 1|
14| C8526| PEDAL| 1| 1| 1| 1| 1
IS| C8611| UPPER DRUM| | | | |
C8613| | 1| 1| |
C8615| | | | 1| 1
16| C8625| BOTTOM DRUM| 1| 1| 1| |
C8626| | | | 1| 1
17| C8632| UPPER BEARING BUSH| 1| 1| 1| 1| 1
18| (8642| BOTTOM BEARING BUSH| 1| 1| 1| 1| 1
19| (8652| DRUM’S AXLE| 1| 1| 1| 1| 1
20| C8661| MIXING BLADE| 2| 2| 2| |
C8662| | | | 2| 2
21| C8672| ZI44 TOOTHED GEAR| 1| 1| 1| 1| 1
22| (81202| DRIVE SET| 1| 1| 1| 1| 1
23| (81235| DRIVE SHAFT WITH TOOTHED GEAR| 1| 1| 1| 1| 1
24| KOLO-1EZDNE-200-25| 200 ROAD WHEEL| 2| 2| 2| 2| 2
25| KOL-SP-5.45| SX45 SPRING PIN| 2| 2| 2| 2| 2
26| KOL-SP-6-40| 6X40 SPRING PIN| 1| 1| 1| 1| 1
27| LOZ-6002-ZZ| 6002 ZZ BEARING| 1| 1| 1| 1| 1
28| LOZ-6207-ZZ| 6207 II BEARING| 2| 2| 2| 2| 2
29| PIE-15-Z| 15Z SPRING STOPPER RING| 1| 1| 1| 1| 1
30| PIE-25-Z-ZA| 25 ZA STOPPER RING| 2| 2| 2| 2| 2
31| PIE381| 38 Z SPRING STOPPER RING| 1| 1| 1| 1| 1
32| SPRE-22,5.50| PULL ROD SPRING| 1| 1| 1| 1| 1
33| TUL-LOZ-XMF8.N| SHORT PLASTIC SLEEVE| | 1| 1| 1| 1

PART NO.
IN DRG.| CODE| DESCRIPTION| C61235
1| CB432| Z12 TOOTHED GEAR| 1
2| CB443| MK165 DRIVE SHAFT| 1
3| CB451| DISTANCE WASHER| 1
4| KOL-SP-5-45| 5X45 SPRING PIN| 1
5| LOZ-6002-ZZ| 6002 ZZ BEARING| 1

PART NO.
IN DRG.| CODE| DESCRIPTION| QTY
1| C8765| WASHER 029| 1
2| C81222| DRIVE GUARD – SET| 1
3| KOLO-PAS-DP160| DP160 BELT PULLEY| 1
4| PAS-5-610| 5P1610 MULTIGROOVE BELT| 1
5| PIE-28-Z| 28 Z SPRING STOPPER RING| 1
6| PODSTAWA-NAPEDU| DRIVE BASE| 1
7| SILN-EL-1F-SEK-110/45-2132| 1-PHASE MOTOR| 1
8| WYL-EL-1F-Z/W| 1-PHASE SWITCH| 1
9| ZASL-FI30| ø30 END PLUG| 2

OPERATION MANUAL

10.1. Personnel qualifications and responsibilities
The concrete mixer may be operated only by adults who has read with present manual and observe safety,  operation and maintenance instructions as well as general safety rules contained in the manual.
The personnel responsibilities include:

• keeping the concrete mixer clean and operational,
• performing periodical inspections
• observance of health and safety regulations

10.2. Preparation of concrete mixer for operation
Clean the concrete mixer of dirt and dust and position it on dry, hardened and level ground. Acceptable roughness of the ground is up to 2 o .
1-phase electric motors used for driving the concrete mixers shall be connected to the 230V/50Hz mains.
Fluctuations of mains voltage allowed for proper motor operation shall not exceed 6% of motor rated voltage. Concrete mixers are produced as class II power tools. Electric shock safety is ensured through durable and continuous insulating housing of the drive and does not depend on the conditions of installation and mains connection.
For power supply connection the machine requires OWY or OPL 2 x 1,5 mm 2 for 10 m long extension cable or 2×2,5 mm 2 longer cable of needed ended with 2pS122 plug-in socket.
WARNING ! Never operate the concrete mixer with drive cover open.
Check the following points, before connecting the concrete to mains:

• verify gear transmission operation through manual drum rotation,
• verify if the power cord is undamaged and if the switch is off.
  Concrete mixer’s power cord shall be plugged in and out while insulated from voltage, i.e. with the switch turned off. After the verification is completed switch the concrete mixer on (with the drum set in horizontal position) and observe the operation without any load paying attention whether the drum rotates evenly, without grinds and jamming and the direction of rotation is anticlockwise.

10.3. Operation of the concrete mixer
Concrete mixer operates in cycles, in the following work sequence: loading the raw materials, mixing, unloading.
The drum is charged manually in accordance with stipulated formula (using spade, bucket). The first step is to pour a portion of water, then to add cement and gradually add aggregate and the remaining portion of water. During mixing, drum shall be positioned at 22 ÷ 30 o to the level. Time of charge mixing is 1.5÷3 minutes. Ready mixture shall be discharged adequately tilting the drum while the concrete mixer is operating.

MAINTENANCE AND REPAIR MANUAL

Proper and adequate maintenance ensures efficient operation and long life- cycle of the concrete mixer.
Maintenance includes the following activities: cleaning the concrete mixer (drum in particular) each time after finishing work, inspection of screw connections, inspection all major parts and removal of failures.
Disconnect the plug from socket before any periodical inspection, removal of any failures, removal of cover. After the season for construction works ends or extended idle time planned the concrete mixer shall be subject to preventive overhaul. Clean it carefully, remove any possible failures, replace damaged screws, nuts and protect it. Thanks to simple construction, concrete mixer is easy to repair. Destroyed or damaged adhesive plates can be ordered from the producer or retailers of concrete mixers.
11.1. Damages and repairs

• Motor does not rotate – check if there is a voltage in a power socket.
• Motor rotates, drum does not rotate – multigroove belt is damaged, it shall be replaced.
• Toothed gear jumps over the rim – excessive wear of driving gear, it shall be replaced.
• Damaged motor – consult electrician.

11.2. Replacement of cast iron rim and Z12 toothed gear.
To replace a cast iron rim or driving toothed gear, mark the position of the drum’s axle on the central sleeve of the bow. Then, knock out the spring pins from the sleeve and axle and then remove the drum from the bow’s sleeve. Replace the cast iron rim. To replace the driving toothed gear, knock out the spring pin, slide the ring from the shaft, put on a new one and reconnect using the pin. During the pin replacement, check the condition of rolling bearings no. 6002 ZZ (6002 RS). After the replacement of the above parts, insert the drum with the axle into the bow’s central sleeve in accordance with the marking made before, then align sleeve and axle holes, pin them together and check the operation.
11.3. Drive unit is produced as class II power tool.
Only qualified electrician is allowed to perform any operations on the motor and electric system. Remove the plug from the mains socket before loosening the drive cover. In the drive units the belt tension is factory adjusted and requires no additional adjustment (tensioning). Drive housing with electric system is a closed system which shall not be opened without special purpose.
NOTE! Insulation class II will be maintained if only original spare parts are used and distance and insulation gaps remain unchanged.

11.4. Lubrication and bearings replacement plan

• Bow’s journal for tilting the drum – remove the guards, lubricate with grease or oil.
• Drive shaft bearings of gear transmission no. 6002 ZZ (2RS) – replace bearings every 4 years. (approx. 4000 workhours).
• Bearings in drum’s sleeve no. 6207 ZZ (2RS) – replace every 4 years. (approx. 4000 workhours).
• Gear transmission of concrete mixer’s drum – not subject to lubrication !
  Each time after finishing work, clean the rim and toothed gear from sand and dirt and flush with water.

PARTS LIST

12.1. Completely assembled concrete mixer (MK-145/B, MK-165/B, MK-180/B) + operation manual.
12.2. Concrete mixer in a carton box MK-165/BK, MK-180/BK):

• Upper frame
• Leg
• Chassis frame
• Road wheel (2 pieces)
• Bottom drum set with a bow
• Tilting wheel
• Mixing blades (2 pieces| • Gasket;
• Upper drum
• Drive unit
• Bottom pull rod
• A bag with fasteners
• Operation manual
---|---

DISASSEMBLY AND DISPOSAL

Concrete mixer’s life cycle is 7-10 years.
4 years if operated every day.
After the life cycle expires the concrete mixer shall be disposed in accordance with paragraph 2 in General section.

MORTAR PREPARATION

Tilt the drum to the demanded position from one or the other side. Tilting closest to horizontal position results in the most efficient mixing of binding materials (mortar), but reduces the volume.
Pour some water to the drum, add a portion of aggregate (gravel or sand) and cement. Then, add water and aggregate as needed. Dosage table will facilitate the mortar preparation.
The given amount of water is approximate; it depends on the aggregate moistness. To mix the mortar properly, the drum shall rotate for approx. 2 minutes. Longer mixing can cause the materials to separate. Quantity of materials given is approximate only and the concrete mixer’s producer shall not be held liable for it.

Dosage of concrete and mortars per one 50kg bag of cement

| Sand 0.2-0.5 mm| Gravel 20 mm| Water
Concrete for foundations| 120 litres| 160 litres| approx. 25 litres
Footing| 70 litres| 110 litres| approx. 25 litres
Reinforced concrete slabs, lintels, beams| 60 litres| 90 litres| approx. 25 litres
Bricklaying mortar| 110 litres| –| approx. 25 litres
Plaster| 100 litres| –| approx. 25-30 litres
Flooring mortar| 200 litres| –| approx. 25 litres

WARRANTY CARD

The concrete mixer was produced in accordance with design and engineering documentation as well as Company standards applicable in the company.
WARRANTY TERMS AND CONDITIONS:
The warranty covers failure-free operation of the concrete mixer within 12 months from the date of purchase.
The warranty terms cannot exceed 24 months from the shipment of the concrete mixer to a distributor.
The producer is obliged under warranty terms and conditions toremove the defects /defective workmanship, use of inadequatematerials) found by the user. – within 30 days from the date the defects were discovered and filing a complaint by the user
(seller) accompanied by the present card.
The warranty shall become ineffective and invalid in the following cases: improper storage, use non-compliant with the operation manual, performing repairs and modifications without the producer’s permit.
Visually inspect the concrete mixer for completeness and mechanical damage within 10 days from the receipt. Any complaint filed after that time and referring to completeness and damage ion transport shall not be accepted.
Not filled in and not signed warranty card is not valid. In case any complaint is not accepted, all repair-related costs shall be borne by the user.
EU DECLARATION OF COMPLIANCE
Supplier (producer): ALTRAD POLAND S.A. 15-617 BIAŁYSTOK, ul. NOWOSIELSKA 6, POLSKA
DECLARES WITH FULL RESPONSIBILITY THAT product: GRAVITY CONCRETE MIXER with parameters: – max operational capacity
– geometric capacity

meets the requirements of the following directives: 2006/42/WE, 2014/35/UE, 2014/30/UE, 2000/14/WE, 2011/65/WE and unified standards:PN-EN-12151/2008, PN- EN ISO 13857/2010, PN-EN-60204-1/2018-12,
PN-EN-60335-1/2012, PN-EN-55014-1/2017-06, PN-EN ISO 12100/2012.
Applied procedure of compliance evaluation is complaint with the appendix no. 6 to the Directive no. 2000/14/WE Warranted level of acoustic pressure LWA – 85 dB
The level of acoustic pressure LWA –82 dB, measured by UDT-CERT Warsaw
Documentation is held by DTK Department of ALTRAD POLAND S.A., under the management of Mr Dariusz Momotko.
**** MODEL

15-617 Białystok ul. Nowosielska 6

15-617 Białystok ul. Nowosielska 6

****+48 856-627-550
+48 856-613-260
 www.altradpoland.pl

References

• Altrad Poland S.A. – Producent betoniarek, taczek, maszyn drogowych

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