Atlas Copco Ground Engineering Products

CEMIX® Grout Mixer

CEMIX®
CEMIX COMPLETE
CEMIX WB
Safety and Operating Instructions
CEMIX 103
CEMIX 203
CEMIX 403

© 2014 Atlas Copco Craelius AB | No.6991 1128 01k | 2014-02-21

 Safety and operating instructions

Contents
Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Safety signal words . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Personal precautions and qualifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Hoisting and transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Storage, repair, maintenance and disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Personal protective equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Drugs, alcohol or medication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Safety area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Hoisting and transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Operation, precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Maintenance, precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9

Signs and stickers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Prohibition signs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
Warning signs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
Slip risk. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Moving parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Regulatory signs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
General regulatory signs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Information signs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Other signs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Rig data plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Patent protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Genuine parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Design and function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
Intended use. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Unintended use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Main parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
CEMIX with electric mixer motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
CEMIX COMPLETE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
CEMIX WB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Mixer with hyd. motor and optional pneumatically operated valve . . . . . . . . . . . . . . . . . . 15
Safety on and around the rig. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
Dangers on the rig . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Danger zones . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

© 2014 Atlas Copco Craelius AB | 2014-02-21 3

01 TOC CEMIX 103, 203, 403 Ed.4
Safety and operating instructions

Safety devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15

Emergency stop button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Hoisting and transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Hoisting the mixer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
Transport the mixer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
Transport lock. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Safety check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
Emergency stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Grouting system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Before start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
Electric cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
Hydraulic motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
Valve system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
Mixing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
After grouting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Daily maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
Replacing the rotating seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
Adjusting the clearance between the impeller and the wear plate . . . . . . . . . . . . . . . . .22
Adjusting of impeller clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
The rotating seal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
Greasing the parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
Wear parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23

Disposal and environmental instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Oil and Grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Electrical components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Chemicals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Dust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Metals (steel, aluminum, etc.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Plastics and rubber. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Pressure vessel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Material Safety Data Sheets (MSDS/SDS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

4 © 2014 Atlas Copco Craelius AB | 2014-02-21

01 TOC CEMIX 103, 203, 403 Ed.4
 Safety and operating instructions

Optional equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Measuring tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
Water meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
Mixer hose with quick coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25

Technical specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
CEMIX 103E. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
CEMIX 203E. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
CEMIX 403E/403H . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Sound power level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27

© 2014 Atlas Copco Craelius AB | 2014-02-21 5

01 TOC CEMIX 103, 203, 403 Ed.4
Safety and operating instructions

Introduction
These instructions are intended for operators of the Atlas Copco equipment. The aim of the
instructions is to provide you with knowledge of how to use the equipment in an efficient
and safe way. These instructions also give you advice and tell you how to perform regular
maintenance on the equipment. It does not replace thorough training of operator, it is a
complement. For further information concerning service measures, please contact your
nearest Atlas Copco representative.
Always read these instructions carefully and make sure that you understand all of them
before starting for the first time.

The owner of the equipment is granted the permission to take copies of this publication
solely for internal use. It is recommended, however, to order additional copies from Atlas
Copco representative in order to benefit from the latest revision. Atlas Copco Craelius AB
reserves the right to make changes in its products in order to improve design or performance
characteristics without notice. The information in this publication is assumed to be accurate at
the time of publication, but is subject to changes in order to remedy detected deficiencies or
to follow changes in the product.
Any user of this publication is requested to inform Atlas Copco Craelius AB about deficiencies
found, particularly in matters concerning product safety.

© 2014 Atlas Copco Craelius AB | 2014-02-21

Introduction

Safety instructions
To reduce risk of serious injury or death to yourself or
others, read these safety instructions before operating
the machine. Post these safety instructions at work
locations, provide copies to employees, and make
sure that everyone reads the safety instructions before
operating or servicing the machine. Comply with all
safety regulations.
All possible hazards cannot be covered here, but we
highlight some of the most important. For additional
safety information consult:
 Other documents and information packed with this
machine.
 Appropriate standards as referred to in the EC
Declaration of Conformity, if provided.
Safety signal words
The safety signal words Danger, Warning and Caution
have the following meanings:
DANGER Indicates a hazardous situation
which, if not avoided, will result
in death or serious injury.
WARNING Indicates a hazardous situation
which, if not avoided, could
result in death or serious injury.
CAUTION Indicates a hazardous situation
which, if not avoided, could
result in minor or moderate
injury.
Personal precautions and
qualifications
Only qualified and trained persons may operate or
maintain the equipment. Always use your common
sense and good judgement.
Hoisting and transport
Hoisting and transport of the equipment may only be
undertaken by persons who:
 are authorized to operate a crane or fork-lift truck in
conformity with the applicable national directives,
 are aware of all the relevant national safety
instructions and accident prevention instructions
 and have read and understood the safety and
hoisting and transport chapters of this manual.
Storage, repair, maintenance and disposal
Storage, repair, maintenance and disposal of the
equipment may only be undertaken by persons who:
© 2014 Atlas Copco Craelius AB | 2014-02-21
02 Safety Instructions Grouting Ed.2
Safety and operating instructions
 are aware of all the relevant national safety
instructions and accident prevention instructions
 and have read and understood the Safety and
operating instructions.
Operation
Operation of the equipment may only be undertaken
by qualified operators. Operators are qualified if they:
 have undergone theoretical and practical training
on the equipment in conformity with the national
directives,
 are aware of all the relevant national safety
instructions and accident prevention instructions
 and have read and understood the Safety and
operating instructions.
Personal protective equipment
WARNING Entanglement hazard
Loose fitting clothing and jewelry can get caught in
the moving parts of the machinery and cause serious
injury or death.
►Do not wear jewelry and loose fitting clothes.
Always use approved protective equipment. Operators
and all other persons in the working area must wear
protective equipment, including at a minimum:
 Protective helmet
 Hearing protection in accordance with occupational
health and safety regulation
 Impact resistant eye protection with side protection
 Respiratory protection when appropriate
 Protective gloves
 Proper protective boots
Drugs, alcohol or medication
WARNING Drugs, alcohol or medication
Drugs, alcohol or medication may impair your
judgment and powers of concentration. Poor reactions
and incorrect assessments can lead to severe
accidents or death.
►Never use the machine when you are tired or under
the influence of drugs, alcohol or medication.
►Prevent other people from using the machine if
they are under the influence of drugs, alcohol or
medication.
7
Safety and operating instructions
Safety area
WARNING Falling objects can cause serious
injury or death
During operation, falling objects from great heights can
cause bodily injury and extensive damage.
►Close off the working area.
►Before starting always make sure no unauthorized
persons are within the working area of the drill rig in
use.
►Immediately stop operation when persons are
present in the danger area.
Hoisting and transport
WARNING Heavy equipment can cause serious
injury
►Use a sling dimensioned for the load it will carry.
►Use only straps that are intact and intended for the
load in question.
►Never use a damaged rope/sling.
►Fasten straps in lifting eyes when present.
►Always lift at the center of gravity.
►Always make sure that nobody is under or anywhere
near a suspended load or within the swing radius of
the rope/sling.
►Observe great care when strapping and lifting heavy
objects.
NOTICE Sling can damage components
►When lifting, make sure that the sling will not
damage the hydraulic hoses, mechanical
components etc.
Operation, precautions
WARNING Hydraulic oil at high pressure
Thin jets of hydraulic oil under high pressure can
penetrate the skin and cause permanent damage.
►Immediately consult a doctor if hydraulic oil has
penetrated the skin.
►Never use your fingers to check for hydraulic fluid
leaks.
►Keep your face away from any possible leaks.
8 © 2014 Atlas Copco Craelius AB | 2014-02-21
WARNING Dust hazard
When drilling with compressed air, the rock cuttings
are carried out of the bore in the form of small cuttings,
and dust, which can cause serious injury.
Some dusts, fumes or other airborne material created
during use of the machine may contain chemicals
known to the State of California to cause cancer
and birth defects or other reproductive harm. Some
examples of such chemicals are:
 Crystalline silica, cement and other masonry
products.
 Arsenic and chromium from chemically-treated
rubber.
 Lead from lead-based paints.
►To reduce your exposure to these chemicals, work in
a well-ventilated area and work with approved safety
equipment, such as dust masks that are specially
designed to filter out microscopic particles.
►Use a dust collector, or spray water with a water/
foam pump.
WARNING Unexpected movement can cause
serious injury
If control levers and switches are not set to neutral
position, starting the machine can lead to unexpected
movements and can therefore cause injury.
►Set control levers and switches to neutral positions
prior to starting up.
WARNING Noise hazard
High sound levels may cause permanent hearing loss.
►Use hearing protection in accordance with
occupational health and safety regulations.
WARNING Emergency situation
An emergency situation can occur due to material
failure or incorrect handling.
►Stop the operation by pushing the emergency stop
button or if available pull the trip wire.
►Check proper function of the rig safety equipment at
least once beginning of each shift.
WARNING Gas line pressurized, Explosion
hazard
If the equipment comes in contact with gas lines and
explosives, an explosion could occur. Explosions will
lead to severe injuries or death.
►Never operate the machine in any explosive
environment.
►Never use the machine near flammable materials,
fumes or dust.
02 Safety Instructions Grouting Ed.2

►Make sure that there are no undetected sources of
gas or explosives.
►When working in areas where gas lines are buried,
make sure that your equipment is placed on the
windward side.
►Shut down all combustion engines, like hydraulic
power pack, generators etc.
►Leave the machine immediately.
►Warn people to evacuate the area.
►Contact emergency personnel.
►Contact the gas company to shut the gas off.
►Stay out of the area until the gas company declares
the area to be safe.
Maintenance, precautions
WARNING Hydraulic oil
Spilled hydraulic oil can cause burns, accidents by
slippery conditions and will also harm the environment.
►Take care of all spilled oil and handle it according to
your safety and environment regulations.
►Never dismantle the hydraulic components when the
hydraulic oil is hot.
WARNING Hydraulic system under high
pressure
Maintenance and repair on the machine and the
hydraulic equipment under pressure can lead to
severe injuries. Connections can loosen suddenly,
parts can suddenly move and hydraulic oil can be
ejected.
►Depressurize the hydraulic system before
performing maintenance on the hydraulic
equipment.
►Never replace high pressure hoses with hoses of
lower quality than the original or with hoses that
have removable couplings
Pressure settings are always performed on a
pressurized system.
►Always exercise the greatest caution.
►Pressure settings must only be performed by trained
personnel.
WARNING Rotating parts can cause serious
injury and damage
►Always turn off the engine before performing any
maintenance or service on the equipment.
WARNING Machine modification
Any machine modification may result in bodily injuries
to yourself or others.
►Always contact your Atlas Copco Customer Center
before you modify the machine.
© 2014 Atlas Copco Craelius AB | 2014-02-21
02 Safety Instructions Grouting Ed.2
Safety and operating instructions
►Always use original parts and accessories approved
by Atlas Copco.
WARNING Heavy machine can cause serious
injury
►During service and maintenance work, all
components that may be brought into motion or fall
must be supported or tied secure.
WARNING Thermal cracks may arise when
welding
►Do not do any welding on the equipment without
consulting Atlas Copco.
WARNING Hot engine parts can cause burn
►Make sure the engine is turned off before all
maintenance work and before refueling
►Be careful when draining hot oil and fluids
►Do not handle flammable fluids in the vicinity of hot
surfaces, sparks or naked flames
WARNING Electric shock
►Do not touch live electrical lines
►Only authorized electricians may carry out work on
the electrical system.
►Only qualified electricians should perform any
electrical troubleshooting or maintenance. Remove
all watches and rings that could contact live electric
circuits.
►Make sure all power to the system has been cut
before carrying out any maintenance work.
►All electric cabinets should remain locked when not
under direct control of qualified electrician.
►Do not use the cabinets as a toolbox or spare
parts storage container. The inherent vibration and
magnetism associated with transformer and motor
starters can cause inadvertent contact of foreign
objects with live circuits.
►Some electrical components may have power when
the main circuit breaker is open, verify that power is
disconnected before servicing.
►Do not tamper with safety interlock circuits, safety
guards or other safety devices, except as required
during normal maintenance and troubleshooting.
►Confirm that all safety devices and circuits are
replaced and functioning before operation is
resumed.
9
Safety and operating instructions

Signs and stickers Moving parts

The equipment is fitted with signs and stickers
containing important information about personal safety
and maintenance.
The signs and stickers shall always be easy to read.
Some of the following signs may be used on your
grouting equipment. Part numbers displayed on these
signs are designated to the plates only.

Prohibition signs

Moving parts can cause injuries.

♦ Keep out of the machine’s working area when it is in
♦ No admittance operation.

♦ No admittance for unauthorized personnel.

♦ Violation can cause personal injury. Regulatory signs

General regulatory signs

8915 0020 84

♦ Never put anything inside the CEMAG/CEMIX while

the engine is running.
♦ Violation can cause personal injury. ♦ The foot protection symbol means that you have to
wear boots.
♦ The eye, ear and head protections symbol means
Warning signs that you have to wear a hard hat, eye and ear
protection.
Slip risk ♦ The hand protection symbol means that you have to
wear hand protection.
♦ The instruction book symbol means that you have
to read the Safety and Operating instructions before
the equipment is used for the first time.

Slippery surface can cause injuries.

♦ Be careful when moving around on the rig.
♦ Do not run on the rig.

10 © 2014 Atlas Copco Craelius AB | 2014-02-21

03 Signs and stickers Unigrout Ed.2
 Safety and operating instructions

Information signs

Hydraulic oil drain

Other signs
Fire extinguisher

Rig data plate

See the Technical specifications section for further
information.

Atlas Copco Craelius

MÄRSTA - SWEDEN

A
Name
Hoisting/lifting point Type
Serial No.
Diesel power kW
B Rated voltage V Hz C
Electric power kW
I.P.
Gross weight kg D
3716 5522 00 Made in Sweden 201
AIB 100000282_00

A. Machine type
B. Serial number
C. The warning symbol together with the book symbol
means that the user must read the safety and operating
Hydraulic oil pressure instructions before the machine is used for the first time.
D. The CE symbol means that the machine is CE-approved.
See the CE Declaration of Conformity which is delivered
with the machine for more information.

Patent protection

Hydraulic oil level and temperature

Hydraulic oil filter

This product is protected by one or several world wide

patents.

© 2014 Atlas Copco Craelius AB | 2014-02-21 11

03 Signs and stickers Unigrout Ed.2
Safety and operating instructions

Genuine parts Cement Additive

3716 5565 83 3716 5565 81

Filling Emptying

3716 5565 87 3716 5565 54

Lower level limit Manually

3716 5565 84 3716 5565 86

Number 1 Number 2

1
3716 5565 78
2
3716 5565 79

For best performance make sure to always use

genuine Atlas Copco spare parts.

Before starting,
oil must be filled
according to lubricant
recommendations in the
Maintenance section
On Off

3716 5565 32 3716 5565 33

On/Off Water flow

3716 5565 31

3716 5565 27

3716 5565 35
Rotation 3716 5565 36
Rotation
Clockwise Counter-
clockwise

Grout flow Grout pressure

G
G
3716 5565 53 3716 5565 37

Rotation speed System pressure

regulation

3716 5565 06 3716 5565 01

Mixer Agitator

3716 5565 51 3716 5565 50

Hydraulic flow Vibrator

3716 5565 52 3716 5565 82

12 © 2014 Atlas Copco Craelius AB | 2014-02-21

03 Signs and stickers Unigrout Ed.2
 Safety and operating instructions

Overview
To reduce the risk of serious injury or death to yourself
or others, read the Safety instructions section found on
the previous pages of this manual before operating the
equipment.

Design and function

CEMIX® is a high speed colloidal grout mixer for
mixing water / cement ratios down to 0,35. The mixer
produces a thoroughly uniform mix free of lumps or
aggregates and with every cement particle individually
separated and wetted.
The cement particles disintegrate in three steps
through shearing actions:
♦ First in the vortex in the container created by the
high velocity impeller.
♦ Second from the shearing action created by the
turbulence in the specially designed mixer housing.
♦ Third, through an eccentric formed vortex to
increase the shear forces; this also keeps the dry
unmixed particles from forming a floating clod in the
centre.
Each cement particle thus becomes separated and
effectively wetted.
When compared to a paddle mixer, CEMIX® is also
more advantageous to use in those cases where the
mix contains bentonite.
CEMIX® can also with advantage be used as a pump
when the grout mixture has to be transported a shorter
distance e.g. to a grouting station.
CEMIX® mixers can be supplied with either electric or
hydraulic motors.

Intended use
The grout mixer CEMIX® is intended for mixing grout,
drilling fluid, mud, paint and pulp.

Unintended use
Any use going beyond this shall be considered
"unintented use". The manufacturer is then not liable
for damage incurred as a result; such use shall be at
the owner's risk. Proper use also includes observing
information in operation-, service-, and maintenance
sections as stipulated by the manufacturer.

© 2013 Atlas Copco Craelius AB | 2013-11-07 13

04 Overview CEMIX 103, 203, 403 Ed.4
Safety and operating instructions

Main parts CEMIX COMPLETE

A. Mixer
A B
B. Bag splitter

C. Circulation and outlet valve assembly

D. Hose

E. Electrical cabinet C

F. Emergency stop

G. Electric motor D

H. Welding feet
F
I. Stand

J. Weight batching housing E

CEMIX with electric mixer motor

A
B

CEMIX WB
Cemix WB (Weight Batching) consists of weight
sensors.

C
A

C
D
J

J
D
I

14 © 2013 Atlas Copco Craelius AB | 2013-11-07

04 Overview CEMIX 103, 203, 403 Ed.4
 Safety and operating instructions

Mixer with hyd. motor and optional Safe zones

pneumatically operated valve The area outside the danger zones are to be
considered as safe zones.

Safety devices

Emergency stop button

Safety on and around the rig

Dangers on the rig

A
A

Cemix complete is equipped with an emergency stop

button. The emergency stop button is located on the
electrical cabinet.

1 2

AIB 100000357_01

A. Grout may splash out of the CEMIX. Always

use eye protection around the rig and when The emergency stop button is activated by pressing
inspecting equipment. them (1). To reset a emergency stop button turn it
clockwise untill it pops out to normal position.
Danger zones

A A

m ft
A 1 3
During normal operation it is advised to always use
personal protective equipment within the danger zone.

© 2013 Atlas Copco Craelius AB | 2013-11-07 15

04 Overview CEMIX 103, 203, 403 Ed.4
Safety and operating instructions

Hoisting and transport Transport the mixer

WARNING Heavy equipment can cause
serious injury All the mixers in the CEMIX® range are easy to
transport or relocate. Slots are placed in the frame
►Use a sling dimensioned for the load it will carry. to facilitate hoisting or moves with a forklift truck for
►Use only straps that are intact and intended for the example.
load in question.
Caution Movement during transport can
►Never use a damaged rope/sling. damage equipment
►Fasten straps in lifting eyes when present.
Transport lock
►Always lift at the center of gravity.
A CEMIX equipped with load cells is also equipped
►Always make sure that nobody is under or anywhere with transport locks to protect the sensors during
near a suspended load or within the swing radius of transport.
the rope/sling.
►Always secure the CEMIX with the three transport
►Observe great care when strapping and lifting heavy locks before transport.
objects.
NOTICE Sling can damage components
When lifting, make sure that the sling will not damage
the hydraulic hoses, mechanical components etc.

A
Hoisting the mixer
Lifting skid
The CEMIX® is mounted on a lifting skid (A) that has
two lifting slots (B) for forklift.

A. Transport lock

A B

16 © 2013 Atlas Copco Craelius AB | 2013-10-22

05 Hoisting and Transport CEMIX 103, 203, 403 Ed.2
 Safety and operating instructions

H. Suction hose
Operation
DANGER Electric shock I. Delivery hose

Touching live electrical lines will cause serious injury J. Grout recorder
or death. K. Ball valve
►Never touch live and damaged electrical lines. L. Packer
►Stop motor before repair or inspection inside the 1. Connect a suction hose between the agitator
container. and pump inlet.
2. Connect a shut-off valve and a pressure hose
of correct rating between the pump outlet and
Safety check packer (or back to the agitator for circulation).
3. Check that the whole grouting system is ready
There are safety devices built into the system of the
for operation – hoses, packers, grout mix
mixer for your personal safety.
e.t.c. A by pass kit for pump recirculation is
Before each shift commences, an extra and thorough recommended.
safety check shall be carried out on the equipment.
♦ Check the safety devices at least once every shift to
ensure that they are in full working order, so that you Before start
know that they will be operational the moment you
need them. ♦ Place platform on level ground.

♦ If you are unsure of the equipment's reliability, do
not put it into operation.
Emergency stop
♦ Check that the emergency stop stop the engine
by pressing the emergency stop button while the
engine is running.
♦ Reset the emergency stop button by turning it
clockwise.
Note: Inclination must be under 5 degrees or the load
cells will not work properly.
Note: If platform in not placed on level ground the
vortex might become unstable and mixing efficiency
will decrease.
♦ When starting the unit with separate startbox, follow
instructions below.
♦ When starting a mixer that is part of a Unigrout, use
the startbox of the Unigrout.

Grouting system
Electric cabinet
Grouting equipment
The electric motor is designed for 7,5 kW 400V, 50 Hz
L
1435 rpm. For other voltage and frequenzy contact
H D your local ACC dealer.
F
C G
B ♦ Check all electric connections.
A
I
A
K
B
E H
J C
A. Measuring meter from Water tank
B. Mixer D
C. Agitator
D. Return hose E
E. Ball valve, outlet
M. Main switch
F. Ball valve, return cirkulation.
N. Start button
G. Grout pump
O. Stop button
P. Emergency stop button
Q. Control lamp

© 2013 Atlas Copco Craelius AB | 2013-11-06 17

06 Operation CEMIX 103, 203, 403 Ed.3
Safety and operating instructions
Start
♦ In case of emergencies, stop the machine by
pressing the emergency stop button.
♦ Reset the emergency stop button by turning it
clockwise.
4. Check that the emergency stop ( is not activated.
(The knob should be in outwards position).
5. Turn on the main switch (A).
6. Start the electric motor by pressing the green
start button (B).
7. Check direction of rotation. When rotating in the
wrong direction, contact electrician and switch
the two phases.
8. To stop the motor press the red stop button(C)
Hydraulic motor
Connect to a separate power pack with a minimum
rating of:
Flow: 19 l/min
Max pressure: 200 bar
The mixer is driven by a electro-hydraulic power unit
PUG 22 with standard speed range between 1750 rpm
and 1800 rpm.
Valve system
A. Grout mix circulates in the mixer.
B. Lever position when emptying the mixer.
18
Mixing
1. Fill mixer with recommended volume of water.
Check counter on water meter or measuring
scale in water tank. *
* Coefficient of fullness without splashing is normally
70-85%, depending on the quality of the grout.
2. Check that lever in the valve system is in mixing
position.
3. Start the motor.
4. Add the right amount of cement into the mixer.
Open the bag against the bag splitter.
5. Let the mixer run until the grout is well mixed
and then put lever in pump out-to-agitator
position and pump out the grout to the agitator.
After grouting
The following steps should be carried out after every
work shift. This is vital to ensure that the equipment
stays in optimal working condition.
1. Check hoses and connections for leaks.
2. Always clean the mixer and hoses after grouting
is done or when there is an extended break in
grouting operations.
3. Fill the tank with water and start-up the mixer.
Allow the water to circulate in the tank until the
interior of the tank appears clean. Brush or
scrape free any remaining particles of grout that
have not been dislodged.
4. Disconnect mixing hose and pump out the
cleaning water on the ground by switching lever
to pump-out position. Repeat the procedure until
the mixer is cleaned.
5. When risk of freezing, remove the drain plug at
the bottom of the mixer housing this will let the
air circulate through the machine.
© 2013 Atlas Copco Craelius AB | 2013-11-06
06 Operation CEMIX 103, 203, 403 Ed.3
 Safety and operating instructions

© 2013 Atlas Copco Craelius AB | 2013-11-06 19

06 Operation CEMIX 103, 203, 403 Ed.3
Safety and operating instructions

3. Undo the setscrew (L) and slide the mixer shaft

Maintenance along the motor shaft until a clearance of 3 mm is
DANGER Electric shock
obtained between the impeller (E) and the wear
►Do not touch live and damaged electrical lines. plate (M).
►Only authorized electricians may carry out work on
the electrical system.
►Only qualified electricians should perform any
Replacing the rotating seal
electrical troubleshooting or maintenance. Remove Replacing the rotating seal (same procedure is valid
all watches and rings that could contact live electric for air and hydraulic driven mixers,
circuits.
4. Disconnect the power supply cable from the
►Make sure all power to the system has been cut electrical cabinet before commencing with the
before carrying out any maintenance work. work on the mixer. (For the hydraulic motor
►All electric cabinets should remain locked when not mixer, shut of the hydr. power pack).
under direct control of qualified electrician. 5. Undo the manifold from quick connection (A) by
WARNING Rotating parts can cause serious undoing the clamp connection.
injury
►Stop the engine before doing any inspection and
service.
►Never use sharp objects during cleaning process.
WARNING Hydraulic system under high
pressure
Maintenance and repair on the machine and the
hydraulic equipment under pressure can lead to severe
injuries. Connections can loosen suddenly, parts can
suddenly move and hydraulic oil can be ejected.
A
►Depressurize the hydraulic system before
performing maintenance on the hydraulic equipment. 6. Undo the 4 screws (B) holding the protective
cover. Remove the protective cover (K) from the
►Never replace high pressure hoses with hoses of motor frame service opening.
lower quality than the original or with hoses that
have removable couplings

Daily maintenance
K
NOTICE Wear on rotating seal
►Always service after each shift.
►Never tighten the rotating seal to hard.
►Use only water when tighten the seal ring. B P
1. Remove the protective cover (K) from the motor
frame service opening. 7. Undo the setscrew (L) on the seal holder (J)

J L H F Q

B P

2. Undo the four screws (B) and take away the

mixer housing.

20 © 2013 Atlas Copco Craelius AB | 2013-10-22

07 Maintenance CEMIX Ed.2
 Safety and operating instructions

F
H Q
F
J

8. Undo the four screws (B) and take away the

mixer housing. Check the o-ring and the drain
14. Inspect the o - ring (H) and replace if necessary.
plug.

K
F
H Q

E
B P

15. Unscrew the rotating seal assembly from the

9. Unscrew the drain plug (P) and check its o-ring.
mixershaft by rotating the seal holder and at the
10. Remove the rubber plug (C) with a screwdriver. same time keep the mixershaft from rotating.
16. Check the surface of the seal plate (F). If any
sign of wear or scratches, replace it with a new
one and a new seal (Q).
17. Reassemble in reverse order.

11. Undo impeller fixing screw (D) using an 8 mm

Allen key.

D E

12. Remove the impeller (E) and replace it with a

new one if it is found to be worn.
13. Undo the three screws (F) holding the seal plate
(G).

© 2013 Atlas Copco Craelius AB | 2013-10-22 21

07 Maintenance CEMIX Ed.2
Safety and operating instructions
Adjusting the clearance
between the impeller and the
wear plate
If the motor has been replaced or dismantled, then the
clearance between the impeller and the wear plate
must be checked and adjusted if necessary.
Adjusting of impeller clearance
1. Remove the protective cover (K) from the motor
frame service opening.
B P
2. Undo the four screws (B) and take away the
mixer housing.
3. Undo the setscrew (L) and slide the mixer shaft
along the motor shaft until a clearance of 3 mm
is obtained between the impeller (E) and the
wear plate (M).
L motor until water stops to leak between
E seal against the underside of the seal plate.
O = The gap between the impeller and thewearplate
shall be 3 mm.
4. Tighten the setscrew (L).
5. Reassemble the mixer housing.
22
The rotating seal
If leakage occurs between the rotating seal and the
seal plate, then do as follows:
1. Disconnect the power supply cable from the
electrical cabinet before commencing with the
work on the mixer. (For the hydraulic motor mixer
shut of the hydr. power pack).
2. Remove protection cover (K) from
the motor frame service opening.
3. Undo setscrew (L) from the seal holder (J) using
a 3 mm Allen key.
J
L
4. Fill up mixer with 5 - 10 l water.
5. Turn the seal holder clockwise towards the
rotating seal and seal plate (1/4 - 1/2 turn
should be sufficient). The rotating seal will now
6. Lock the seal holder (J) on mixer shaft by
tightening the setscrew (L).
7. Mount the protection cover (K) to the motor
frame.
© 2013 Atlas Copco Craelius AB | 2013-10-22
07 Maintenance CEMIX Ed.2
 Safety and operating instructions

Greasing the parts

When reassembling after service use grease on
all parts which are in contact with grout for easier
dismantling at the next service

Wear parts
A D
M
N

O
F

P
K
B J
C
Q
G H E I

A. Set screw
B. Seal plate
C. Packing
D. Seal holder
E. Cap screw
F. Screw
G. Impeller
H. Washer
I. Rubber plug
J. Cap screw
K. O-ring
L. Wear plate
M. Set screw
N. O-ring
O. Seal washer
P. Water connection
Q. Drain plug

© 2013 Atlas Copco Craelius AB | 2013-10-22 23

07 Maintenance CEMIX Ed.2
Safety and operating instructions
Disposal and environmental
instructions
Always follow the local regulations in force for the
handling and disposal of waste.
Oil and Grease
Leaking hydraulic connections and lubrication grease
are environmentally hazardous. Changing oils,
replacing hydraulic hoses and different types of filter
can be environmentally hazardous.
♦ Always collect oil residue, oil spillage, waste with
oil content, lubrication grease residue and spillage.
Treat the hazardous material in accordance with
local regulations.
♦ Use biodegradable hydraulic fluids and lubrication
oils for Atlas Copco products wherever possible.
Contact your local Atlas Copco office for further
information.
Engine
Engine exhausts are poisonous and environmentally
hazardous.
♦ Good ventilation is essential when the diesel engine
is running.
♦ Well-maintained air filters help to keep down
emission levels.
Fuel
Fuel spillage is environmentally hazardous and a fire
hazard.
♦ Always collect fuel residue and spillage. Treat in
accordance with local regulations.
Batteries
Batteries contain acids and heavy metals. For this
reason, expended batteries can be hazardous to the
environment and to health.
♦ Expended batteries must be sent for destruction in
accordance with local regulations.
Electrical components
Some electronic components contain batteries and
other components which could be hazardous to the
environment and personal health. Certain types of
work lighting contain mercury and could therefore
constitute environmental and health hazards.
♦ Treat the components according to local regulations
in force for destruction and waste disposal.
24
Chemicals
Chemicals such as flushing additives, other additives
and coolants can be environmentally hazardous.
♦ Dispose of chemicals such as drilling additives, other
additives, glycol etc. according to the manufacturer’s
instructions.
♦ Treat the chemicals in accordance with local
regulations for both handling and waste disposal.
♦ Avoid the use of cleaning agents containing solvents
like carbon tetrachloride. There are environmentally
better alternatives now available on the market.
Dust
Rock dust can pose a health danger.
♦ Use dust binding oil.
Metals (steel, aluminum, etc.)
♦ These products are recyclable and should be taken
care of according to national regulations.
Plastics and rubber
♦ These products are often labeled according to
different classes. In those cases they are recyclable,
they should be taken care of according to national
regulations.
Pressure vessel
A pressure vessel can cause serious injury.
♦ Discarded accumulators or gas springs must be
rendered harmless.
♦ A discarded pressure vessel that has not been
punctured must be treated like a pressure vessel.
Material Safety Data Sheets (MSDS/SDS)
Material Safety Data Sheets (MSDS/SDS) for the
chemical products included in the delivery are
available at the:
Atlas Copco Safety Data Sheets Repository
Full link
http://www-1.atlascopco.com/__C125712A0045C780.
nsf/CustViewProd20?OpenView
Please download the specifications from this link.
© 2014 Atlas Copco Craelius AB | 2014-02-21
09 Disposal Ed.3
 Safety and operating instructions

Optional equipment Mixer hose with quick coupling

A
Measuring tank
B

C EM I X CEMAG
C

A. Measuring tank
B. Water meter
The measuring tank is placed above the mixer. In three C. Mixer hose
possible positions Mixer hose with quick coupling, a 2” hose for
connection between the mixer - agitator - grout pump.

Water meter

The water meter has a volumetric counter which can

be hung on the edge of the mixer. It is available in two
versions:
a. Gallon
b. Liter

© 2013 Atlas Copco Craelius AB | 2013-10-22 25

10 Optional equipment CEMIX 103, 203, 403 Ed.2
Safety and operating instructions

Technical specifications
Specifications and dimensions given in this manual represent the state of engineering at the time of printing.
Modifications may take place and materials may be replaced by others without prior notice.

Denomination Prime Mover Container Weight (kg) Weight (lb)

Volume (litre)
CEMIX 103E Electric motor 7,5 kW at 1435 rpm (400V, 100 175 386
50Hz,15,5A)
CEMIX 103H Hydraulic motor (11 cm3 / r) 100 125 275.5
CEMIX 203E Electric motor 7,5 kW at 1435 rpm (400V, 200 220 485
50Hz,15,5A)
CEMIX 203H Hydraulic motor (11 cm3 / r) 200 155 342
CEMIX 403E Electric motor 7,5 kW at 1435 rpm (400V, 400 250 551
50Hz,15,5A)
CEMIX 403H Hydraulic motor (11 cm3 / r) 400 205 452

Dimensions

Dimensions

A
B

CEMIX 103E
Dimensions mm in
A 750 29.5
B 650 25.6
C 980 38.6

CEMIX 203E
Dimensions mm in
A 920 36.2
B 810 32
C 1200 47.2

26 © 2013 Atlas Copco Craelius AB | 2013-10-22

11 Technical Specifications CEMIX 103, 203, 403 Ed.0
 Safety and operating instructions

CEMIX 403E/403H
Dimensions mm in
A 1260 49.6
B 1000 39.4
C 1400 55.1

Sound power level

Conditions dB(A) rel 1pW
1 meter from rig 72

© 2013 Atlas Copco Craelius AB | 2013-10-22 27

11TechnicalSpecificationsCEMIX103,203,403Ed.0
 © Copyright 2014, Atlas Copco Craelius AB, Märsta, Sweden. Any unauthorized use or copying of the contents or any part thereof is
prohibited. This applies in particular to trademarks, model denominations, part numbers and drawings. Illustrations and photos in this
document may show equipment with optional extras. Specifications and equipment subjects to change without notice. Consult your

www.atlascopco.com
6991 1128 01k Märsta, Sweden, 21 February 2014 Atlas Copco Customer Center for specific information.