PROALL G Series Operator'S Manual Download

Page: 3 / 59

MX05001

Rev.

3 March 2022

Table of Contents

Model Number ................................................................................... 1-3

Serial Number .................................................................................... 1-3

Safety Decals ...................................................................................... 2-1

Safety Alert Symbol ............................................................................ 2-4

Signal Words ...................................................................................... 2-4

Safety ................................................................................................. 2-5

General Safety .................................................................................... 2-5

Operating Safety ................................................................................ 2-6

Maintenance Safety ........................................................................... 2-6

Hydraulic Safety ................................................................................. 2-6

Storage Safety .................................................................................... 2-7

Transport Safety ................................................................................. 2-7

Tire Safety .......................................................................................... 2-7

Safety Signs ........................................................................................ 2-8

How to Install Safety Signs: ......................................................................... 2-8

Mixer Controls ................................................................................... 4-1

Mix Auger Paddle ........................................................................................ 4-2

Operator Control ......................................................................................... 4-2

Operating Keypad ....................................................................................... 4-3

Valve Locations .................................................................................. 4-6

Traditional Gunite Production Calibration Procedure ....................... 5-1

Step 1: Cement Output per Conveyor Count .............................................. 5-1

Step 2: Counts per Unit Volume of Mix ...................................................... 5-1

Summary of Contents for G Series

Page 1: ...ProAll Mobile Mixer Operator s Manual G Model MX05001 3 March 2022 Rev 1 ...

Page 2: ...MX05001 Rev 1 3 March 2022 5810 47 Avenue Olds Alberta Canada T4H 1V1 E support proallinc com P 403 335 9500 F 403 335 9560 ...

Page 3: ... Maintenance Safety 2 6 Hydraulic Safety 2 6 Storage Safety 2 7 Transport Safety 2 7 Tire Safety 2 7 Safety Signs 2 8 How to Install Safety Signs 2 8 Mixer Controls 4 1 Mix Auger Paddle 4 2 Operator Control 4 2 Operating Keypad 4 3 Valve Locations 4 6 Traditional Gunite Production Calibration Procedure 5 1 Step 1 Cement Output per Conveyor Count 5 1 Step 2 Counts per Unit Volume of Mix 5 1 ...

Page 4: ...ibration 5 4 Principle of Operation 6 1 Mix Batching 6 1 Aggregate 6 1 Aggregate Control Gate 6 1 Cement Powder 6 2 Mix Auger 6 2 Drop Away Bottom Mat 6 3 Auger Bearing 6 3 Mix Bowl 6 3 Auger Top Drive 6 4 Fibre Feeder 6 5 Setting up to Pour 6 6 Pouring 6 7 Clean up and Preparation for Transport 6 7 Chain Oiler 6 8 Tarp 6 9 Tarp Control 6 9 Maintenance 7 1 Speed Sensor 7 1 Take Up Bearing 7 1 Oil ...

Page 5: ...2 Minimum Requirements for Replacement Oil 7 1 Hydraulic Oil Filter 7 2 Wear Plates 7 2 Service 7 3 Lubrication and Maintenance Points 7 4 Lubrication and Maintenance Frequency 7 9 Electrical Distribution Box 7 10 Bolt Torque 7 11 ...

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Page 7: ...e have helped us develop and engineer a mobile mixer that will give many years of dependable and profitable service This manual provides operating and maintenance procedures that are critical to the profitable and successful operation of your ProAll Mobile Mixer Operation and maintenance of your new mixer in accordance with this manual will assure you of long and trouble free service Keep this man...

Page 8: ...L NUMBER when ordering parts or requesting service or other information The serial number plate is located where indicated Please mark the number in the space provided for easy reference Model Number Serial Number Plate 1 Model and Serial Number Plate 1 ...

Page 9: ...ame Extension G95 8 50 Cubic Meter 9 50 Cubic Meter Base Model Capacity Serial Number K 2 N 2 VA 120 L 10950 Manufacturer s Serial Number Code X Swing system not required 69 137 Conveyor length indicating the number of cross bars on the chain VA VB 12 Volt Operating System 24 Volt Operating System X Water tank not required T9 Mixing Auger 12in body 9in screw x 96 in 2 Tandem Pump K System Electric...

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Page 11: ... safety decals have been placed on your machine in the areas indicated They are intended for your personal safety and for those working with you Please take this manual and walk around your machine noting the location of the decals and their significance 1 3 1 2 1 5 4 ...

Page 12: ...MX05001 2 2 Rev 1 3 March 2022 Decal 1 Decal 2 Decal 3 1 2 1 3 4 4 6 ...

Page 13: ...MX05001 2 3 Rev 1 3 March 2022 Decal 4 Decal 5 Decal 6 Decal 7 Decal 8 ...

Page 14: ...ded will result in death or serious injury This signal word is to be limited to the most extreme situations typically for machine components which for functional purposes cannot be guarded Indicates an imminently hazardous situation that if not avoided could result in death or serious injury and includes hazards that are exposed when guards are removed It may also be used to alert against unsafe p...

Page 15: ...nt is a SAFE operator It is the operator s responsibility to read and understand ALL Safety and operating instructions in the manual and to follow them All accidents can be avoided We feel that a person who has not read and understood all operating and safety instructions is not qualified to operate this machine An untrained operator exposes himself and bystanders to possible serious injury or dea...

Page 16: ...sonnel annually Maintenance Safety Follow ALL the operating maintenance and safety information in the manual Support the machine with blocks or safety stands when changing tires or working beneath Follow good shop practices Keep service area clean and dry Be sure electrical outlets and tools are properly grounded Use adequate light for the job at hand Use only tools jacks and hoists of sufficient ...

Page 17: ...nit in an area away from human activity Do not permit children to play on or around the stored machine Store the unit in a dry level area Support the base with planks if required Transport Safety Make sure you comply with all local regulations regarding transporting equipment on public roads and highways Make sure all the lights and reflectors that are required by local highway and transport autho...

Page 18: ... the installation area is clean and dry Be sure temperature is above 50 F 10 C Decide on the exact position before you remove the backing paper Remove the smallest portion of the split backing paper Align the sign over the specified area and carefully press the small portion with the exposed sticky backing in place Slowly peel back the remaining paper and carefully smooth the remaining portion of ...

Page 19: ...verall Description The major mixer system components are shown in the following figures Table 1 Driver Left Side System Components Aggregate Bin Aggregate Control Gate Mixer Controls Enclosure Cement Bin Tarp Hydraulic pump 1 5 4 2 3 6 ...

Page 20: ...MX05001 3 2 Rev 1 3 March 2022 Table 2 Right Side System Components Mixing Auger Mixing Bowl Hydraulic Valve Enclosure Oil Cooler Oil Reservoir Cement Bin Electrical Junction Box 1 2 3 4 7 5 6 ...

Page 21: ...on Mixer Controls Table 3 Mixer Control Panel Table Mixer Control System Computer Ranger Ranger Gunite Manual Mix Auger Paddle Master Switch On Off Operating Keypad Push Button Speed Control Push Button Dial Knob Emergency Stop Button In Stop Twist Reset 2 1 4 5 6 3 ...

Page 22: ...or Control Rotate the Selection Knob until the desired speed is shown on the mixing computer refer to the mixer computer manual Push the Selection Knob to accept the value Table 5 Speed Control Table Auger Speed Function not equipped Conveyor Speed Auger Forward Conveyor Start Select Knob Push Selection Confirmation Turn Increase Decrease Speed 6 ...

Page 23: ...r lights are shown in the next section Operating Keypad Status Indications Figure 1 Operating Keypad Table 6 Operating Keypad Table Print Function not equipped Function not equipped Vibrator 1 Reset Chain Oiler Function not equipped Vibrator 2 Function not equipped Conveyor Unload Momentary Function not equipped Vibrator 3 Function not equipped Cement Feed Fibre Feeder Vibrator 4 Function not equi...

Page 24: ...is in the ON part of the cycle during conveyor operation Automatic chain oiler is activated Manual chain oiler will cycle ON OFF during conveyor operation for maximum 60 seconds 5 Functio n not equippe d Vibrator 2 Indicates a selectable vibrator see computer manual for further details ON holding this button will manually vibrate Automatic vibrator will engage at intervals set on the computer 6 Fu...

Page 25: ...ble vibrator see computer manual for further details ON holding this button will manually vibrate Automatic vibrator will engage at intervals set on the computer 10 Engine High Idle ON engine high idle 11 Automatic Link ON ramps up engine mix auger and conveyor begin running when button 5 Conveyor Start on page 4 2 is pressed 12 Mix Auger Reverse ON momentary reverse Indicator mix auger forward ac...

Page 26: ... The following identifies valve locations for hydraulic oil Numbers in the following figures correspond to the following valve locations Valve Location 1 Fibre feeder control valve if equipped Valve Location 2 Full Lean Cement Bypass valve 4 1 2 3 ...

Page 27: ...MX05001 4 7 Rev 1 3 March 2022 Valve Location 3 Gunite pump control valve if equipped Valve Location 4 Hydraulic oil control valve ...

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Page 29: ...mixer cement calibration should be confirmed after 500 unit volumes of mix have been produced 1 Empty material from the sand bin the cement bin should be at least 1 2 full 2 Discharge an adequate amount of cement to ensure that the cement metering system is full by pressing button 8 Cement Feed on the Operating Keypad refer to page 4 3 3 Determine the empty weight of the container being used to co...

Page 30: ...TE After the control gate has been adjusted the conveyor must be run until the adjusted material flow is past the discharge point Disregard the material released during this operation and re zero the meter Equation 3 Sand Formula 𝑀𝑖𝑥 𝐷𝑒𝑠𝑖𝑔𝑛 𝑊𝑒𝑖𝑔ℎ𝑡 𝑜𝑓 𝑆𝑎𝑛𝑑 𝑝𝑒𝑟 𝑈𝑛𝑖𝑡 𝑉𝑜𝑙𝑢𝑚𝑒 𝐶𝑜𝑢𝑛𝑡𝑠 𝑝𝑒𝑟 𝑈𝑛𝑖𝑡 𝑉𝑜𝑙𝑢𝑚𝑒 𝑓𝑟𝑜𝑚 Step 2 𝑊𝑒𝑖𝑔ℎ𝑡 𝑜𝑓 𝑆𝑎𝑛𝑑 𝑝𝑒𝑟 𝐶𝑜𝑢𝑛𝑡 NOTE Once a gate setting is established check it by taking a minimum...

Page 31: ...based on the calibration data entered This is done in the mix entry screen after calibration see Control System manual Step 3 Gate Calibration Determine the weight of sand that is released per count of the conveyor The computer will generate the curve for gate height wheel position vs weight per count based on the data entered Gate calibration can be done at various gate heights up to a total of 3...

Page 32: ...entered and saved manually Fibre Feeder Calibration NOTE There is a flow rate chart inside the front cover of the fibre feeder for reference 1 Determine the amount of fibre required in kg lb per minute according to the mix design refer to the Calibration Sheets 2 Set the fibre feeder air pressure with the air pressure control valve refer to Fibre feeder control valve on page 4 6 and the fibre feed...

Page 33: ...ent is fed into the mix at a constant rate that is proportional to the movement of the conveyor belt The control gate allows the operator to change the proportional flow of sand in relation to the movement of the conveyor belt and therefore to the flow of cement Because the cement and aggregate feeders are mechanically synchronized the proportions of each of the dry ingredients are constant once t...

Page 34: ...om mat 1 mix auger 2 mix bowl 3 lower link arm 4 auger top drive The mixing auger receives the gunite materials through the mix bowl mixing throughout its length and discharging the mix through the top of the auger The auger position is controlled through the Mix Auger Paddle and its speed and direction are controlled using the Operator Control refer to page 4 2 The auger cover is latched and may ...

Page 35: ...rication and to keep contaminants from wearing on the bearing and shaft components Refer to Lubrication and Maintenance Frequency on page 7 9 for lubrication maintenance The lower bearing supports the auger shaft and includes seals that help to keep materials from exiting the mix auger Figure 8 Mix auger bearing and seals Mix Bowl The mixing auger attaches to the mix bowl by way of two removable m...

Page 36: ... the swivel in place and need to be removed to use the link swivel Figure 11 Lower link swivel Auger Top Drive IMPORTANT The mix auger top drive must be greased regularly Refer to Lubrication and Maintenance Frequency on page 7 9 for lubrication maintenance The hydraulically driven top drive holds and drives the auger Refer to the Operator Control section on page 4 2 for information on auger drive...

Page 37: ...ecrease the air pressure with the air pressure control valve refer to Valve Location 7 on page 4 6 Load the fibre feeder by placing the fibre spool into the fibre feeder cabinet Fibre from the center of the spool is fed into the tubing at the top corner of the cabinet The fibre is then passed through the top hole of the fibre cutter and fed through the rubber wheel and cutter as shown in Figure 14...

Page 38: ...ght according to the desired mix design SET AND LOCK THE CONTROL GATE Refer to the Aggregate Control Gate section on page 6 1 for specific information concerning the control gates 6 Adjust the fibre feeder flow rates refer to the Fibre Feeder section on page 6 5 7 Pre adjust conveyor and mix auger speeds Set speeds using the Operator Control refer to page 4 2 a Adjust conveyor speed using the Erro...

Page 39: ...e flow of concrete to ensure that the customer is receiving a concrete product that is true to the desired specifications Clean up and Preparation for Transport When the pour is complete or the mixer is empty it is important that the mix auger be properly cleaned up to prevent an excessive material build up which could interfere with the operation of the mixer on subsequent loads The operator shou...

Page 40: ...ransport position The retaining lock will automatically engage IMPORTANT Check for proper alignment as the auger is being raised 9 Master switch in the display box or if equipped with an engine in the engine enclosure OFF Chain Oiler The chain oiler consists of the chain oil reservoir and lubrication solenoid valve and is located between the gussets on the right hand side of the mixer at the rear ...

Page 41: ...ot clogged Replace as necessary Tarp The tarp is used to cover the aggregate bin Operate the tarp use the tarp control toggle switch located on the front left hand side of the machine Figure 19 Tarp mechanism Tarp Control The tarp control is a single toggle switch located on the left hand side of the sand bin Figure 20 Tarp control switch ...

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Page 43: ...e center of the shaft Misalignment will result in sensor reading errors Take Up Bearing Ensure the take up bearing has a inch gap between the washer and tubing as shown in Figure 18 Figure 21 Take up bearing gap Oil Specifications Cleanliness The hydraulic fluid must be maintained at ISO Cleanliness Code 20 18 15 or better Hydraulic System Your ProAll Mobile Mixer has been filled with Petro Canada...

Page 44: ...ted frequently and replaced when they wear down to the auger flighting IMPORTANT Never allow the plates to wear into the mounting holes drilled into the flighting The complete auger or portion of it will have to be replaced if this occurs Inspect the wear plates during clean up and monitor their condition Also be aware of the nature of upcoming pours this will help prevent a wear plate failure par...

Page 45: ...age lower the mix auger and support it with blocking to allow for the removal of the cylinder pin clevis end Loosen the tightening bolt to turn the clevis Replace the pin and test for proper lock engagement Repeat this procedure as necessary IMPORTANT Over adjustment puts undue stress on the swivel ring and support pins When turning the clevis do not hold the cylinder rod with a pipe wrench or oth...

Page 46: ...oints The following inspection and maintenance schedule acts as a guideline only It should be noted that extreme weather conditions aggressive aggregates the nature of the mix being produced and other factors will affect the frequency of service required 2 3 1 4 ...

Page 47: ...MX05001 7 5 Rev 1 3 March 2022 2 13 14 10 8 7 6 9 11 12 15 5 4 ...

Page 48: ... sensor gap check left Maintenance 2 Front conveyor shaft right and left 1 bearing grease 2 tension adjust Maintenance 3 Cement bin sump bearing grease Maintenance 4 Conveyor chain brush check Maintenance 5 Mix auger top bearing grease Maintenance 6 Upper lift link grease 1 2 ...

Page 49: ...aintenance 7 Lock arm grease Maintenance 8 Lifting mechanism 1 Lower lift link grease 2 Boom cylinder Maintenance 9 Mix auger bottom grease Maintenance 10 Rear conveyor shaft grease right Maintenance 11 Cement bin sump brush check 1 2 ...

Page 50: ...001 7 8 Rev 1 3 March 2022 Maintenance 12 High pressure hydraulic oil filter Maintenance 13 Chain oil level check Maintenance 14 Hydraulic reservoir check 1 check oil level 2 check return suction filter 2 1 ...

Page 51: ...t hydraulic oil G The filter is located within the tank A visual inspection of the filter will be required to ensure the filter is not clogged Maint Item Number No Points Daily Every 1 Load Every 20 Hrs Every 50 Hrs Every 500 Hrs 1 1 Rear conveyor shaft grease right 2 2 Front conveyor shaft grease right and left 2 2 A Rear conveyor shaft sensor gap check 3 1 Cement bin sump bearing grease 4 2 B Ch...

Page 52: ... through the Mixer display box master electrical switch refer to page 6 6 The electrical functions including lights and vibrators will not work unless the power switch is set to ON Electrical 1 Inside of distribution box 1 Pwr module vib admix 2 Master relay 3 High idle relay 4 Cooler fan relay 5 Fuse 30 A Cooler 6 Fuse H6 15 A Display 7 Fuse H7 15A Module 1 8 Fuse H8 15A Module 2 9 Ground termina...

Page 53: ... 95 215 160 305 220 3 4 225 165 390 290 540 400 7 8 230 170 570 420 880 650 1 345 225 850 630 1320 970 Torque figures indicated above are valid for non greased or non oiled threads and heads Therefore do not grease or oil bolts or capscrews unless otherwise specified When using locking nuts increase torque values by 5 Torque value for bolts and capscrews are identified by their head markings Bolt ...

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Page 55: ...is turned on Electrical failure Check main circuit fuse breaker located at the battery If a short circuit is indicated find the short and repair To check for any alarms and their resolutions please refer to the Ranger s Operator s Manual If you have any further questions or need assistance please contact the ProAll Customer Service at 8 335 PROALL 833 577 6255 ...

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Page 57: ...March 2022 9 1st 50 Hour Service CHECK AND ADJUST AS REQUIRED 1 Check mixer tie down bolts are the proper torque refer to Bolt Torque section on page 7 11 2 Check all hydraulic connections for leaks and tighen if necessary ...

Page 58: ...tter 6 5 flow rate chart 5 4 gates See control gates high idle 6 7 hydraulic suction filter 7 8 IMPORTANT definition 2 4 lift cylinder 7 3 adjustable clevis 7 3 cylinder pin 7 3 lock arm 7 7 lower lift link 6 4 7 7 lubrication solenoid valve 6 8 maintenance schedule 7 4 master switch 6 8 mix auger 6 7 6 8 alignment 6 8 control 6 8 cover 6 8 hopper 6 8 speed 6 8 speed control 6 8 top bearing 7 6 to...

Page 59: ...ft link 7 6 vibrate 6 7 vibrators 7 10 viscosity 7 1 viscosity range 7 1 WARNING definition 2 4 wear plates 6 7 7 2 weight of stone per count 5 2 yield box 5 2 5810 47 Avenue Olds Alberta Canada T4H 1V1 E info proallinc com P 403 335 9500 F 403 335 9560 ...

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