Clarke 3400820 CCM125P Cement Mixer Instructions PDF

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Summary of Content for Clarke 3400820 CCM125P Cement Mixer Instructions PDF

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1005 Part No. 3400820

Model CCM125P

CEMENT MIXER

OPERATING & MAINTENANCE

INSTRUCTIONS

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Copyright CLARKE International. All rights reserved. March, 2001

Please read this manual in conjunction with the Engine Handbook

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Thank you for purchasing this CLARKE Engine Driven Concrete Mixer, model CCM125P.

Please read this leaflet thoroughly and follow the instructions carefully, in doing so you will ensure the safety of yourself and that of others around you, and you can look forward to the mixer giving you long and satisfactory service.

GUARANTEE

This CLARKE product is guaranteed against faulty manufacture for a period of 12 months from the date of purchase. Please keep your receipt as proof of purchase.

This guarantee is invalid if the product is found to have been abused or tampered with in any way, or not used for the purpose for which it was intended.

Faulty goods should be returned to their place of purchase, no product can be returned to us without prior permission.

This guarantee does not effect your statutory rights.

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General Safety Precautions ................................................................... 4

Unpacking & Pre-Assembly ................................................................... 5

Assembly ................................................................................................. 6

General Information ............................................................................... 11

Operation ................................................................................................ 11

Maintenance ........................................................................................... 12

Specifications .......................................................................................... 13

Parts & Service Contacts ........................................................................ 13

Parts List and Diagram ............................................................................ 14-15

CONTENTS

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WARNING: As with all machinery, there are certain hazards involved with their operation and use.

Exercising respect and caution will considerably lessen the risk of personal injury. However, if normal safety precautions are overlooked or ignored, personal injury to

the operator or damage to property may result.

ALWAYS READ THE MANUAL. Become familiar with the entire operating manual. Learn the machines applications and limitations as well as the specific potential hazards peculiar to it.

ALWAYS CHECK FOR DAMAGED PARTS. Before use of the machine, it should be checked to ensure that it will operate properly and perform its intended function. Check for any condition that may affect its operation. A part that is damaged should be properly repaired or replaced before the mixer is put into use.

ALWAYS KEEP COVERS AND GUARDS IN PLACE and in good condition.

ALWAYS REMOVE TOOLS etc. Form habit of checking to ensure that any tools used for adjusting/ repairs, are removed from machine before use.

NEVER operate the machine whilst under the influence of DRUGS, ALCOHOL or any MEDICATION.

NEVER STAND ON THE MACHINE. Injury could occur from a fall.

NEVER LEAVE MACHINE RUNNING UNATTENDED. Turn the engine OFF.

NEVER put your hands inside the drum when it is rotating. Keep your hands well clear of the rotating drum at all times.

NEVER WEAR JEWELLERY or loose clothing that could be snagged by the rotating drum.

DO NOT LOAD THE DRUM WHEN IT IS STATIONARY. Always start the engine and ensure the drum is rotating.

GENERAL SAFETY RULES

CAUTION: TAKE ALL PRECAUTIONS REGARDING THE USE OF PETROL.

Always switch the engine OFF when refuelling. Always refuel away from any source of heat or naked flames. Always refuel in a well ventilated area. Never smoke whilst refuelling. Never start the engine if there is spilled fuel. Any spillage must be wiped clean and

allowed to dry before attempting to start the engine.

WARNING: EXHAUST FUMES CAN KILL

Always use in a well ventilated area. Always position the exhaust outlet away from people. Always keep children away from the mixer Never use the mixer indoors or in a confined space.

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UNPACKING & PRE-ASSEMBLY CHECK

Remove all components from the packing cases and lay them out neatly so that they may be identified and checked for any possible damage during transit.

Should any component be found to be damaged, please contact your Clarke dealer immediately.

Check off the components against the following list, and referring to Fig. 1.

Also included in the packing case is a 6mm x 305mm steel rod (used for pulley alignment), and a bag containing all nuts, bolts, washers and fixings. (Please refer to the parts list on page 15 for full list).

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A. Upper Drum Section

B. Drum Collar (2 pcs)

C. Rubber Sealing Ring

D. Bottom Drum Assembly

E. Mixing Blades (2 pcs)

F. Locking Plate

G. Hand Wheel

H. Engine (Packed Separately)

J. Driven Pulley

K. Inner Engine Cover

L. Pulley/Drive Belt

M. Motor Pulley and Key

N. Engine Support Plate

O. Outer Engine Cover

P. Axle Assembly

Q. Wheel (2 pcs)

R Main Frame

S Leg with handle

Indicated also are the Bearing Blocks (X)

Fig.1

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NOTE: 1. Letters in brackets refer to Fig.1 2. Unless otherwise stated, all nuts, bolts, washers and fixings are supplied.

IMPORTANT For maximum safety and to ensure the adjustments are carried out correctly,

assistance should be employed during the assembly operation.

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ASSEMBLY

1. The Stand 1.1 Attach the axle assembly (P) to the frame

(R), using two M8 x 60 bolts, together with nut, spring and flat washers, ( see Fig.2).

NOTE: A number of holes are provided to mount the Axle assembly. Select those you feel will provide a comfortable working height ....bearing in mind the minimum height required to allow a wheelbarrow to be placed beneath the drum.

1.2 Turn the frame over and attach the Leg (S), in the same manner, as shown in Fig.2.

1.3 Slide a wheel on to each stub axle, followed by a large flat washer and locate them using the split pins provided.

Tighten all nuts securely before righting the stand.

Fig.2

Fig.3

2. The Bottom Drum 2.1 Carefully, and with assistance, lower the

bottom drum assembly (D), on to the stand as shown in Fig.. 3, so that the bearing blocks (X), slot into the channels provided by the side supports.

The drive shaft end, i.e. that end where the pinion drives the drum, should be at the AXLE end of the Frame.

2.2 Line up the holes in the side support with those in the bearing block and enter an M8 x 60 bolt with flat washer and secure using a nut and spring washer.

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3. The Hand Wheel & Fittings

3.1 Slide the Locking Plate (F), over the large diameter shaft, at the leg end of the frame, with the rim facing inwards, as shown in Fig.4. (Note that the hole in the Plate is notched. This is to allow the plate to slide over the lugs of the circlip on the shaft). Secure with two M8 x 25 bolts, each with a nut, flat and spring washer, ensuring nuts are tight.

3.2 Insert the spring, into its holder in the Handwheel, and holding it in place, slide the wheel over the large diameter shaft so that the shaft retains the spring.

NOTE: This operation may need a little exertion in order to compress the spring sufficient to be able to slip the handwheel on to the shaft.

3.3 Line up the holes in the bracket (Y, Fig.. 4), with the hole drilled in the shaft, then insert the M10 x 65mm bolt with flat washer at the bolt head.

NOTE: You will find it an easier task to line up the holes on one side of bracket Y only, to begin with. Enter the bolt, then use that as a pivot, by pushing the handwheel IN to square it up, in order to line up the holes on the other side. When the holes at the opposite side are aligned, tap the bolt through GENTLY to avoid damaging the threads.

3.4 Screw on two nuts. Screw the first nut up against the bracket firmly, but not so tightly so as to prevent the handwheel from pivoting about the bolt. Lock the nut in this position by screwing up the second nut, tightly so that it locks.

NOTE: The handwheel must be allowed to pivot about the bolt so that the lugs on the bracket (Y) can be engaged or disengaged from the slots in the Locking Plate.

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Fig..4

Fig.5

4. The Mixing Blades

4.1 Bolt the blades in place loosely as shown in Fig. 5.

It is IMPORTANT that the blades are orientated exactly as shown. This ensures that the mix will be thrown OUTWARDS when the drum turns

Two holes are provided at the base of the drum into which a M6 x 20 bolt may be inserted from the outside. These bolts are provided with a flat washer and leather washers. The leather washer should bear against the drum. A spring washer and a nut should be threaded on loosely on the inside. Do not tighten the nuts.

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5. The Upper Drum

Note: Before bolting down the upper drum section, it is necessary to perform a dry run in order to determine the correct orientation, to ensure all components are correctly aligned.

5.1. With assistance, lower the upper drum section on to the lower drum.

Rotate it until the position is found where the mixing blade upper mounting holes line up with the corresponding square holes in the upper drum section, and the holes in the rims of the two drum sections also become aligned.

Mark this position on the upper and lower rims with a pencil or chalk mark, then remove the upper drum section.

5.2. Apply a film of impact adhesive (not supplied) to the rim of the drum, according to the manuf- acturers instructions, and ensuring the rim is perfectly clean beforehand. Position the rubber seal on to the rim so that the holes in the seal and those in the rim of the drum are aligned.

5.3. With assistance, lower the Upper Drum section on to the Lower Drum, so that the two marks, previously made, are aligned.

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Insert M6 x 16 cross headed screws into each of the holes in the rim together with a flat washer, and secure from below with a spring washer and nut, ensuring the tightening process is carried out progressively.

5.4. Secure the Mixing Blades to the Upper Drum by inserting a coach bolt, with leather washer, through the square hole in the drum. (See Fig.6).

NOTE: The square portion of the bolt should sit snugly in the square hole in the upper drum section, with the leather washer squeezed between the bolt head and the drum, see Fig.. 6.

Secure the mixing blade on the inside using a flat washer, spring washer and nut.

5.5 Finally, ensure both top and bottom Mixing Blade mountings are tight.

6. The Engine Covers and Fittings

6.1 Bolt the Inner Cover (K) to the Bearing Block (X). Use two M8 x 25mm bolts, with flat washers at the bolt heads, (within the Inner Cover), and spring washers with nuts to the rear of the Bearing Block. Leave the nuts loose at this stage.

6.2 Bolt on the Engine Support Plate (M), as shown in Fig.. 7, by inserting four M6 x 65mm bolts, with flat washers, through the holes in

a. the Support Plate (M),

b. the slotted holes in the Inner Cover (K),

c. the spacer, (which is inserted between the Inner Cover, and the Frame

d. the Securing plate.

Fig.7

Fig.6

NOTE: The securing plate is painted, whereas the spacer is unpainted and is the thicker of the two plates

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6.4 When all four bolts are fitted, centralise the Inner Cover (K) about its mountings, then fully tighten the two bolts securing it to the Bearing Block (X). (See Fig.7)

6.3 Slide the Pulley (J) on to the shaft, having lined up the key and keyway, ensuring the grub screw in the hub of the pulley faces outwards (see Fig. 8). It may be necessary to drive the pulley on to the shaft using a soft faced hammer, until the end of the shaft is slightly proud of the central boss. This is not a critical measurement. Lock the pulley in this position by tightening the grub screw.

6.4 Manoeuvre the Engine Support Plate (M) upwards as far as possible, and secure in this position temporarily, by nipping up two of the four nuts securing it, (do not fully tighten them) with the Support Plate judged to be as near parallel to the ground as possible.

7. Mounting the Engine

7.1 Apply a little light oil to the engine output shaft, then locate the key, firmly in the keyway.

Fig.8

Fig.9Slide the motor pulley on to the shaft, with the grub screw, in the centre boss, facing inwards towards to engine. Leave the grub screw loose.

IMPORTANT! Slip the drive belt over the motor pulley, then place the engine on to the support plate.

Enter the four M8 x 25mm bolts through the slotted holes in the Engine Mounting and those in the Engine Support Plate, ensuring flat washers are in place against the bolt head. Thread on a flat washer, followed by a spring washer and nut to each of the bolts, from below, leaving the nuts loose.

Fig.107.2 Position the engine so that it lies entirely square on the support plate. (One method of achieving this is shown in Fig. 9).

It is also IMPORTANT that the engine be positioned so that a gap of approx. 5mm exists between the air filter housing and the Inner Cover.

When these conditions are met, fully tighten the engine mountings to a torque setting of 12 ft lb.

6.3 Thread on a spring washer and nut, but DO NOT tighten the nuts at this stage

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8. Fitting the Drive Belt

NOTE: It is now most important that the motor pulley be aligned so that it is directly in line with the driven pulley (J).

8.1 A piece of 6mm rod is provided which is used to align the pulleys as follows:

Hold the rod firmly in the Vee of the upper, driven pulley, then rotate the pulley and rod together so that the other end of the rod comes into contact with the vee of the motor pulley.

The rod should come to rest perfectly symmetrically in the motor pulley vee. Move the motor pulley in or out, as appropriate, until this condition is met. When satisfied, tighten the motor pulley grub screw.

It is important that time is taken to ensure this adjustment is correct, otherwise premature failure of the drive belt could occur.

8.2 Slip the drive belt over the top pulley, then over the motor pulley.

NOTE: The gap between the cover and top pulley is small but the operation is possible by rotating the upper pulley whilst easing the belt between the cover and pulley rim.

8.3 Slacken off the two nuts, previously nipped up to secure the Engine Mounting Plate in position, then push down on the engine so that tension is applied to the belt.

Tension is correct when there is approximately " total movement at the centre of the belt run when using moderate thumb pressure.

The Support Plate should be as near parallel to the ground as possible when making this adjustment.

8.4 When satisfied, secure the Engine Support Plate by tightening the nuts behind the Securing Plate, ensuring the Support Plate remains perfectly parallel to the ground.

CAUTION: The nuts MUST tightened progressively.

8.4 Finally, lower the Outer Cover so that the channel formed on the rim of the cover engages over the rim of the Inner Cover. Slide the cover down as far as possible and secure with the screws provided.

Fig.11

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9. Fitting the Drum Collar

Before the collar is attached, it is strongly recommended that a layer of grease (not supplied) be applied to the underside of the serrated rim of the lower drum.

9.1 Secure each half of the collar to the side brackets first. (Shown at 1, Fig. 12). Use a single M6 x 10mm bolt with a flat and spring washer.

9.2 Bolt the two halves together using two M6 x 20mm bolts with a flat washer, spring washer and nut, shown at 2 Fig.. 12

Fig.12

IMPORTANT: The Drum Collar is a Safety Feature, and must ALWAYS be in place. NEVER operate the machine with the collar removed.

Congratulations......your Concrete Mixer is now fully assembled and ready for use.

Please consult the engine manufacturers handbook, enclosed, for full details as to how to start, operate and maintain your engine.

OPERATION

IMPORTANT: ALWAYS start the engine and have the drum rotating, BEFORE loading the drum.

To start the engine please refer to the manufacturers handbook which accompanies this manual.

In addition to the precautions laid out in the engine manual, ensure the throttle is set to fully open, i.e. against the stop, before pulling the recoil starter. In this position, the engine is set to run at an ideal speed for drum rotation.

NOTE: If the choke is used to start the engine, it is advised that you allow the engine to warm up sufficient for the choke to be disengaged, before loading the drum.

Once the engine is running smoothly, and the drum rotating, proceed to load the drum with sand/cement, ensuring the drum is inclined upwards (approx. 30 degrees minimum), to avoid having the mix thrown out.

In order to rotate the drum, push the Hand Wheel inwards at the rim to disengage the wheel from the Locking Plate. Turn the drum to the required position then release the handwheel to lock it in that position.

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MAINTENANCE - General

Before each use

Inspect the machine to ensure it is not damaged and will perform its normal functions correctly. If any damage is apparent, have it fixed before putting into service.

Periodically

Inject a few drops of light oil into the oil points, located on top of the Bearing Blocks and rotate the drum to ensure distribution of oil within the bearing surface.

Inspect the paintwork and remove any rust that may be apparent before touching up where necessary, with a rust resistant paint.

It is recommended that the Collar be removed, at least annually, and grease smeared on the serrated underside of the lower rim. Ensure the collar is replaced correctly.

After each use.

It is strongly recommended that the machine is hosed down thoroughly with clean water, taking care to prevent water from entering the engines electrical components by wrapping a polythene sheet or bag over the engine during the cleaning process.

Turn the drum so that it is face down to allow all water to drain off. Protect it from the elements by covering with a tarpaulin. This is particularly important if the machine is to be stored for a period of time.

Storage

It is possible to fold the leg and axle assembly beneath the frame by removing their upper mounting bolts, and slackening off the lower mounting bolts so that the leg, or axle assy. pivots beneath the frame.

MAINTENANCE - Engine

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It is important to maintain the engine according to the manufacturers handbook, which accompanies this manual.

The location of the Oil Filler, and Oil Drain, is indicated in Fig.13.

Checking oil level, topping up and changing the oil can all be done with the engine cover in place, as can the air filter replacement and spark plug maintenance. For all other work it will be necessary to remove the cover.

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SPECIFICATIONS

Engine ............................................................................ Honda GC135

Engine Power Rating .................................................... 135cc

Drum Capacity ............................................................. 3.5 cuft / 125 litre

Dimensions .................................................................... 1190x710x465mm

Sound Power Level (Guaranteed) ............................. 94dBLWA

Weight ............................................................................ 63kg

Part Number .................................................................. 3400820

Please contact your nearest dealer, or CLARKE International, on one of the following numbers.

PARTS & SERVICE TEL: 020 8988 7400 PARTS & SERVICE FAX: 020 8558 3622

or e-mail as follows: PARTS: Parts@clarkeinternational.com

SERVICE: Service@clarkeinternational.com

SPARE PARTS & SERVICE CONTACTS

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PARTS DIAGRAM

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SPARE PARTS LIST

The following items are the nuts bolts and washers packed separately and which may be locally procured from any Hardware or DIY store, or from your CLARKE dealer quoting the part numbers given.

No. Description Qty Part No.

1 Frame Assy 1 SD0001

2 Axle Assy 1 SD0002

3 Leg 1 SD0003

4 Wheel 4 SD0004

5 Flat Washer 2 SD0005

6 Split pin 2 SD0006

7 Engine Support Plate 1 SD0007

8 Spacer/Plate 6mm 2 SD0008

9 Engine Assy 1 7999010

10 Pulley, Engine 1 SD0010

11 Key 1 SD0011

13 Outer Cover 1 SD0013P

15 Pulley, Drive 1 SD0015

16 Grub Screw 1 SD0016

17 Inner Cover 1 SD0017P

18 Circlip 4 SD0018

19 Flat Washer 4 SD0019

20 Bearing Block 2 SD0020

21 Drive Shaft 1 SD0021

22 Key 1 SD0022

23 Circlip 1 SD0023

24 End Cap 1 SD0024

25 Bearing Set 1 SD0025

26 Pinion 1 SD0026

27 Yolk Assy 1 SD0027

28 Bearing Plate Lower 1 SD0028

29 Bearing Set 1 SD0029

30 Bearing Plate Upper 1 SD0030

31 Locking Plate 1 SD0031

32 Hand Wheel 1 SD0032

33 Spring 1 SD0033

34 Lower Drum Assy 1 SD0034

35 Sealing Ring 1 SD0035

36 Upper Drum 1 SD0036

37 Collar Assy 1 SD0037

38 Drive Belt 1 SD0038

39 Mushroom Hd Bolt 2 SD0039

40 Leather Washer 4 SD0040

41 Mixing Blade 2 SD0041

42 Chain 1 SD0042

No. Description Qty Part No.

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a. M5 x 10 Slot Rd Hd 5 3044701 b. M6 x 20 Hex Bolt 6 3044501 c. M6 x 16 Cross Hd 6 3044705 d. M6 x 65 Hex Bolt 4 3044702 f. M8 x 60 Hex Bolt 6 3044703 g. M10 x 65 Hex Bolt 1 3044704 h. M5 Nut 11 3040608 i. M6 Nut 16 3040600

j. M8 Nut 10 3040601 k. M10 Nut 2 3040602 l. 5mm Flat Washer 4 3040574

m. 6mm Flat Washer 24 3040575 n. 8mm Flat Washer 10 3040576 p. 5mm Spr. Washer 11 3040595 q. 6mm Spr. Washer 20 3040581 r. 8mm Spr. Washer 10 3040582

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