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KYC

TWIN SHAFT COMPULSORY MIXER

EX SERIES
OPERATION & MAINTENANCE
MANUAL

CAUTION! See safety manual before repairing/replacing/adjusting by all means.

KYC MACHIE INDUSTRY CO. LTD

May/2017
§CAUTION FOR MAINTENANCE & INSPECTION OF MIXER §

★ Keep following matters strictly when you go into mixer for maintenance &
inspection.

(1) Turn operation switch off.

(2) Turn the switch (2nos of breaker) off for mixer in power board.

(3) Lock the door of power board and put the “Under Repairing” plate on the door.

(4) Push emergency stop switch of control panel at mixer side and pull the key out.

(5) Operators must keep keys for power board and mixer side control panel.

(6) Block air resource and release air by stop valve.


Method; Shut stop valve ① and block air supply from air resource.
And open stop valve ⑥ and release residual pressure in air cylinders.
(See Figure-A)

★ Keep following matters strictly when maintenance/inspection is complete.

(1) Confirm safety of operators’ position when turning operation switch on, turning on
breaker in power board and canceling emergency stop switch control panel at mixer
side.

(2) Confirm if stop valve ⑥ is closed and stop valve ① is open..

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Figure A

① Stop valve
② Air filter
③ Air lubricator
④ Electromagnetic valve
⑤ Silencer
⑥ Stop valve
⑦ Air cylinder

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INTRODUCTION

Thank you for choosing, twin shaft compulsory mixer


KYC-EXEX2000EX30004000.
For making lifetime of twin shaft compulsory mixer longer, enough satisfaction
and reliability for use, it is necessary to keep matters to be attended on this manual for
operation and maintenance. Matters to be attended are mentioned on this manual and
describe about daily advice for driving, lubrication method and maintenance method.

1) Mentioned contents of operation manual are shown on index.


Please see parts list about parts.

2) Type of twin shaft compulsory mixer


Brand plate is mounted on side of the mixing tank and type and serial number are
shown on it.
When ordering or asking for twin shaft compulsory mixer, please be sure to specify
its type and serial number.

(Example of KYC-EX3000)

KYC MIXER
MODEL KYC-EX3000
CAPACITY : 3m3 Weight : 9200kg MOTOR : 55Kwx2
ROTATIONAL FREQUENCY 28min-1
DATE : SERIAL No.:

KYC MACHINE INDUSTRY CO. LTD.


OSAKA JAPAN

3) Revision
Partial little design remodeling may be done for feedback of using experience and/or
for users’ sake, and materials may be changed due to unavailability of designated
materials at first. If design is necessary to be changed like this case, parts and
assemblies are designed for interchangeability with former design. If design
remodeling with no interchangeability is done, we inform you parts revision notice.

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4) Explanation
The legend of this operation manual describes about representative structure from
parts of each type. Therefore, drawn shapes and subtle structures of parts may be
shown inappropriately comparing with appearance of real ones. However, we are
making effort that explained operation method, maintenance method or
identification of parts could be easily understood.

5) Ordering parts
Please order parts to the nearest Service Company or Sales Office.
Use KYC parts for supplement by all means. When ordering, see ordering
conditions to be attended on parts list.

6) Inquiry
Please inquire the nearest Service Company or Sales Office about questions and
uncertain points of this operation manual.

7) Warranty
KYC provides warranty period of this mixer for 1 year, and in particular 3 years for
Gear reducers.
*Initial date in reckoning of warranty is refer to Sales Agreement.

During this period, KYC repairs for free if the accident is apparently caused by
KYC’s fault of design or manufacturing.
Warranty condition is also mentioned on a specification sheet.
Please acknowledge that in case of normal abrasion, replacement of broken or
imitation parts, neglecting duties of replacing parts and accident caused by breaking
normal operation method, maintenance method and contraindicated matters
mentioned on this operation manual, KYC does not warrant.

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INDEX

Chapter 1 GENERAL MATTERS

1. Outline.................................................................................................... 9

2. Mechanism of mixer and operation principle


1) Mechanism and construction group ................................................ 9
2) Operation principle ......................................................................... 9
3) Specification ................................................................................... 10

3. Delivery of mixer
1) When delivering mixer ................................................................... 11
2) Trial run........................................................................................... 11

4. Transportation of mixer
1) Dimension and weight .................................................................... 11
2) Transportation ................................................................................. 11

5. Installation of mixer
1) Foundation ...................................................................................... 12
2) Installation....................................................................................... 12

6. Driving mixer
1) Motor setup ..................................................................................... 13
2) Confirmation of connecting with motor and rotating direction ...... 14

7. Lubricating oil to gear reducer for driving mixer


1) Necessary oil volume ...................................................................... 14
2) About designated oil ....................................................................... 14
3) Oil replacement and cleaning.......................................................... 15

8. Lubricating oil to bearing part


1) Amount and filling of grease .......................................................... 15
2) Lubricating grease to bearing part .................................................. 15
3) Lubricating grease to seal part ........................................................ 16
4) Cleaning of grease sump at seal part............................................... 16

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9. Starting mixer
1) Maintenance of oil level of gear reducer ........................................ 16
2) Lubricating oil to all grease fillers .................................................. 16
3) Maintenance of discharging gate .................................................... 16
4) Adjustment of discharge completion by automatic operation ........ 17
5) Setting continuous throw-in ............................................................ 17
6) Mixer running-in ............................................................................. 18

10. Maintenance and inspection


1) Supplying time and amount of grease............................................. 18
2) Inspection of mixer driving............................................................. 18
3) Daily inspection and maintenance .................................................. 19
4) Gap adjustment ............................................................................... 19

11. Matters to be attended in case of failure and long-term stop


1) Power cut when operating ............................................................... 19
2) Stop caused by overloading ............................................................ 19
3) Long-term stop ................................................................................ 19
4) Cause of failure and revising method ............................................. 20,21

Chapter 2. Mixer construction

Construction group: 1. Lined mixing tank


a. Replacement of side gate liner ............................. 22
b. Readjustment of gate seal plate............................ 22
c. Replacement of tile .............................................. 22
d. Repair and replacement of side liner ................... 23
e. Mounting view of liner ........................................ 24,25

Construction group: 2. Discharging gate


a. Replacement of gate liner .................................... 26
b. Parts figure ........................................................... 26,27

Construction group: 3. Mixing shaft and bearing part


a. Removal of bearing .............................................. 27
b. Replacement of floating seal................................ 27
c. Replacement of dust cover and ring liner ............ 28
d. Parts figure ........................................................... 29

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Construction group: 4. Mixing implement
a. Adjustment of blade ............................................. 30
b. Replacement of mixing arm ................................. 30
c. Hard facing of mixing arm ................................... 31
d. Adjustment of side blade ..................................... 31
e. Parts figure and mounting placement figure ........ 32.33

Construction group: 5. Operation of discharging gate


a. Lubricating oil to pin ........................................... 34
b. Parts figure ........................................................... 35

Construction group: 6. Mixer driving part


a. Removal of gear reducer ...................................... 36
b. Installation of gear reducer .................................. 36
c. Adjustment of V belt ............................................ 36
d. Parts figure ........................................................... 37
e. Check mixer level and Coupling…………………38

Chapter 3.
1. Placement figure of mixing implement ............... 39
2. Specification figure of oil lubrication .................. 40
3. Electrical drawing of Oil temp.alarm…………….41
4. Specification chart of maintenance
and inspection .................................................... 41

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CHAPTER 1. GENERAL MATTERS

1. Outline
This machine was completed by updated technology has an unique performance and
excellent features such as compact, strength, high reliability, easy maintenance, low
exhaustion and best mixing effect.
For making lifetime of twin shaft compulsory mixer longer, enough satisfaction and
reliability for use, it is necessary to keep matters to be attended on this manual for
operation and maintenance. Matters to be attended are mentioned on this manual and
describe about daily advice for operation, lubrication method and maintenance method
for responsible person for operation and maintenance in your company.

2. Mechanism of mixer and operation principle


2.1 Mechanism and construction group
KYC Twin shaft compulsory mixer is designed to install mixing bearing parts,
mixing implement, discharging gate, control system, mixer driving parts and protection
cover to self-supporting mixing tank welded and assembled on 4 legs.
Construction group 1: Abrasion resisting steel plate or tiled mixing tank
Construction group 2: Discharging gate
Construction group 3: Mixing shaft, bearing part
Construction group 4: Mixing implement
Construction group 5: Operation of discharging gate
Construction group 6: Mixer driving part
Each of construction group of mixer is drawn and mentioned the explanation on parts
list.

2.2 Operation principle


KYC Twin shaft compulsory mixer is batch type concrete mixer.
Aggregate, cement and water are thrown into the mixer with constant interval.
Simultaneous rotating of mixing implement arranged to 2 mixing shafts materializes
accurate forced mixing. Materials in the mixing tank are flown to horizontal and
vertical directions forcedly and mixed adequately.
By the virtue of mixing implement’s simultaneous rotating, mixed materials are
lifted, sent to inner mixer again and calculatedly moved. This moving produces
homogeneously best mixed concrete as short time as possible.

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2.3 Specification
a) Size of using aggregate

Model KYC-EX1250 KYC-EX1500

Capacity m3 1.25 1.5


Maximum dimension
40~60 40~60
of usable size
Not more than 20 % Not more than 20 %
aggregate (mm)

Model KYC-EX2000 KYC-EX2000 KYC-EX2000

Capacity m3 2.0 3.0 4.0


Maximum dimension
40~80 40~80 40~80
of usable size
Not more than 20 % Not more than 20 % Not more than 20 %
aggregate (mm)
(1) Capacity indicates 1 batch capacity at producing of more than 6cm
slump concrete.
(2) In case of less than 5cm slump or High-strength or High- fluidized
concrete, reduce mixing volume with checking load current value.

b) Driving
Low voltage 3 phase squirrel cage induction motor is used.
Model KYC-EX1250 KYC-EX1500

Motor capacity 2 x 22 kW 2 x 30 kW
Number of
4 pole 4 pole
electrodes

Model KYC-EX2000 KYC-EX3000 KYC-EX4000

Motor capacity 2 x 37 kW 2 x 55 kW 2 x 75 kW
Number of
4 pole 4 pole 4 pole
electrodes

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c) Operation of discharging gate
Pneumatic operation of air cylinders is 0.5 to 0.7MPa, withstanding pressure
is 1.0MPa.
Model KYC-EX1250, EX1500

Diameterφx Stroke 160mm x 250mm

Quantity 2nos

Model KYC-EXEX2000EX30004000

Diameterφx Stroke 160mm x 400mm

Quantity 2nos

3. Delivery of mixer
3.1 When delivering mixer
At delivery time, gear oil may not be filled in gear reducers. Fill oil into the line
between full and empty while seeing the oil gauge before trial running.

3.2 Trial run


All of our mixers are given trial runs with no load before delivery, but No trial with
a load is conducted. Therefore, strictly follow instructions for trial run of mixer with
load. (See 9, 6.)

4. Transportation of mixer
4.1 Dimension and weight
Appearance dimension and weight are as follows:
*KYC-1250EX
Length = 2,730 mm, Width = 2,042 mm, Height = 1,800 mm, Weight = 4,500 kg
*KYC-1250EX
Length = 3,000 mm, Width = 2,042 mm, Height = 1,800 mm, Weight = 5,400 kg
*KYC-EX2000
Length = 3,035 mm, Width = 2,474 mm, Height = 2,000 mm, Weight = 8,300 kg
*KYC-EX3000
Length = 3,600 mm, Width = 2,474 mm, Height = 2,000 mm, Weight = 9,200 kg
*KYC-EX4000
Length = 4,230 mm, Width = 2,474 mm, Height = 2,000 mm, Weight = 10,200 kg

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4.2 Transportation
Four hanging grips are attached on mixing tank of the mixer. Therefore, secure
those positions with wire ropes and transport it thusly in all cases.
Do not use other parts for fixing wires, it becomes cause of trouble of mixer.

5. Installation of mixer

--- IMPORTANT ---


When Mixer is not correctly set up, the durability of Mixer might be
remarkably ruined.
Please inquire of us or our authorized sales agent if when there is
something an uncertain point.

5.1 Foundation
Mixer must be installed on strong and safe horizontal foundation.
Consult foundation chart, and consider load during operation and enforce properly.

5.2 Installation
When installing this mixer in Batching plant, check the horizon of four mounting
bases within ±1.0mm before fastening foundation bolts tightly. If not horizontal,
height must be adjusted by inserting shim plates (thin steel plate).
If not horizontal, Mixer body could be deformed and troubles may be incurred such
as excessive force being exerted upon mixer driving part.
Remove V-belt cover and check the tension of V-belts and level of coupling which
connects two gear reducers.

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V-belt tension Tmin~Tmax : 10.1mm/6.3kg~10.4mm/6.4kg

6. Driving mixer
6.1 Motor setup
λ-△setup is adopted in general. Normally, equip to both motors the timer to go
fromλsetup to △setup automatically at same timing of both motors for easy and
safety driving operation.

In case of abnormal stop such as power cut during operation or re-setup after
artificial stoppage, △ setup requires a substantial setup torque. Therefore, we
recommend wiring with direct △setup. (λ-△timer set is Zero)
In case of stop with materials in mixing tank, re-start by direct △setup after natural
discharging of some materials.
For your safety, please equip an emergency stop switch for turning off motor
directly in case of emergency.

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6.2 Confirmation of connecting with motor and rotating direction
Check rotating direction with no load.
Turn one side motor switch Off, turn another motor switch On, and confirm the
rotating direction. Then, turn switch Off, turn first one On, and confirm rotating
direction once again.


Rotating direction Rotating direction

7. Lubricating oil to reducers for driving mixer


7.1 Necessary oil volume
2 planetary gear reducers are used for this mixer. Necessary oil volume is shown in
following table. As already mentioned (See 3-1), at delivery time of mixer oil may not
be filled in, so check and fill oil into the line between full and empty while seeing the
oil gauge before trial running.

Model KYC-EX1250 KYC-EX1500

Necessary oil volume per one reducer litter litter

Total volume litter litter

Model KYC-EX2000 KYC-EX3000 KYC-EX4000

Necessary oil volume per one reducer 9 litter 8.5 litter 16 litter

Total volume 18 litter 17 litter 32 litter

7.2 About designated oil


Lubrication requirements are more demanding than in other cases. Therefore,
selection of wrong oil decreases not only gear efficiency but also lifetime of reducers.
Please use the following standard of oil. (Do not mix different standard oil.)
Wash up air-breathers on top of reducers regularly.

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Kind of Oil Standard

Gear Oil ISO VG 220

7.3 Oil replacement and cleaning


Replace first oil after initial completion of trial run with load and real operation for
first two weeks.
Oil should be replaced about every 1,000 hours, or every 6 months, whichever
comes first. This is standard replacement period. Inspect regularly and, if necessary,
replace it early in case of exceptional conditions.
Before replacement of oil in reducers, operate mixer to increase oil temperature so
that discharging of oil is become easier.

Cleaning when replacing oil


When replacing oil, it is necessary to wash out fouling oil held inner gear case.
Use same gear oil. Do not use other oils such as thinners, gasoline or washing oil.
Inner gear case is filled with clean recent oil which, if mixed with these, reduces
quality.
Please heat the oil to the same degrees as using oil to make viscosity lower and to
ensure proper operation. Lubricate, oil and operate the reducer with no load for a few
minutes and wash thoroughly.
When replacing oil, Pay special attention to prevention of contaminants entering
inner gear case. Reducers could be damaged if starting operation with contaminants
inside.

8. Lubricating oil to bearing part


8.1 Amount and filling of grease
Use lithium No.2 grease (e.g.Shell alvania No.2) for bearing portions of mixing
shafts, which has superior tightness under pressure, resistance to both heat and water,
mechanical stability and effectiveness at high as well as low temperatures.
Caution : Do not use other group greases, it shorten lifetimes of bearing and seals.
8.2 Lubricating grease to bearing part
Administration of lubricating grease to bearing part is different for high speed and
low speed.
a) Low speed : Bearing of Mixing shaft and discharge gate (Speed n ≦ 60min-1)
Space of bearing box is filled with designated grease.
b) High speed : Bearing of motors
Please follow instruction on the motors.

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8.3 Lubricating grease to seal part
Floating seal is used to prevent entry of cement paste passing from mixing shaft.
Two grease sumps seal inside of mixing tank. Outside grease sump seals external
part.
Use the grease designated as per 8.1.

8.4 Cleaning of grease sump at seal part


Dust covers and Ring liners must be replaced and greased up every time when
replacing inside liner and arm.

9. Starting mixer
Perform following inspection points before and after operating mixer.

9.1 Maintenance of oil level of reducer


At an inspection of mixer and before operation of mixer, check oil level of reducers.
If oil level is not enough to designated mark, gear oil must be added.

9.2 Lubricating to all grease fillers


There are 14 grease fillers(Grease nipple) in the mixer in total.

• Seal part of shaft (inside) : 4 (indicated by red)


Once a day after washing of mixer inside, apply approx.100g of grease until the
dust in dust cover flowing out with grease with mixing shaft rotating.

• Seal part of shaft (outside) : 4 (indicated by yellow)


• Bearing parts of shaft : 2 (indicated by yellow)
Once a week apply 4 to 5g of grease with mixing shaft rotating.

• Bearing parts of discharge gate and Motor bearing parts: 2


See 10.1.
9.3 Maintenance of discharging gate
a) Maintain correct air pressure for operation.
Air pressure must be within 0.5 to 0.7MPa.
b) Open and Close operation test
Check if discharging gate is operating smoothly and limit switches are working
properly. In case it is not smooth, check if mixer is installed properly as instructed in
5.2. Loosen four foundation bolts at legs of mixer, then operate discharge gate again
and check if it is smooth.

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Insert shim (thin steel plate) in mounting part of leg with biggest gap, and tighten
foundation bolts. If discharging gate is still in contact with inside liner., it must be
adjusted as above again.

9.4 Adjustment of discharge completion by automatic operation


When discharging to truck mixer, open discharging gate half at first and control the
discharging volume.
For this purpose, discharge gate has two limit switches with four-way solenoid
valve at the position of half-open and full open then the gate performs “Full open”,
“Half open” and “Close”. Therefore, please install a timer for automatic operation.

Check of discharge completion


Opening time of discharging gate as adjusted by timer must be checked to ensure
that it is discharging correctly during a loaded test run. Then, it must be tested using
hard-mixed (low slump) concrete. Please re-adjust timer to test results again.

9.5 Setting continuous throw-in


In order to produce a concrete, one batch volume of aggregates, cement and water
are thrown into the mixer and mixed together. It is necessary to constantly add them in
the correct order. Although it is difficult to do so uniformly due to different plant types,
General throw-in order is as follows.
Even if aggregates and cement are thrown into the center of the mixer properly at
the same time, a small volume and light cement is pushed to the end by aggregates and
it adheres to sidewall & mixing implements and so they are not mixed homogeneously.
Therefore, cement should be thrown after aggregates have been thrown in.
Water should start to be thrown in with aggregates.
Throwing in water in early reduces load of motors and it never adversely affects
mixing performance.
Standard throw-in time table is as follows. (Example for KYC-EX3000)

*Mixing time of normal concrete is 30sec.after all materials thrown into mixer.

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--- IMPORTANT ---
When materials are not throw-in correctly, the durability of reducers
and motors might be remarkably ruined due to too high load.
Please inquire of us or our authorized sales agent if when there is
something an uncertain point.

9.6 Mixer running-in


When starting to use new mixer, do not use it with full power at the beginning.
If no breaking in of reducers, its lifetime will be shortened markedly.
Breaking in is done in following order. Operate for about 30 minutes to one hour
with no load first then start loading operation.
Firstly operate for 5min.with 50 % volume of mortar once, and next 50 % volume
of concrete and last 100 % volume of concrete.

10. Maintenance and inspection


10.1 Supplying time and amount of grease
There are totally 14 pcs of colored grease fillers in the mixer. (See 9.2)
Others are as below.
a)There are two grease fillers of discharging gate bearing(Pillow unit).
Apply grease once a week as shown in Table: 1.

Table: 1. Grease lubrication instruction for pillow unit bearing


Model Pillow shaped unit Supplying amount

KYC-EX3000 UCP 214SWH 17g

b) Greasing to motor bearing, follow the instruction described in brand plate on the
motors.
c) Apply 4 to 5g of grease to fork-end pin of discharge gate once a week.

Note :
Grease should be lithium group, and check function of grease gun to be employed
and confirm discharging amount per stroke.

10.2 Inspection of driving mixer


When inspecting, pay attention to the initial oil level of reducers and tension of
V belts. V belt must be adjusted sometimes especially for initial operation.
Ensure oil replacement of reducers as previously mentioned in 7.3.

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10.3 Daily inspection and maintenance
a) In case mixer is stopped for more than one hour, wash inside with water and open
discharging gate.
b) When completing daily operation, throw coarse aggregates (25 – 40 mm) and
water into mixer and run for about 5 minutes to remove adhered concrete, and then
discharge aggregates. Afterward clean inside of mixer by high-pressure water and
apply drained oil or concrete peeling agent to make next cleaning easier.
In particular, apply it on slide surface of discharge gate sufficiently.

10.4 Gap adjustment


Check the gaps between blade and liner, and between discharging gate and gate seal
plate to conform designated dimensions. If necessary, adjust them.
(Construction group: 1 Figure-4); (Construction group: 4 Figure-9)

11. Matters to be attended to in case of failure and long-term stoppage


11.1 Power cut when operating
In case of power cut when operating, discharge concrete from mixer immediately
according to the following instructions.
1. Open gate using open/close button at solenoid valve by hand.
Even after compressor is stopped, you can operate by residual pressure in tank.
2. Concrete is not discharged completely even if gate is open, so wash it out using
high-pressure water.
Caution : Whenever entering mixer due to power cut or maintenance, turn the switch
OFF, engage safety device, and only then, enter mixer to work.

11.2 Stoppage due to overloading


When throwing over-weight materials into mixer, or throwing one more batch
materials into mixer before discharge of existing concrete, it becomes overload and
mixer is automatically stopped by thermal relay. (adjustment of thermal relay must be
set as proper current value) When mixer is stopped due to above,
1. Change automatic operation to manual, open discharging gate, and discharge
concrete by rotating the motor for a few seconds.
2. Repeat 3 to 4 times above operation to empty mixer.

11.3 Long-term stoppage


If mixer is idle for one week or longer, it must be operated with no load for about 30
minutes once a week.

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11.4 Cause of failure and revision method

Description of
Probable cause Countermeasure
problem

A) Mixer cannot be 1. Single phase operation Connect 3 phases certainly.


rotated. 2. Discontinuity Connect discontinued part.
3. Aggregates overloaded Reduce the amount of
aggregates in mixer.
4. Adherence of concrete Clean concrete in mixer.
5. Damage to machines and parts Parts replacement; engineer
required
6. Drop of power source voltage Ask electric power company to
examine.

7. Motor burnout Replacement; rewinding of


coil

Exchange any 2 wires among


B) Mixer is reversed. 1. Wrong connection
3 wires.

C) Vibration, 1. Contact of liner with blade Blade adjustment


abnormal sounds 2. Abnormal sounds from reducer; Bearing, gear, or oil
vibration replacement
3. Loosening of V belt Belt tension adjustment
4. Abnormal sounds from motor, Bearing or gear replacement;
vibration lubricating grease
Tighten bolts for motor
5. Damage to bearing Replacement
6. Gate open and shut end vibration Cylinder cushion thread
adjustment

D) Discharging gate 1. Insufficient air pressure Must be higher than 0.5MPa/


does not open or insufficiency cm2.
close.
2. Cylinder cushion out of Cushion thread adjustment
adjustment
3. Cylinder air leakage Packing replacement
4. Gravel pinching at gate Remove gravels
5. Adherence of concrete Remove adhesive concrete
6. Damage of bearing; Replacement, lubricating
insufficient lubrication grease
7. Loosening of bearing BT, Complete consolidation of
eccentricity bearing
8. Solenoid valve relational defect Overhaul

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E) Mixing is bad. 1. Blade abrasion Blade replacement
2. Mixing time is too short. Set up for 30-40 seconds.
3. Improper aggregates throw-in Adjust to standard throw-in
time time
4. Adherence of concrete to mixer Hack concrete off.

F) Intense. leakage 1. Gate seal plate abrasion Seal plate adjustment ;


replacement
2. Gate liner abrasion Gate liner replacement
3. Gate not shut completely. Gate open and shut adjustment

G) Adherence of 1. Neglected washing Wash when mixer is stopped


concrete longer than one hour.
2. Incorrect order for material Throw-in order should be: sand,
throw-in gravel, water and cement.
3. Blade out of adjustment Blade adjustment

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CHAPTER 2. MIXER CONSTRUCTION

Construction group: 1. Lined mixing tank

Mixing tank is welded structure and made of steel plate..


For protection against abrasion of mixing tank, replaceable inside liner and side liner
are installed. Liners are divided, so worn liners are easily reversed and replaced. Mixing
shaft part, driving part and discharging gate at the bottom are installed on mixer body.
Liners are fixed in correct places with bolts.

a Parts No. ⑦, Replacement of Side gate liner (See figure-3.)


When installing side gate liner ⑦ , adjust the gap between inner radius
(Construction group: 2 ⑦) and mounting surface of gate liner to 0.5-1.0 mm, and
then install. Liner has been fitted with large hole for adjustability. It also can be
adjusted by inserting shim (thin steel plate).

b Parts No. ⑥, Re-adjustment of Gate seal plate (See figure-3.)


Gate seal plate ⑥ can be adjusted easily by loosening bolts. When mounting
bolts are completely tightened, (Construction group: 2 ⑦) adjust gap to 0.5-1.0 mm.
If the gap is too small, discharge gate is pushed out too much and cannot open/close
smoothly.

c Parts No. ⑤, Replacement of Tile (See figure-1.)


Lower half of tile is especially easily abraded. When its thickness becomes
2-3 mm, it should be reversed and mounted again. If abnormal abrasion occurs, it is
necessary to reverse or replace promptly.
Tile is divided for manageable weight to enable easy replacement by hand.
Replacement is performed easily by only removing upper liner ⑧ (Construction
group: 4) ,and no need to remove arms or blades.
Replacing of tiles is started from the bottom portion. If difference in thickness of
tiles is more than that shown in Figure: 1, upper portion of tiles also must be replaced.
Otherwise, tiles may be excoriated by aggregates pinched into gap of blade and tile
when mixing.

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Figure-1

Blade rotating direction


Using tile
2~3mm
or bottom liner

New replaced tile

d Parts No. ①②③④, Repair and replacement of Side liner (See figure-2.)
Left and right cross arms and blades are rotating facing of surface of side liners
with constant gap. Therefore, the gap between divided liners must be kept to a
minimum. Otherwise, partial abrasion occurs and reduces lifetime of liner.
Adjust blade and arm regularly to avoid pinching in by aggregates, and also adjust
the entire gap between side liner and ring liner (Construction group 3, Parts No.⑫)
as 3-5 mm homogenously at circumference.

1. Side liners
Figure-2
2. Dust cover
3. Ring liner

When replacing each of liners, completely remove the concrete intruding between mixer
tank and liners. Replace liners after apply grease on mixer tank lightly, next replacement
will be easier.
Adjust liners are not uneven and make gap homogenous between arm and blade.

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Gap of Side gate liner

⑦Side gate liner Gap 0.5 to 1.0mm

Gap of Gate seal plate

Gap 0.5 to 1.0mm Gate seal plate

Figure-3

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Figure-4

1. Side liner (Center) 2. Side liner (L) 3. Side liner (R)


4. Side liner (Outer) 5. Tile 6. Gate seal plate
7. Side gate liner 8. Upper liner 9. C’sunk B,N,SW,PW
10. B,SW,PW 11. B,SW,PW

*Above picture is KYC-EX3000.

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Construction group: 2 Discharging gate

Discharging gate is cylindrically shaped and mounted on bottom of mixing tank with
two bearings.
In order to prevent abrasion of discharging gate drum, it is protected by easily
replaceable liners made of abrasion-resistant casting iron. To close discharge gate
completely, adjustable and replaceable gate seal plates are mounted to left and right.
Gate seal plates must be adjusted sometimes depending on abrasion condition.
When a gap exceeds 3-4 mm, pinching in of aggregates occurs and gate does not
open/close smoothly. Same phenomenon occurs if adhesive concrete is not removed
completely. (See 11.4.) As already mentioned, after completing operation, mixer must
be cleaned with special care, lubricated with drained oil to prevent adherence of
concrete.

a) Parts No. ⑦, Replacement of gate liner


Remove all gate seal plates ⑥ and side gate liners ⑦ (Construction group : 1)
and loosen bolts from bottom. Then, gate liners can be removed from top.

Figure 5

Gate liner

Gate shaft Discharge gate drum Pillow unit


Pillow unit Gate shaft

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Gate liner


Discharge gate drum

Construction group: 3 Mixing tank, bearing part

Mixer has two mixing shafts aligned parallel to horizontal direction. Each mixing
shaft has an easily removable bearing housing, and is attached to mixing tank by screws.
Spherical roller bearing is inside of each bearing housing.
To prevent cement paste from entering mixing shaft, a special seal is used. Dust
cover and ring liner (divided in half) are mounted to sidewall of mixer. Inside them is
designed to become a grease sump for preventing entry of cement paste.
Special attention must be paid to abrasion of dust cover. Check dust cover whenever
adjusting cross arms. (See Figure-6.)
Dust cover and ring liner can be easily replaced by removing cross arm.

a Parts No. ④, Removing bearing


Remove outer cap ⑮ and end cap ⑭, and remove bolt ⑧ of bearing housing,
and screw three forcing bolts up evenly, and pull bearing out, then spherical roller
bearing ④ of inside also can be removed.

b Parts No. ①, Replacement of floating seal


After removing fixing collar ⑳ of driving side and spacer bush ⑱ of fixing
side, bolt of seal fixing metal ⑩ and then, remove seal fixing metal with chisel or
screwdriver.
One floating seal is removed with seal fixing metal. The other side of floating seal
remains in bush ⑨.
Carefully remove O-ring from inside of floating seal with screwdriver or wire. Take
special care not to allow contaminant or trash to enter.

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Apply grease to contact surface of rings of floating seal carefully to prevent any
damage and rust go inside.
And carefully clean inner surface of seal fixing metal and bush which contact
O-ring and then apply grease
Afterward, when assembling floating seal, insert O-ring and rings using special tool
not to damage to sliding surfaces of both seal fixing metal and bush.

c Parts No. ⑪&⑫ Replacement of dust cover and ring liner


Dust cover and ring liner are divided in half. They can be removed from inside of
mixing tank.
Both parts can be removed only by removing cross arm and bolt ⑥ with
hexagonal hole. If dust cover and ring liner are abraded as shown in Figure-3,
replace with new ones. When replacing, adjust a gap with side liner homogenously.

Ring liner and dust cover must be replaced


when ring liner is abraded about 7mm.
When adjusting cross blade, always check
liner and replace a little earlier.
Side liner

Ring liner

Maximum: about 7mm

Gap: 2-3mm

Figure 6
Dust cover

It is abraded and bent


backward to inside,
(In this case, please replace
immediately.)

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Figure-7

1. Floating seal 2. O-ring 3. Oil seal 4. Bearing 5. Mixing shaft


6. Hex. Bolt 7. B,SW 8. B,SW 9. Bush 10. Seal fixing metal
11. Dust cover 12.Ring liner 13. B,SW 14. End cap 15. Outer cap
16. Feather key 17. Bearing housing 18.Spacer bush(B) 19. Spring pin
20. Fixing collar

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Construction group: ④, Mixing implement

Mixing implements are installed with bolts and arm and counter piece made of
special casting iron are holding hexagonal mixing shaft. Each blade is installed with two
bolts at the tip of the arm. In order to prevent abrasion of bolts, abrasion-resisting plate
(See figure : 9 ⑧) is mounted.
Pay attention to following matters in order to keep abrasion and maintenance costs as
low as possible.
1. To avoid adherence of concrete in mixing implement, aggregates and cement
should be thrown into between both mixing shaft and center of mixer.
2. Throwing materials must be follow the proper order. (See 9.5.)
3. If concrete is adhering to mixer, abnormal abrasion ensues. So, inside of the mixer
must be always cleaned using high-pressure water.
4. Gaps between blade and liners and between cross arm and side liner are widened
by abrasion. If adjustment is not done regularly, the gaps increased more and more.
Ideal gap is 3-5 mm.
5. Just after replacing blade, arm and etc, bolts could loosen during loaded operation
and the bolts will contact with liners. Therefore, tighten them sufficiently.

a Parts No. ⑦⑫⑬, Adjustment of blade(See figure: 8,9)


After loosening mounting bolt ⑩, blades ⑦⑫⑬ can be moved to radius
direction.
Long hole of arms ①②③ are designed to make blades adjustable for several
settings. Gap between blade and side liner and tile must be adjusted for 3-5 mm.
Check gap by a piece of metal with suitable measurements. When adjusting, pull
the V belt by hand and rotate mixing implement, then find place where gap is
smallest, and check the dimensions there.

b Parts No. ①②③, Replacement of arms (See figure: 8,9)


Concrete is adhering to pits of bolt mounting part of arms ①②③ and counter
piece ④. Therefore, remove it using tool such a chisel, then detach nuts and remove
the arm.
When mounting new arm, rotate the mixing shaft to put arm upright position and
fix counter piece from bottom.
Tighten bolt ⑤ to make left and right spaces equal.
Adjust gap of cross arms ①③ to 3-5 mm throughout entire length against side
liner of mixing tank.

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c Parts No. ①②③, Hard facing of arms (See figure: 9)
When abrasion of arm ①②③ is extreme, pad surface of arm to diamond-shape
using a welding electrode. This will extend lifetime of arm.
If it is welded too tightly, the material quality changes, so weld it with an interval
of about 50 mm
For hard facing, use welding electrode designed for hard padding which is
manufactured by Kobe Steel Inc.(HF-800K)
Blade is made of special abrasion-resistant casting iron, so it cannot be welded.

d Parts No. ⑫⑬, Adjustment of side blade (See figure: 8,9)


Contact surface of cross arm and side blade has wave-shaped irregularities.
Therefore, when adjusting, remove bolts and chip off concrete adhering to these
irregularities. Cement paste enters the spaces between these irregularities and
prevents the blade from shifting.

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Construction group: 4 Mixing implement

Figure 8

1. Left-turned cross arm 2. Right-turned middle arm 3. Right-turned cross arm


4. Counter piece 7. Middle blade 12. Left-turned side blade
13. Right-turned side blade

*Above picture is KYC-EX3000.

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Figure 9

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Construction group: 5 Operation of discharging gate

Pneumatic operated discharging gate is moved by using one lever with two cylinders,
and the cylinders are adjusted by 4-way solenoid valve.

※ Limit switchs are set up to work at the position of gate half-open and gate-close.
※ Adjust opening time by operating timer for half- open and full- open positions.

When power cut or solenoid valve coil is burned, 4-way solenoid valve can be
operated by hand.
Required pressure of cylinder is 0.5-0.7MPa. and 4-way solenoid valve is used
AC200V or DC24V or AC100V. (*Please check before use)
As already mentioned in 3.1, in special circumstances, 4-way solenoid valve is
transported with separately from cylinder. In this case, install them properly.
When wiring limit switch or 4-way solenoid valve, handle with care so as not to
interfere with the operation by cylinder.

(Note) ※ are for standard specification..

a Parts No. ④⑤, Lubricating oil to pins


For smooth operation of air cylinder, lubricate pin with oil regularly using oil can
(about once a week). If pin is rusted, the gate cannot be open/close smoothly.

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Construction group: 5 Operation of discharging gate

Figure 10

1. Gate open/shut lever 2. Headed taper key 3. Cylinder bracket


4. Pin for bracket 5. Pin for fork end 6. Fork end 7.Air cylinder
8. Solenoid valve 9. Solenoid valve mounting base 10. Silencer
12. Silencer 13. Air hose 14. Hose adapter

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Construction group: 6 Mixer driving part
Low-voltage 3 phase squirrel cage induction motor is used and Gear reducers are
driven by V belt.
Each gear reducer is jointed to spline portion of mixing shaft, and both ends of
input shaft are connected by coupling.
Gear reducers are mounted on each fixing base which installed on mixing tank.
If coupling is broken, mixing implements are hit and seriously damaged.
After disassembling coupling, re-assemble it to ensure that mixing implements
always returns to normal position.
Check tension of V belt before operation. If it has loosened, tighten it accordingly.
If initial tension is inadequate, lifetime of V belt is reduced noticeably.

a Parts No. ①②, Removal of gear reducer


Remove coupling ⑬ and loosen bolts⑰, then remove gear reducer horizontally
paying most attention not to damage spline of shaft.

b Installation of gear reducer


Insert bolts into holes of reducer fixing base, then push reducer horizontally and
install on mixing shaft carefully not to damage spline.
Position of mixing implement is adjusted by coupling. (See Chapter 3: 1
Configuration figure of mixing implement.)
Rotate the mixing implement by hand again, and check if blades are hitting each
other.

c. Adjustment of ⑪ V belt
1. If old belt and new belt are used together, part of belt can be overloaded.
Therefore, when replacing, replace all belts together.
Matching number is indicated on V belt. Replace with belt using same matching
number.
When a few belts are cut off, replace all belts at same time and store old ones for
spare use. Combination of old and new belts causes irregularities in size due to
stretching and stress, and reduces hardiness.
2. When preserving belt, store in place with no sunlight or heat in order to prevent
adherence of oil. If it absorbs moisture, the length can be changed and stretching
can occur easily. Therefore, avoid storing on ground or floor.
Storage by hung on wall is recommended.
3. Install motor in order to make center axle of V pulley accurately. If not accurate,
one side of belt is damaged terribly and excessive heat occurs.

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4. It takes a few days to adopt the belt to V pulley. Adjust belt tension a bit strongly
because the distance of both pulleys is short.
Re-adjust the tension 3 - 4 days after operation to obtain the best result.

d. Construction group: 6 Mixer driving part

Figure 11

1. Planetary gear reducer -L 2. Planetary gear reducer – R


3. Motor – L 4. Motor – R
5. Reducer fixing base - L 6. Reducer fixing base
7. Motor adjust bolt 8. Headed taper key
9. Motor side V-sheave 10. Reducer side V-sheave
11. V belt 12. Hex.B, SW
13. Coupling 14. Hex.B, SW
15. B, N, SW, 2PW 16. Mixing shaft
17. HT B, N, SW

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e. Check mixer level and Coupling
Before checking of coupling level, check the mixer level which must be completely
horizontal.
Afterward remove V-belt cover and check the level of coupling which connects two
gear reducers (see below photo)

--- IMPORTANT ---


When operate Mixer not in horizontal condition, the durability of
Mixer and Reducers and/or other parts might be remarkably ruined.
Please inquire of us or our authorized sales agent if when there is
something an uncertain point.

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CHAPTER 3.

1. Placement figure of mixing implement

1. Left-turned cross arm 2. Right-turned middle arm 3. Right-turned cross arm


4. Counter piece 7. Middle blade 12. Left-turned side blade
13. Right-turned side blade

*Above picture is KYC-EX3000.

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2. Specification figure of oil lubrication

Grease Oil /Week


70g/6month
Oil /Week

Grease
5g/week
Grease Grease
100g/Daily 100g/Daily

Grease Grease
5g/week 5g/week
Grease
5g/week

8.5L Gear Oil /


1000hour or 6mth

Grease Oil /Week


17g/week Grease
17g/week
Oil /Week

8.5L Gear Oil /


1000hour or 6mth Grease
5g/week
Grease Grease
5g/week 5g/week

------- Please refer to Chapter 1, 9 & 10 ------


○ : Grease lubrication : once a day (about 8 hours)
□ : Grease lubrication : once a week
▽ : Cylinder pins (upper, bottom) and rotation part of limit switch : once a week

: Check oil level of gear reducer : once a week

: Grease lubrication following by brand plate on motors


*While greasing time, motors shall be running, and lubricate must be from
grease nipple.

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3. Electrical drawing of Oil temp.alarm

Connect the cable of Monitor to Oil temp.sensor under each reducer, then keep the
monitor in your control room.
Alarm rings and lamp lights when oil temp. becomes 80degrees.
In case of this STOP mixer immediately and confirm whether to find abnormality in mixer.
Re-start mixer after confirming of no abnormality and lamp off.

4. Specification chart of maintenance and inspection

Description of
Probable cause Countermeasure
problem

A) Power lamp of 1. Fuse blowed off (1A) Change fuse


watching monitor 2. Power supply error (DC24V) Repair power supply.
does not work.
3. Lamp spoiled Change lamp.

B) Oil temp. alarm 1. Over load Stop mixer, and re-start after
rings and lamp lamp off
lights 2. Trouble of gear reducer Check oil level & reducer
3. Breakdown of monitor Change lamp or fuse
4. Sensor & circuit Change sensor & check circuit

41