Atlas Copco Ground Engineering Products

Unigrout Grouting Platform

Flex S
Safety and Operating Instructions

© 2014 Atlas Copco Craelius AB | No. 6991 5280 01a | 2014-04-22

Safety and operating instructions

Contents
Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Safety signal words . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Personal precautions and qualifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Hoisting and transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Storage, repair, maintenance and disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Personal protective equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Drugs, alcohol or medication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Safety area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Hoisting and transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Operation, precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Maintenance, precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8

Signs and stickers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Prohibition signs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Warning signs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Slip risk. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Moving parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Regulatory signs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
General regulatory signs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Information signs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
Other signs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
Rig data plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Patent protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Genuine parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Design and function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
Intended use. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Unintended use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Flex S E15-110/80 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Mixer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Power unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Safety on and around the rig. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
Dangers on the rig . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Danger zones . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Safe zones . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Safety devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Emergency stop button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

2 © 2014 Atlas Copco Craelius AB | 2014-04-22

01 TOC Unigrout Flex S Ed.0
 Safety and operating instructions

Fire extinguisher. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Hoisting and transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Hoisting the unigrout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15

Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Setting up the rig . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
Pre-start. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
Safety check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Pre-start procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Start procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
Mixing and emptying . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
Water dosing kit (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
Programming water dosing kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
Injecting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
Presetting of maximum low grout pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
Presetting of maximum high grout pressure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Cleaning procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
Mixer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Agitator and pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Lubricant recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21

Disposal and environmental instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Oil and Grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Electrical components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Chemicals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Dust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Metals (steel, aluminum, etc.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Plastics and rubber. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Pressure vessel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Material Safety Data Sheets (MSDS/SDS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Technical specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
Flex S E15-110/80 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
Sound power level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24

© 2014 Atlas Copco Craelius AB | 2014-04-22 3

01 TOC Unigrout Flex S Ed.0
Safety and operating instructions

Sound pressure level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24

Vibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24

4 © 2014 Atlas Copco Craelius AB | 2014-04-22

01 TOC Unigrout Flex S Ed.0
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 | 2014-04-22

Introduction
Safety and operating instructions
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:
6 © 2014 Atlas Copco Craelius AB | 2014-04-22
 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.
02 Safety Instructions Grouting Ed.1

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.
© 2014 Atlas Copco Craelius AB | 2014-04-22
02 Safety Instructions Grouting Ed.1
Safety and operating instructions
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 the 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.
7
Safety and operating instructions
►Never use the machine near flammable materials,
fumes or dust.
►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.
8 © 2014 Atlas Copco Craelius AB | 2014-04-22
►Always contact your Atlas Copco Customer Center
before you modify the machine.
►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.
02 Safety Instructions Grouting Ed.1
 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.

© 2014 Atlas Copco Craelius AB | 2014-04-22 9

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.

10 © 2014 Atlas Copco Craelius AB | 2014-04-22

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

© 2014 Atlas Copco Craelius AB | 2014-04-22 11

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 machine.
Design and function
The grout plant consists of a high-speed mixer,
a agitator and a grout pump mounted on a steel
platform provided with slots for forklift and lifting
eyes. Two ball valves are mounted on the pump
outlet: one for the groutline and one for the
recirculation line back to the agitator. One electrical
cabinet with start/stop buttons for the unit. The grout
plant is delivered without electric supply cables.
Intended use
The Unigrout is intended for grout, drilling fluid, mud,
paint and pulp.
Unintended use
Any application other than this shall be considered
”non-intended 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
compliance with instructions in manuals as stipulated
by the manufacturer.
Main parts
Flex S E15-110/80
A. Emergency stop
B. Hydraulic motor
C. Flow controller
D. Electrical cabinet
E. Platform
F. Forklift eye
G. Mixer (Cemix)
H. Agitator (Cemag)
I. Grout pump unit (Pumpac Complete)
12
Mixer
The Cemix is a high-speed and high-shear mixer of
a colloidal type, producing a thoroughly uniform mix
free of lumps or aggregates. The cement particles
disintegrate in three stages 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
center.
Each cement particle thus becomes separated and
effectively wetted. The mixing impeller is directly
driven by the hydraulic motor, through a shaft
extension.
Agitator
The Cemag is an agitator fitted with a container that
has twice the volume of the mixer. This is in order
to ensure that grout is always kept available for the
pump when grouting and mixing are being carried
out simultaneously. The cylindrical container with
a conic base and agitator shaft with offset blades
creates the necessary counter currents, which keep
the mixture in suspension and release mixed-in air
bubbles.
B
G
H
D A
C
I
E
AIB 100000384_00
© 2014 Atlas Copco Craelius AB | 2014-04-22
04 Overview Unigrout Flex S Ed.0
 Safety and operating instructions

Pump Safety on and around the rig

The Pumpac is a single cylinder double acting piston
pump capable of pumping most grout mixtures used
for sealing and reinforcement of for example rock and Dangers on the rig
concrete. It is designed with easy-to-clean ball valves
and with a hydraulic system allowing pressure and
B
flow to be independently controlled during grouting A
operations. Maximum flow and pressure can,
however, not be achieved simultaneously. The grout
pump is provided with water flushing of the piston
rods for longer life of the piston rods and seals. One
46 mm spanner is the only tool necessary to service
the fluid end of the grout pump.
Standard valve system: Ball valve (B).
Optional valve system: Heavy duty (HD) or Disc
valve (DV)
AIB 100000385_00

A. The lid on the CEMAG can fall shut

Grout cylinder 110 unexpectedly and injure limbs. Use caution
Grout flow 0-120l /min when working around open CEMAG.
Two grout pressure setting levels B. Grout may splash out of the CEMIX. Always
Low pressure.........................2 - 10 bar use eye protection around the rig and when
inspecting equipment.
High pressure........................8 - 100 bar

Danger zones

Power unit
The Power unit is mounted on a steel platform A
together with a pump which form the unit Pumpac
Complete.
The hydraulic power unit is designed to supply
hydraulic power to one mixer, one agitator and
one grout pump. A variable hydraulic piston pump A A
feeds hydraulic flow to the grout pump for easy,
independent control and setting of grout flow and
pressure. Two hydraulic gear pumps feed hydraulic
flow to the mixer and agitator. One hydraulic pump
for each unit. Both gear pumps are provided with
pressure relief valves set at 210 bar. On the front A
side of the power unit is the operator’s position, with
the electric cabinet and hydraulic controls for all units
and the water flow control for the grout mixer. AIB 100000386_00

Electric motor 15 m ft
A 1 3
Hydraulic power unit.............................................15
kw During normal operation it is advised to always use
personal protective equipment within the danger zone.

Safe zones
The area outside the danger zones are to be
considered safe zones.

© 2014 Atlas Copco Craelius AB | 2014-04-22 13

04 Overview Unigrout Flex S Ed.0
Safety and operating instructions

Safety devices Fire extinguisher

Emergency stop button

AIB 100000391_00

The Unigrout Flex S platform is equipped with one

portable fire extinguisher (B). The fire extinguisher
AIB 100000387_00

The emergency stop button (A). is located on the front is placed on the back side of the electrical cabinetv.
panel of the power unit. This fire extinguisher is suitable for putting out
fires in electrical cables, fuel and engines and
lasts for approximately one minute when operated
1 2 continuously.
Note: Make sure the fire extinguisher follows local
rules and regulations.

OK
OK

0
0

AIB 100000357_01

70000005 A
The emergency stop buttons are activated by pressing
them (1). To reset a emergency stop button turn it
clockwise untill it pops out to normal position.
Check before each shift that the needle on the gauge
is within the green zone and make sure that the
fire extinguisher is replaced as soon as the needle
approaches the red zone.

For use
1. Remove the safety pin.
2. Direct the jet towards the base of the fire.
3. Press the handle.

1 2 3
AIB-100000020_04

If the fire extinguisher has been used, it must be

replaced immediately.

14 © 2014 Atlas Copco Craelius AB | 2014-04-22

04 Overview Unigrout Flex S Ed.0

Hoisting and transport
WARNING Heavy equipment can cause
serious injury.
►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 lifting heavy objects.
© 2014 Atlas Copco Craelius AB | 2014-04-22
05 Hoisting and Transport Unigrout Flex S Ed.0
Safety and operating instructions
Hoisting the unigrout
Forklift eyes
The Unigrout platform is equiped with forklift eyes (A).
Before lifting the platform with a forklift:
♦ Center the load on the forks
♦ Make sure the platform rests evenly on the forks
♦ Make sure that the forklift will not damage the
hydraulic hoses, mechanical components etc.
AIB 100000390_00
15
Safety and operating instructions
Operation
WARNING Engine running
If the Unigrout is left unattended with the engine
running it can cause serious injury.
►Never leave the Unigrout unattended.
Setting up the rig
1. Place the platform on level ground, away from
falling rocks, in a dry and well illuminated
location.
Note: If platform is not placed on level ground the
vortex might become unstable and mixing efficiency
will decrease.
2. Connect the water.
AIB 100000378_00
3. Connect electricity and switch on circuit breaker.
16
Pre-start
Safety check
There are safety devices built into the system of the
Unigrout for your personal safety.
Before each shift commences, a extra and thorough
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 know that they will be operational the moment
you need them.
♦ If you are unsure of the equipment's reliability, do
not put it into operation.
Pre-start procedure
4. Connect the electricity supply cable.
5. Check the oil level in the hydraulic tank.
6. Connect a water supply hose at the water inlet.
7. Turn on the main switch.
8. Check that the emergency stop button is set to
operation mode.
Start procedure
1. Start the electric motor by pushing the green
start button.
2. Start the agitator with the start and stop valve.
© 2014 Atlas Copco Craelius AB | 2014-04-22
06 Operation Unigrout Flex S Ed.0
 Safety and operating instructions

Mixing and emptying Water dosing kit (optional)

NOTICE Empty mixer running continously can
damage the equipment
►Never run the empty mixer continously for longer
periods of time.

1. Flow meter
2. EL.magnetic valve
3. Pulse transmitter\Measuring pipe
A
4. Button to scroll-up the menu or increase a value
5. Button to scroll-down the menu or select a digit
to be modified
6. Confirm input and menu points

AIB 100000379_00

A. Water meter hanging on the side of the mixer container

1. Connect water supply to the water meter and
fill up the mixer container with a predetermined
volume of water.
2. Check that the lever on the circulation and outlet
valve is in the mixing position.
3. Start the mixer with the start and stop valve.
4. Open the cement bags against the bag splitter
and add the correct amount of cement to the
mixer container.
5. Let the mixer run until the grout is well mixed.
6. Pump the grout into the agitator by switching the
lever,(circulation and outlet valve), into pump out
position.
7. Go to step one and repeat mixing or stop the
mixer.

© 2014 Atlas Copco Craelius AB | 2014-04-22 17

06 Operation Unigrout Flex S Ed.0
Safety and operating instructions

Programming water dosing kit Injecting

Connect electricity
At start you can read ”BATCH M” in the display. Press
A
enter and the button beside with arrow down on simul- C
taneously for 5 seconds to reach programming.

“LANGUAGE” press enter.

Choose language with the buttons on the left side of
the enter button (arrow up and arrow down). D
B
“ENGLISH”. Press enter
“UNIT” press enter.
“BATCH” chooses ”LITRE” press enter.
“LITRE” press enter.
Choose ”LITRE/MIN” press enter.
“TOTAL” press enter.
“LITRE” press enter.
‘’K-FACTOR’’ press enter.
“TEACH NO” press enter.
“K = xXX.xx “ (This value is set from factory) press
enter.
“OPTIONAL” press enter. Choose ”LOC MANU” press
A. High pressure setting valve.
enter.
B. High and low pressure valve.
“OVERFILL” press enter choose “OVERFILL y” press
C. Grout flow setting valve.
enter.
D. Low pressure setting valve.
“ALARM” press enter.
“DURING” press enter. 1. Check that the grout flow regulating valve (C) is
“OFF” press enter. closed (turned clockwise) and that the pressure
“AFTER” press enter. setting valve (pos A or D, depending on if you
“OFF” press enter. are doing a high or low pressue setting) is fully
“RELAY” press enter. open (turned counterclockwise).
“RELAY I” press enter. 2. Start the grout pump motor by turning the lever
“DEL=OOO” press enter. on the hydraulic control unit to the high or low
“100 % “press enter. pressure position (B)
“INV NO” press enter.
“RELAY 2” press enter. 3. Close the groutline ball valve.
“END DOSE” press enter. 4. Open the recirculation ball valve.
“INV NO” press enter.
“TOTAL” press enter. 5. Open the flow regulating valve (C) slightly, if
“RES NO” press enter. necessary turn the pressure setting valve (Pos A
“END” press enter. or D, depending on if you are doing a high or low
pressure setting) until the pump starts, watch for
Now the display should read ”BATCH M”, press enter when the piston rods start to move.
and choose with the two buttons on the left side of 6. Let the pump make a few pump strokes to get rid
the enter button how many litres you want. When the of any air in the grout pump cylinder.
amount of litres is chosen press enter, then “OK y” is
7. When grout starts to flow back into the agitator,
shown on display press enter again. Now the valve
will let the chosen amount of water pass. The amount close the recirculating ball valve.
of litres counts down backwards on the display to O.
If you don’t get the right amount oflitres adjustments
of the ”K-FACTOR” has to be done until it will be right.
K=049.03 is according to the table right for I” flow me-
ter but must sometimes be adjusted.
(Use a tank with scales to measure and adjust when
it’s necessary). When the programming is finished just
choose the amount of litres you want.

18 © 2014 Atlas Copco Craelius AB | 2014-04-22

06 Operation Unigrout Flex S Ed.0
 Safety and operating instructions

Presetting of maximum low Cleaning

grout pressure See "Cleaning procedure" on page 20 under
Maintenance chapter.
♦ Be aware that a pressure under 30 PSI (1-2 bar) is
not practical because of the internal friction in the
grout line.
Stop procedure
1. Set all valves for the mixer, agitator and pump to
1. Set the high pressure valve to estimated 140
the off position.
psi/10 bar (one full rotation on the knob).
2. Turn off main water intake.
2. Look at the grout pressure gauge and turn the
pressure setting valve until the desired grout 3. Stop the electric motor by pushing the red stop
pressure is shown on the gauge (recommended button.
maximum is 140 psi).
4. Turn off the main switch.
3. Proceed to set the high pressure.

Presetting of maximum high

grout pressure
1. Make sure that the PUMPAC is full and that the
ball valves are closed.
2. Look at the grout pressure gauge and turn
the high pressure setting valve clockwise until
maximum allowed grout pressure is shown on
the gauge.
3. Lock the grout pressure setting valve with the
knurled locking knob.
When the pump, during grouting operation, will reach
preset value, it will automatically stop and keep the
pressure. If the pressure drops the pump will start
again.

© 2014 Atlas Copco Craelius AB | 2014-04-22 19

06 Operation Unigrout Flex S Ed.0
Safety and operating instructions
Maintenance
DANGER Electric shock
►Do not touch live and damaged 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 flush the electrical equipment with water.
►Use flush clothes for protection of the electrical
equipment, during cleaning.
WARNING Rotating parts can cause serious
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.
►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
For information on maintenance, see the Safety and
operating instructions for the Cemix, Cemag, Pumpac
and Power unit.
20
Cleaning procedure
The following steps should be carried out after every
work shift. This is vital to ensure that the equipment
stays in optimal working condition.
Mixer
1. Fill the container with water and put the lever
on the circulation and outlet valve in the mixing
position.
2. Start the mixer and let the mixer run for a few
minutes.
3. Disconnect the mixer hose and pump out the
water by switching the lever on the circulation
and outlet valve to pump out position.
4. Stop the hydraulic motor and open the mixer
housing drain plug located at the bottom of the
mixer housing and drain remaining water.
Agitator and pump
1. Fill the agitator, close the grout line ball valve
and open the recirculation ball valve.
2. Start the grout pump and the agitator, and
adjust the grout pump to maximum flow using
the groutflow setting valve. The water will now
circulate at a high flow rate through the pump,
the recirculating hose and back into the agitator.
Continue for a few minutes and then open the
grout line ball valve and pump out water.
3. Repeat the procedure until the pump, agitator
and hoses are clean.
4. Switch off the pump and agitator.
5. Disconnect the mixer hose to drain the pump
inlet and agitator.
6. Wash the equipment to keep it clean.
Spray the platform with anti-sticking oil.
Important: always cover the CEMIX and CEMAG
openings before spraying with anti-sticking oil.
Anti-sticking oil must never be applied to the
inside of the CEMIX or CEMAG.
© 2014 Atlas Copco Craelius AB | 2014-04-22
07 Maintenance Unigrout Flex S Ed.0
 Safety and operating instructions

Lubricant recommendations
Lubricant Recommendation
Hydraulic oil Use mineral-based hydraulic oil with good anti-wear, rust (oxidation) and foam inhibiting
properties, as well as effective air and water separation abilities. The viscosity grade should
correspond to the ambient temperature and ISO 3448, as follows:

Ambient temp. °C (°F) Viscosity grade Viscosity index

+25 to +40 (77 to 104) ISO VG 68 Min.95
0 to +25 (32 to 77) ISO VG 46 Min. 95
-30 to 0 (-22 to +32) ISO VG 32 Min. 95
Examples of oil grades in the temperature range 0 to + 25°C
Shell Tellus T46
BP Bartran HV 46
Castrol Hyspin T 46
Mobil DTE 15M
Texaco Rando HDZ 46
Exxon UNIVIS HP 46
Use of flame proof or vegetable hydraulic oil, please contact the
nearest Atlas Copco representative for information.
Grease Universal grease NLG12 .............................Operating temperature °C (°F)
lithium/molybdenum additive........................Max. 100° (212°)
Synthetic sodium or calcium grease.............Max. 140° (284°)
Example of grease grades
Shell Retinax AM
Esso MP Grease
BP Energrease LS-EP 2

© 2014 Atlas Copco Craelius AB | 2014-04-22 21

07 Maintenance Unigrout Flex S Ed.0
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 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
risk.
♦ 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 according to local regulations in force for
destruction and waste disposal.
22
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 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 | 2014-04-22
09 Disposal Ed.2
 Safety and operating instructions

Technical specifications
Dimensions

Flex S E15-110/80

mm in
A 1285 50.6
B 1600 63
C 1400 55.1

B
C

AIB 100000389_00

© 2014 Atlas Copco Craelius AB | 2014-04-22 23

11 Technical Specifications Unigrout Flex S Ed.0
Safety and operating instructions

Weight

Weight kg lb
Flex S E15-110/80 912.4 2011.5

Sound power level

Conditions dB(A) rel 1pW

Normal operation 104

Sound pressure level

Conditions dB(A) rel 20μPa

Operators station 83
1 meter from rig 83 ± 6

Vibration

Position m/s2
Operator's station 0.11

24 © 2014 Atlas Copco Craelius AB | 2014-04-22

11 Technical Specifications Unigrout Flex S Ed.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.
6991 5280 01a Märsta, Sweden, 22 April 2014 Specifications and equipment subjects to change without notice. Consult your Atlas Copco Customer Center for specific information.

www.atlascopco.com