Atlas Copco Ground Engineering Products

CEMAG® Grout Agitator

CEMAG®
CEMAG COMPLETE
Safety and Operating Instructions
CEMAG 201
CEMAG 203
CEMAG 403
CEMAG 803
CEMAG 1603

© 2013 Atlas Copco Craelius AB | No.6991 5016 01c | 2013-11-11

 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
Main parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
CEMAG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Safety on and around the rig. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
Dangers on the rig . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Danger zones . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Safe zones . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Safety devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
Emergency stop button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

© 2013 Atlas Copco Craelius AB | 2013-11-11 3

01 TOC CEMAG 203, 403, 803, 1603 Ed.2
Safety and Operating Instructions

Hoisting and transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Hoisting the agitator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Transport the agitator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14

Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Safety check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
Grouting system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Before start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
Electric cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
Agitator with an electric motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
Agitator with hydralic motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
Worm gear unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
Grouting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
After grouting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Cleaning procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
Agitator and pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Disposal and environmental instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Oil and Grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Electrical components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Chemicals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Dust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Metals (steel, aluminum, etc.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Plastics and rubber. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Pressure vessel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Material Safety Data Sheets (MSDS/SDS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Technical specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
CEMAG 200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
CEMAG 400 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
CEMAG 800 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
CEMAG 1600 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Voltage ( V) / Frequency (Hz) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
Sound pressure level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20

4 © 2013 Atlas Copco Craelius AB | 2013-11-11

01 TOC CEMAG 203, 403, 803, 1603 Ed.2
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.

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

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 © 2013 Atlas Copco Craelius AB | 2013-11-11
 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.2

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.
© 2013 Atlas Copco Craelius AB | 2013-11-11
02 Safety Instructions Grouting Ed.2
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 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 © 2013 Atlas Copco Craelius AB | 2013-11-11
►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.2
 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.

Warning signs ♦ The eye, ear and head protections symbol means
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.

© 2013 Atlas Copco Craelius AB | 2013-11-11 9

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

Information signs

Hydraulic oil drain

Fire extinguisher
Other signs

Rig data plate

See the Technical specifications section for further
information.

Atlas Copco Craelius

MÄRSTA - SWEDEN

A
Name
Type
Hoisting/lifting point 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

Hydraulic oil pressure
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
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 © 2013 Atlas Copco Craelius AB | 2013-11-11

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

Genuine parts Cement Additive

3716 5565 83 3716 5565 81

Filling Emptying

3716 5565 87 3716 5565 54

Lower level limit Manually

3716 5565 84 3716 5565 86

Number 1 Number 2

1
3716 5565 78
2
3716 5565 79

For best performance make sure to always use

genuine Atlas Copco spare parts.

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

On Off

3716 5565 32 3716 5565 33

On/Off Water flow

3716 5565 31

3716 5565 27

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

Grout flow Grout pressure

G
G
3716 5565 53 3716 5565 37

Rotation speed System pressure

regulation

3716 5565 06 3716 5565 01

Mixer Agitator

3716 5565 51 3716 5565 50

Hydraulic flow Vibrator

3716 5565 52 3716 5565 82

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

03 Signs and stickers Unigrout Ed.2
Safety and Operating Instructions

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

Design and function

The CEMAG® agitator serves an intermediate vessel
between the mixer (which mixes by batches) and the
pump (which requires continous supply).
The CEMAG® comprises a cylindric container with
conic base and an inclined agitator shaft with offset
blades. The blades creates the necessary counter
currents which keeps the mixture in suspension and
releases mixed air in bubbles.
The shaft rotates at approximate 60 rpm and is
powered by an electric motor via a gear box or directly
by a hydraulic motor.
A strainer at the intake prevents large particles from
entering the mixture.

Intended use
The agitator CEMAG® is intended for grout, drilling
fluid, mud, paint and pulp.

Unintended use CEMAG COMPLETE

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

Main parts
A. Agitator (Cemag)
D
B. Hydraulic motor
C
C. Electrical cabinet

D. Emergency stop

E. Forklift eye

E
E

12 © 2013 Atlas Copco Craelius AB | 2013-11-11

04 Overview CEMAG Ed.3
 Safety and Operating Instructions

Safety on and around the rig Safety devices

Dangers on the rig Emergency stop button

Cemag complete is equipped with an emergency stop

button (A). The emergency stop button is located on
the electrical cabinet.
A. The lid on the CEMAG can fall shut 2
1
unexpectedly and injure limbs. Use caution when
working around open CEMAG.
Grout may splash out of the CEMAG. Always
use eye protection around the rig and when
inspecting equipment.

Danger zones
AIB 100000357_01

A
The emergency stop button is activated by pressing
them (1). To reset a emergency stop button turn it
clockwise untill it pops out to normal position.

A A

m ft
A 1 3
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 as safe zones.

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

04 Overview CEMAG Ed.3
Safety and Operating Instructions

Hoisting and transport Transport the agitator

WARNING Heavy equipment can cause
serious injury All the mixers in the CEMAG® range are easy to
transport or relocate. Slots are placed in the frame
►Use a sling dimensioned for the load it will carry.
to facilitate hoisting or moves with a forklift truck for
►Use only straps that are intact and intended for the example.
load in question.
NOTICE Movement during transport can damage
►Never use a damaged rope/sling. equipment
►Fasten straps in lifting eyes when present. ►Make sure that all the components are securily
fastened before transport.
►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.

Hoisting the agitator

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

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

05 Hoisting andTransport CEMAG 203, 403, 803, 1603 Ed.0
 Safety and Operating Instructions

Operation H. Suction hose

DANGER Electric shock I. Delivery hose

Touching live and damaged electrical wires will cause J. Grout recorder
serious injury or death. K. Ball valve
►Never touch live electrical wires.
L. Packer
►Stop motor before repair or inspection inside the 1. Connect a suction hose between the agitator
cabinet. and pump inlet.
2. Connect a shut-off valve and a pressure hose
of correct rating between the pump outlet and
Safety check packer (or back to the agitator for circulation).
There are safety devices built into the system of the 3. Check that the whole grouting system is ready
agitator for your personal safety. for operation – hoses, packers, grout mix
e.t.c. A by pass kit for pump recirculation is
Before each shift commences, an extra and thorough
recommended.
safety check shall be carried out on the equipment.
♦ Check the safety devices at least once every shift to
ensure that they are in full working order, so that you Before start
know that they will be operational the moment you
need them. ♦ Place platform on level ground.
♦ If you are unsure of the equipment's reliability, do Note: Inclination must be under 5 degrees or the load
not put it into operation. cells will not work properly.
Note: If platform in not placed on level ground the
General vortex might become unstable and mixing efficiency
will decrease.
♦ Before starting to use the agitator, check that the ♦ When starting the unit with separate startbox, follow
impellers and drive unit are securely tightened in instructions below.
position, and that all hoses and connections are
♦ When starting a mixer that is part of a Unigrout, use
properly secured.
the startbox of the Unigrout.
♦ At the end of each shift, carefully and thoroughly
flush clean the tank and hoses with water.
Electric cabinet
Grouting system
Grouting equipment See the PUG Safety and operating instructions for
further information.
L

H D
F
C G I
B
M

O 1
A 0
B D
I
C

K A
E H
J

A. Measuring meter from Water tank A. Main electric switch (on/off)

B. Mixer B. Start (I) / Stop (O) of agitator
C. Agitator C. Emergency stop
D. Return hose
D. Control Lamp, indicates motor overload.
E. Ball valve, outlet
F. Ball valve, return cirkulation.
G. Grout pump

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

06 Operation CEMAG Ed.3
Safety and Operating Instructions
Agitator with an electric motor
♦ Before starting to use the agitator, check that the
motor is connected to the correct line voltage (see
info plate on motor).
♦ Start the agitator and check that the impeller rotate
clockwise. If this is not the case, then call in an
authorised electrician for advice and assistance.
♦ Check, regularly, the function of the emergency
stop.
Agitator with hydralic motor
♦ Check that all hoses are correctly connected and
securely tightened.
♦ Start the agitator and check that the impeller rotate
counter clockwise. If this is not the case, switch
pressure(A) and return hoses (B).
A
B
A. Return hose connection
B. Pressure hose connection
Worm gear unit
♦ The worm gear unit is only used on agitators with
electric or air motors.
♦ Worm gear units are supplied lubricated
for life, packed with synthetic oil.
16
Grouting
The size of the CEMAG® agitator ought to be selected
so that the volume capacity is at least twice the mixing
volume capacity of the CEMIX® mixer.
The reason for this is to prevent the grout pump from
emptying the agitator, while grouting and mixing
are being carried out simultaneously. An agitator
is necessary when mixing is being carried out in a
colloidal-type mixer, which in turn adds a large amount
of air to the mix.
The main purpose of the agitator is to bleed or vent
the air from the mix, in addition to serving as a storage
tank between the grout pump and the mixer. It should
also keep the mix in a usable condition for as long as
possible. This is achieved by means of two blades that
rotate at 60 rpm inside the tank.
The tank is equipped with a removable strainer
that separates any coarse particles that might
unintentionally be transferred from the mixer. The
blades inside the agitator are either powered by an
electric or air motor equipped with a simple gear; or
powered direct via a hydraulic motor.
After grouting
The following steps should be carried out after every
work shift. This is vital to ensure that the equipment
stays in optimal working condition.
1. Always clean the agitator and hoses after
completion of grouting or when there is an
extended break in grouting operations.
2. Fill the tank with water and start the agitator.
Allow the water to circulate in the tank until the
interior of the tank appears clean. Brush or
scrape free any remaining particles of grout that
have not been dislodged.
3. Clean the outside of the equipment.
© 2013 Atlas Copco Craelius AB | 2013-11-11
06 Operation CEMAG Ed.3
 Safety and Operating Instructions

Maintenance 5. Disconnect the mixer hose to drain the pump

inlet and agitator.
DANGER Electric shock
►Do not touch live and damaged electrical wires. 6. Wash the equipment to keep it clean.

►Only authorized electricians may carry out work on Spray the platform with anti-sticking oil.
the electrical system. Important: Always cover the CEMAG openings
►Only qualified electricians should perform any before spraying with anti-sticking oil. Anti-sticking
electrical troubleshooting or maintenance. Remove oil must never be applied to the inside of the
all watches and rings that could contact live electric CEMAG.
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.
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 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

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.

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.

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

07 Maintenance CEMAG 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 the hazardous material in accordance with
local regulations.
♦ Use biodegradable hydraulic fluids and lubrication
oils for Atlas Copco products wherever possible.
Contact your local Atlas Copco office for further
information.
Engine
Engine exhausts are poisonous and environmentally
hazardous.
♦ Good ventilation is essential when the diesel engine
is running.
♦ Well-maintained air filters help to keep down
emission levels.
Fuel
Fuel spillage is environmentally hazardous and a fire
hazard.
♦ Always collect fuel residue and spillage. Treat in
accordance with local regulations.
Batteries
Batteries contain acids and heavy metals. For this
reason, expended batteries can be hazardous to the
environment and to health.
♦ Expended batteries must be sent for destruction in
accordance with local regulations.
Electrical components
Some electronic components contain batteries and
other components which could be hazardous to the
environment and personal health. Certain types of
work lighting contain mercury and could therefore
constitute environmental and health hazards.
♦ Treat the components according to local regulations
in force for destruction and waste disposal.
18
Chemicals
Chemicals such as flushing additives, other additives
and coolants can be environmentally hazardous.
♦ Dispose of chemicals such as drilling additives, other
additives, glycol etc. according to the manufacturer’s
instructions.
♦ Treat the chemicals in accordance with local
regulations for both handling and waste disposal.
♦ Avoid the use of cleaning agents containing solvents
like carbon tetrachloride. There are environmentally
better alternatives now available on the market.
Dust
Rock dust can pose a health danger.
♦ Use dust binding oil.
Metals (steel, aluminum, etc.)
♦ These products are recyclable and should be taken
care of according to national regulations.
Plastics and rubber
♦ These products are often labeled according to
different classes. In those cases they are recyclable,
they should be taken care of according to national
regulations.
Pressure vessel
A pressure vessel can cause serious injury.
♦ Discarded accumulators or gas springs must be
rendered harmless.
♦ A discarded pressure vessel that has not been
punctured must be treated like a pressure vessel.
Material Safety Data Sheets (MSDS/SDS)
Material Safety Data Sheets (MSDS/SDS) for the
chemical products included in the delivery are
available at the:
Atlas Copco Safety Data Sheets Repository
Full link
http://www-1.atlascopco.com/__C125712A0045C780.
nsf/CustViewProd20?OpenView
Please download the specifications from this link.
© 2013 Atlas Copco Craelius AB | 2013-11-11
09 Disposal Ed.3
 Safety and Operating Instructions

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

Denomination Prime Mover Volume (litre) Weight (kg) Weight (lb)

CEMAG® 201H Hydraulic motor 200 cc* 200 125 275.50

CEMAG® 203E Electric motor 1,5 kW (400V, 50Hz, 3,4A) 200 130 287
CEMAG 203H®
Hydraulic motor 200 cc* 200 125 275.50
CEMAG 403E®
Electric motor 1,5 kW (400V, 50Hz, 3,4A) 400 200 441
CEMAG® 403H Hydraulic motor 200 cc/80 cc* 400 195 423

CEMAG® 803E Electric motor 1,5 kW (400V, 50Hz, 3,4A) 800 250 551
CEMAG 803H®
Hydraulic motor 200 cc* 800 245 540

CEMAG® 1603E Electric motor 1,5 kW (400V, 50Hz, 3,4A) 1600 355 783
CEMAG 1603H
®
Hydraulic motor 200 cc* 1600 350 772
*Flow:
 200 cc 12-14 litre/min
 80 cc 5-6 litre/min
Pressure: 210 bar

Dimensions

B A

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

11 Technical Specifications CEMAG 203, 403, 803, 1603 Ed.1
Safety and Operating Instructions

CEMAG 200
Dimensions mm in
A 523 20.6
B 547 21.5
C (El) 1318 52
C (Hyd) 1272 50

CEMAG 400
Dimensions mm in
A 680 26.7
B 680 26.7
C (El) 1550 61
C (Hyd) 1503 59

CEMAG 800
Dimensions mm in
A 780 31
B 800 31.5
C (El) 1907 75
C (Hyd) 1860 74

CEMAG 1600
Dimensions mm in
A 1050 41.3
B 885 35
C (El) 2115 83.3
C (Hyd) 2068 81.4

Voltage ( V) / Frequency (Hz)

All electrically driven equipment are as standard delivered with 5-lead connected 400V, 50 Hz, 3- phase electric
motors, unless otherwise stated.
Voltage requirements must be clearly specified, e.g.

Country V / Hz Country V / Hz
Canada 440 / 60 Korea 440 / 60
Canada 550 / 60 Norway 220 / 50
India 420 / 50 Taiwan 440 / 60
Korea 220 / 60 USA 440 / 60

The electrical protection class is IP 54 or higher.

Sound pressure level

Conditions dB(A) rel 20μPa

1 meter from rig <70

20 © 2013 Atlas Copco Craelius AB | 2013-11-11

11 Technical Specifications CEMAG 203, 403, 803, 1603 Ed.1
 © Copyright 2013, 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 5016 01c Märsta, Sweden, 07 November 2013 Specifications and equipment subjects to change without notice. Consult your Atlas Copco Customer Center for specific information.

www.atlascopco.com