User Manual

Jolting Apparatus
Model 6135
according to EN 196-1 / ISO 679

Content List of Figures

1 General product description...................2 Fig. 1: Emergency facility ................................. 3
1.1 Use according to regulations / Fig. 2: Foundation set 6135.001....................... 4
conformity to standard ...........................2 Fig. 3: Socket of ready mixed concrete
1.2 Design ....................................................2 6135.005 ................................................ 4
1.3 Working principle ...................................2 Fig. 4: Noise absorption hood 6135.002 .......... 5
1.4 Technical Data .......................................2 Fig. 5: Control element ..................................... 6
1.5 Advantages ............................................2 Fig. 6: Overview drawing .................................. 7
1.6 Accessories (options).............................2
1.7 Safety remarks / remaining risk.............3
1.8 Emergency facility..................................3 Caution:
2 Setting into operation .............................3 The device only has to be connected to a
2.1 Unpacking ..............................................3 230 V socket with earth contact (PE-ground-
2.2 Basement and Installation .....................3 ing.
2.2.1 Foundation set, model 6135.001 ...........4
2.2.2 Socket of ready-mixed concrete, model Only qualified personnel are allowed to handle
this device. The knowledge of this User Manual is
6135.005 ................................................4
obligatory. The device has only to be used for the
2.3 Noise absorption hood, model destined purpose.
6135.002 ................................................5
3 Working with the joilting apparatus ........6
3.1 Operational Elements ............................6 © Toni Technik Baustoffprüfsysteme GmbH 2004
3.2 Test Procedure.......................................6 Gustav-Meyer-Allee 25
3.3 Hints for maintenance............................6 D-13355 Berlin
4 Technical documents.............................7 Germany
4.1 Overview drawing ..................................7 Tel.: 030/46 40 39-23, Fax: 030/46 40 39-24
4.2 Wiring diagram .......................................8 We made strong efforts to the correctness of this
4.3 List of spare parts ..................................9 Manual, but, we cannot overtake any guarantee for
4.4 Maintenance check list.........................10 the validity of the instructions in the case of technical
4.5 CE-Declaration.....................................11 modification.
4.6 Declaration of conformity for the
product .................................................12
4.7 User manual preselection counter.......13 This user manual is applicable from serial number
124/2003.

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1 General product description 1.4 Technical Data
Base plate app. mm 1100 x 4001
Jolt table plate app. mm 300 x 2002
1.1 Use according to regulations / Dropping height mm 15.0 + 0.3
conformity to standard Length of guiding arms mm 800
Working height including founda- app. mm 950
Compacting test samples 40 x 40 x 160 mm accord- tion block 6135.001 (height of jolt
ing to EN 196, part 1 and ISO 679. table plate over floor)
Power supply V/Hz/kW 230V/50 Hz/ 0.25
Model 6135 is a standard product matching the triple- earth conductor PE
gang mould model 6012 inclusive top box model Weight gross/net
6012.001 mounted on a concrete base model – basic equipment only kg 225/150
– incl. accessories 6135.001and 002 kg 330/220
6135.001 or model 6135.005. The declaration of con- Shipping volume
formity (chapter 4.6) only is valid in combination with – basic equipment only m³ 0.3
the listed models. – incl. accessories 6135.001and 002 m³ 1

1.5 Advantages
1.2 Design
The design of the apparatus corresponds strictly to • Particularly robust and durable construction
the requirements of ISO 679 and EN 196, part 1, if
the models are used as listed in chapter 1.1. To avoid
• Rigid and bending resistant table plate
an annihilation of the shock energy by swinging parts • Quick-acting clamping device for triple-gang
the whole construction is designed very rugged (see moulds
high own weight of the device).
• Foundation set and noise absorption hood avail-
The supports for the pivot of the guiding arms and for able as accessories
the hardened stop (impact anvil) as well as the elec-
tromotive drive are mounted on a heavy and bending • No frictional detection is needed
resistant base plate. The jolt table plate is provided
with quick-acting clamping elements to fix the triple- • Compression always is guaranteed
gang moulds.
1.6 Accessories (options)
3
For safety reasons all machine parts with the excep- Foundation set Model 6135.001
tion of the jolt table plate are protected by a sheet-
consisting of:
metal case.
The housing IP 54 contains the operating elements • Casting box made of stainless sheet steel, 1100 x
and the counting device. 400 mm, height 650 mm. The casting box is to be
filled with fresh concrete by the customer.

1.3 Working principle • Insulating slab made of rubber to be used as bed

plate below the casting box for means of vibration
The triple-gang mould is fixed on the jolt table by the
absorption.
quick acting clamping elements. The jolt table plate is
lifted by the motor driven cam and drops down in free • Fixing screws.
fall on the hardened impact anvil, which is based on a
shock-proof and vibration-free support. During the • Mat for the form-closed connection between base
operation the jolt table plate is kept in position by ball- and base-plate (compensation of concrete-
bearing arms. unevenness)

The number of strokes is fixed to 60, in accordance

with ISO 679 and EN 196. After 60 strokes the ma-
1
chine switches off automatically. The great dimensions of the base plate result
from the noise protection hood (accessory 6135.002)
2
Weight and dimensions of the table top are
adapted to the triple-gang mould model 6012 from
Toni Technik.
For other moulds adaptation construction is
needed.
3
For producing the conformity to standard ac-
cording to chapter 1.1
4
To meet CE -conformity
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 3
Socket of ready-mixed concrete Model 6135.005 1.8 Emergency facility
according to EN 196-1 and ISO 679 fitting for model The emergency function according to EN 418 – stop
6135 key 0 – (switching off the voltage for the whole plant)
is guaranteed via the mains switch (red turn switch on
• dimensions l x w x h 1170x141x650 mm yellow background / see figure 1), following EN
60204.
• weight ca. 600 kg
• with recessed threaded rods M12,screw nuts

• compensating material

• with sparing for standard Pallet stacker

• ribbon mats

Test tool Model 6135.15

for checking the dropping height.
3
Triple-gang mould Model 6012
for production of prisms 40 x 40 x 160 mm made of
mortar, especially cement mortar according to EN
196-1, EN 1015-11, ISO 679, DIN 1164 and ASTM C
348. Fig. 1: Emergency facility

triple-gang mould 10.1 + 0.11 kg

3 2 Setting into operation
Triple-split top box Model 6012.001
made of aluminum, fitting to compression with manual 2.1 Unpacking
stamp, with vibration table model 5530 or jolting ap-
The jolting apparatus is fixed with four screws in the
paratus model 6135.
anchorage holes of the base plate at the bottom of
0.9 + 0.03 kg the dispatch box or pallet.
4
Noise absorption hood Model 6135.002 If the jolting apparatus is delivered with additional
noise absorption hood this is fixed with four hexagon
For reduction of noise emission, consisting of a pro-
socket screws at the front side of the device's base
tection case made of insulating material, which sur-
plate. In this case you have first to remove the noise
rounds the whole device; swinging out in the are of
absorption hood and subsequently the four fastening
the table plate.
screws.

1.7 Safety remarks / remaining risk 2.2 Basement and Installation

To reach the total CE-conformity (see chapter 4.5)
In accordance with EN 196, Part 1, Section 4.6 or
model 6135.002 have to be ordered and mounted.
ISO 679, Section 4.2.5 the jolting apparatus has to be
Besides the protection against too high noise emis-
fixed rigidly at a concrete block of 600 kg weight or
sion this protection cap prevents grapping into the
0.25 m³ volume. In case the jolting apparatus is deliv-
operating device and therefore the danger of squeez-
ered with the foundation set, model 6135.001, the
ing.
procedure is the following:
When opening the hood the test will be terminated
and has to be started again with closed hood.
Caution:
Without the protection cap there is an increased risk
referring “squeezing of extremities”. The operator has If no foundation set or socket of ready-mixed
to take suitable measures. concrete was ordered, it should be followed up
the same procedure as prescribed in the follow-
Without the protection cap there is an increased risk ing with appropriate supplementary means to
referring “defective hearing”. In this case the operator guarantee the function of the device according to
has to use an ear protection when working with the the standard.
device.

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2.2.1 Foundation set, model 6135.001 • After hardening of the concrete the centering
template has to be removed from the casting box.
It is no more needed.
• The jolting apparatus has to be put exactly hori-
zontal using collars or distance tubes.

• Then the jolting apparatus has to be lifted again

and the casting box has to be totally filled with the
delivered special cement (mortar mass quick
binding, free of swinging).

• Then immediately the jolting apparatus has to be

put into the fresh mortar layer so that the base
Fig. 2: Foundation set 6135.001 plate stands on the distance tubes again and the
interim between base plate and concrete surface
• A plane bottom area of minimal 1,100 x 400 mm is totally filled with mortar.
is necessary. If the bottom has a larger slope this
has to be leveled by a leveling mortar.
• The delivered mortar has the following data:
• At installation place the delivered casting box of Processing temperature: + 5 °C to + 30 °C
stainless steel has to be put on the also delivered
rubber slap. It has to be filled with fresh concrete Proportion of mixture: app. 0.3 l water for 1 kg dry
up to approx. 1 cm below the upper edge. This mortar
concrete should have a consistency of 45 N/mm². Consumption: app. 1.6 kg per 1 l hollow space

• Into the fresh concrete the delivered foundation

Caution:
screws have to be lodged. As aid for exact ad-
justing serves the delivered centering template. The process time is only a few minutes. Within
The four foundation screws have to be lodged this time the placing and alignment of the jolting
into it provisionally. Then they will be pressed into apparatus on the mortar layer has to be finished.
the fresh concrete so that they stand approx.
35 mm out from the centering template and have • After totally hardening of the concrete and the
during hardening of the concrete a perpendicular mortar layer (24 hours as minimum) the base
and fix position. plate has to be fixed at the basement by the col-
lars and the self-locking nuts.

2.2.2 Socket of ready-mixed concrete,

model 6135.005

Fig. 3: Socket of ready mixed concrete 6135.005

• A plane bottom area of minimal 1,100 x 400 mm
is necessary. If the bottom has a larger slope this
has to be leveled by a leveling mortar.

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• Bring the socket at the desired position using a
elevating truck. Place the delivered rubber mats 2.3 Noise absorption hood, model
left and right below the socket before setting 6135.002
down.

• Screw the nuts on the recessed fastening screws.

• Place the jolting apparatus and align it via the
nuts to 0.1 mm/m using a bubble level.
• Then the jolting apparatus has to be lifted again
and the casting box has to be totally filled with the
delivered special cement (mortar mass quick
binding, free of swinging).
• Then immediately the jolting apparatus has to be
put into the fresh mortar layer so that the base
plate stands on the distance tubes again and the
interim between base plate and concrete surface
is totally filled with mortar.

• The delivered mortar has the following data:

Processing temperature: + 5 °C to + 30 °C
Proportion of mixture: app. 0.3 l water for 1 kg dry
mortar Fig. 4: Noise absorption hood 6135.002
The noise absorption hood is strongly recommended
Consumption: app. 1.6 kg per 1 l hollow space
for protecting the operators against noise and
Caution: squeezing. In case it belongs to the extension of de-
The process time is only a few minutes. Within livery, the procedure is the following:
this time the placing and alignment of the jolting
apparatus on the mortar layer has to be finished. • The noise absorption hood has to be put over the
apparatus. The connection cable has to be
• After totally hardening of the concrete and the lead through the slot at the back of the hood.
mortar layer (24 hours as minimum) the base • The hood will be centered via the liners in front
plate has to be fixed at the basement by the col- and at the back of the base plate.
lars and the self-locking nuts.
• Subsequently, the plug of the safety switch has to
Hint: be connected.
The needed mould has to be realized by fixing a • In the area of the jolt table plate the noise absorp-
“good” adhesive tape or normal plain wooden tion hood is swiveling. On safety reasons the flap
boards (not in the extension of delivery). is equipped with a protective switch. The appara-
tus can only be switched on if this switch is
closed.

• If the noise absorption hood is delivered, it is not

permissible to use the apparatus without it.
Caution:
The work described above has to be finished be-
fore it is allowed to connect the device with a
230 V socket with earthing contact.
Pay attention to the safety remarks and remaining
risk, chapter 1.7!

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3 Working with the joilting appara- • The filling of the triple-gang mould with the pre-
tus pared mortar takes place with exact attention to
EN 196, part 1, section 7.2, or ISO 679, section
7.2.
3.1 Operational Elements
The switchboard of the apparatus is equipped with
• After filling in the first mortar layer the flap of the
noise absorption hood has to be closed. Then the
the following operational elements (order from the left
first series of 60 shocks will be initiated via the
to the right):
start key.
• The second mortar layer will be handled in the
same manner.
• No manually turning back of the counter is nec-
essary. The counter automatically turns back at
the start of the next series of shocks.

• After the second series of shocks the quick acting

clamping device will be loosen and the triple-
gang mould can be removed from the jolt table
plate and further handled according to the stan-
dard.

Fig. 5: Control element 3.3 Hints for maintenance

• Main switch (emergency switch) According to the maintenance checklist, chapter 4.4,
has to guaranteed that the conformity to standards
• Counter with adjustable code switches for selec- survives. For checking the dropping height, the test
tion of the desired number of shocks (according tool model 6135.15 can be ordered.
to the standard: always 60 shocks). (see sepa-
rate user instruction, chapter 4.7). The counter contains two storage batteries (Lithium
type ½ AF 3,6 V). These will keep 8 years.
• Stop switch (red – marked with “0”). It serves for
switching off the apparatus at any desired phase
– this means also before the adjusted number of
shocks is reached.
• Start switch (white – marked with “I”). Using this
key the compaction process will be started. Using
a noise absorption hood, the apparatus can only
be started if the safety switch of the flap is closed.
The integrated lamp in the switch will lighten dur-
ing operation.

3.2 Test Procedure

• With open flap of the noise absorption hood the
triple-gang mould will be put onto the jolt table
plate.
• Mould and top case are fixed on the base plate
by quick acting clamping elements. These ele-
ments are adjustable. They have to be adjusted
in the manner that a perceptible force is neces-
sary to bend them. With too small initial tension it
may be possible that they get loose during the
compaction process by shock stress.

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4 Technical documents

4.1 Overview drawing

Fig. 6: Overview drawing

1. cover plate 12. main switch

2. sheet 13. preselector counter
3. quick clamping device 14. start key
4. pressure screw 15. stop key
5. toothed belt 16. back-geared motor
6. lifter wheel 17. fine-wire fuse 1A
7. ram 18. fine-wire fuse 4A
8. limit stop 19. power supply
9. carrier 20. lamp
10. receiver 21. relay with base
11. limit switch 22. safety switch (option)

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 Z 1 - > c on ta ct ( 3 . 4) o n Z 1 p rog ra m m ed as b re ak o pe ne r
4.2 Wiring diagram

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Version 02_08
BDA6135E_02_08.doc
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* - > k e y b o a r d l o c k a f te r p r o g r a m m i n g Z1
a nd s e t ti n g d e fa u l t to 6 0 ,

Erstellungsdatum: 19.02.08
p l u g -i n b r i dg e 1 - 2
4.3 List of spare parts

Pos. Number Name Order-No.

1. 1 cover plate 6135-01.09
2. 2 sheet 6135-01.22
3. 2 quick clamping device 290.093
4. 2 pressure screw 147.002
5. 1 toothed belt 111.306
6. 1 lifter wheel 6135-01.15
7. 1 ram 6135-01.39
8. 1 limit stop 6135-01.06
9. 1 carrier 6135-01.12
10. 1 receiver 6135-01.38
11. 1 limit switch 706.129
12. 1 main switch 706.672
13. 1 preselector counter 721.043
14. 1 start key 706.661+706.666
15. 1 stop key 706.674+706.675
16. 1 back-geared motor 714.332
17. 1 fine-wire fuse 1A 712.154
18. 1 fine-wire fuse 4A 712.074
19. 1 power supply 709.586
20. 1 lamp 712.223
21. 1 relay with base 708.219
22. 1 safety switch (option) 706.668 (option)

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4.4 Maintenance check list

once a half
Mechanical maintenance work once a year
year

Check of the dropping height with model 6135.15 (option) X

Pressure of the quick clamping device (3.) by adjusting the pressure screw X

Check the rubbers of the pressure screw whether they are worn-out X

Check the lifter wheel (6.) (greased) and ram (7.) whether they are worn-out X

Check cover plate (1.) whether it is worn-out and plane X

Check toothed belt (5.) whether it is worn out and test its tension force X

once a half
Electrical maintenance work once a year
year

Check the safety switch (22.) by opening the noise absorption hood during
X
operation (option)

Check the adjusted number of strokes by counting X

Check of the earth conductor according to „DIN EN60204 T1“ (VDE 0113 T1) X

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4.5 CE-Declaration

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4.6 Declaration of conformity for the product
(only valid when used with the models 6135.001 or 6135.005 / 6012 and 6012.001)

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4.7 User manual preselection counter

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