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Operation and Maintenance Manual – 4000 Series

© COPYRIGHT – Thompson Meat Machinery 11/2001

THOMPSON MEAT MACHINERY

FOREWORD To our valued Customer,

We thank you for your decision to purchase a Thompson Meat Machinery Mixer

Mincer. It is a precision built machine, designed to give many years of trouble free service.

This Operation and Maintenance Manual makes it easy for you to get to know the Thompson Meat Machinery 4000 MIXER MINCER and learn how to use

it correctly. This manual contains important information and instructions that, when followed, makes it possible to operate the 4000 MIXER MINCER safely,

correctly, and economically. It is essential that you become familiar with the

contents of this manual to avoid potential hazards, as well as extending the reliability and life-expectancy of the machine.

Only authorized and trained personnel should install, operate, clean and

maintain the Thompson Meat Machinery 4000 MIXER MINCER. The machine

should only be operated in a fully maintained and safe condition.

The warranty, as stated in our terms and conditions of sale, will become null and void where regular maintenance cannot be substantiated. Only original

Thompson Meat Machinery spare parts guarantee quality and exchangeability.

We draw your attention to the fact that we assume no liability for damage or

operational disturbances resulting from failure to comply with the guidelines and

instructions set out in this Operation and Maintenance Manual.

Should you have any questions which you believe are not sufficiently answered

by this manual, please contact our Customer Service Division or your local Thompson Meat Machinery authorised agent.

Prior to operating the machine:

It is necessary to become familiar with and comply with all local statutory regulations and industry codes of practice, as well as the Operating Safety

Instructions outlined in Section 2 of this manual. The following laws, rules and

regulations are a minimum guideline to meeting your obligations:

All other commonly valid laws and associated regulations concerning accident

prevention and environmental protection must be complied with. Such duties

could, for example, concern the handling of hazardous materials or the

availability and wearing of personal protective equipment.

When the Thompson Meat Machinery 4000 MIXER MINCER is turned off for

cleaning and maintenance work, it MUST be electrically isolated from the mains

power supply by TURNING OFF and locking the electrical ISOLATOR switch.



In the event of a safety concern or a change in the performance of the machine,

the operator MUST immediately stop and electrically isolate the machine and

report the problem to the responsible person(s).

No changes, additions or reconstruction of any type that may interfere

with the safety or operation of the machine are allowed without the

manufacturer’s authorisation in writing.

Only qualified persons or authorised persons under their guidance are allowed to

service the electrical equipment of the Thompson Meat Machinery 4000 MIXER

MINCER.

Use of this machine for other than its intended purpose will void all

warranties and liabilities held by the manufacturer, unless prior approval, in writing, has been obtained from THOMPSON MEAT MACHINERY.

The manufacturer/dealer will not be held responsible for any injury or

damage resulting from the improper use of the machine. The operator

assumes all risk.



THOMPSON MEAT MACHINERY

Foreword Page 1

Table of contents Page 3

Safety Notes Must be read prior to installation or operation Pages 4 & 5

Section 1 Installation Page 6 Section 2 Operating Safety Instructions Page 8

Section 3 Machine Assembly Page 10

Section 4 Operation Page 13

Section 5 Maintenance Page 16

Section 6 Standard Wear Parts Page 19

Section 7 Options Page 21

Section 8 Specifications Page 22

Section 9 Risk Assessment Procedure Page 26 Section 10 Copyright Page 27

Section 11 Trouble - Shooting Guide Page 28 Appendix A C.E. Declaration Page 29

Appendix B Material Safety Data Sheets Cleaning Agents Page 31 Lubricants Page 34

Appendix C Photographic Illustrations Page 37

Appendix D Technical Drawings Page 45



PLEASE READ PRIOR TO INSTALLATION

TO AVOID SERIOUS INJURY AND / OR MACHINE DAMAGE, FOLLOW THESE SAFETY GUIDELINES BEFORE INSTALLATION AND

PRIOR TO COMMENCING OPERATION.

1) THE MACHINE MUST BE INSTALLED BY A SUITABLY QUALIFIED PERSON.

2) THE MACHINE MUST BE LOCATED ON SOLID LEVEL SUPPORT AND IF THE

MACHINE IS FITTED WITH CASTOR WHEELS, THE BRAKES ON THE CASTORS MUST BE ACTIVATED.

3) GUARDS, WHERE FITTED, MUST BE SECURELY IN PLACE OTHERWISE

THE MACHINE WILL NOT START.

4) NEVER OPERATE THE MACHINE WITHOUT TRAINING AND

AUTHORISATION FROM YOUR SUPERVISOR.

5) NEVER TAMPER WITH THE SAFETY DEVICES BUILT INTO THE MACHINE.

6) ONLY USE THE ATTACHMENTS PROVIDED BY THE MANUFACTURER.

7) KEEP HANDS, ARMS, HAIR AND LOOSE CLOTHING CLEAR OF ALL MOVING PARTS.

8) ALWAYS USE QUALITY EAR AND EYE PROTECTION AS A MINIMUM.

9) NEVER TOUCH ROTATING KNIVES.

10) SHOULD THE MACHINE STALL OR JAM, TURN THE MACHINE OFF USING

THE ISOLATOR SWITCH AND LOCK IN THE OFF POSITION. IF

POSSIBLE,REMOVE THE PLUG FROM THE POWER OUTLET BEFORE ATTEMPTING TO CLEAR ANY OBSTRUCTION.

11) ISOLATE THE MACHINE FROM THE ELECTRICAL POWER SOURCE BEFORE CLEANING, SANITISING OR SERVICING.

12) ALWAYS EXERCISE CARE WHEN HANDLING THE CUTTING KNIVES, THESE CAN BE VERY SHARP AND IF HANDLED INCORRECTLY MAY CAUSE

PERSONAL INJURY. (IT IS RECOMMENDED THAT STEEL MESH GLOVES BE WORN WHEN CHANGING OR SERVICING THE KNIVES).



Section 1 - INSTALLATION NOTE: INSTALLATION MUST ONLY BE CARRIED OUT BY

COMPETENTLY TRAINED PERSONNEL AND A SUITABLY QUALIFIED ELECTRICIAN. IMPORTANT NOTICE;

Fuse protection and electrical isolation. NOTE: The machine is not supplied with an electrical connection

plug. This must be supplied and fitted in accordance with the local electrical standards by a suitably qualified electrician.

Fuse Protection.

No protection is supplied for the mains circuit, therefore, the machine owner must ensure suitable provision is made on-site to prevent an over current

situation in the main power supply to the machine. A suitable D-Curve Circuit

Breaker MUST be installed before the power outlet to the machine. Refer Section 8, Page 23: Technical Specifications. This table shows the maximum

current draw for the machine.

METHOD OF ISOLATING THE MACHINE To isolate the machine from all energy sources, turn the machine's electrical

isolating switch to the OFF position. Fit a safety lockout device of a type

approved by your local authority to the lock receiver in the isolating switch,

holding the keys to the lock yourself whilst servicing the machine.

INSTALLATION 1.1 Ensure that any lifting devices to be used are appropriate and adequate.

Refer Section 8, page 23: Shipping Specifications.

1.2 Move the machine to its designated area (exercise CAUTION on sloping,

uneven or wet surfaces) If the machine is fitted with Castor Wheels, ensure the brakes on the wheels are activated.

1.3 Remove the transportation crate. Please dispose of crate in an

environmentally friendly manner.

CAUTION

1.4 Ensure the Feedscrew, Mincing Knives and Plates are NOT FITTED

during any of the following installation steps. Wire the machine into an appropriate power source. See the important notice at the top of this

page.

!



1.5 CHECK FOR DIRECTION OF ROTATION. Without the Mincing

Feedscrew, Knives and Plates fitted, start the Mixer Mincer (Mix-Mince button) and carefully check the direction of rotation. The mincer feedscrew

drive shaft MUST rotate in an Anti-Clockwise Direction as indicated by

the Directional Arrow on the Barrel Flange. Refer to Appendix D,

Illustration A – page 37: Directional Arrow.

If the direction of rotation at the Feedscrew is incorrect, have a qualified

and authorised electrician change the phase at the power source, in order

to correct the direction of rotation.

NOTE: Should the machine be wired into another subsequent

power outlet, other than the original outlet when the direction was originally checked, it is ESSENTIAL that the direction of rotation be checked again before the knives and plates are installed in the

new location.

1.6 TEST RUN ALL OPERATING FUNCTIONS. Ensure the lid is in the closed

position and the front discharge guard (if fitted) is also closed around the Mincer Plate.

(The machine lid and safety discharge guard are fitted with electrical

safety switches that prevent operation if the either are opened). Refer -

Appendix D, Illustration B - page 38: Location of Magnetic Safety Sensors

on Lid and Appendix D, Illustration D - page 40: Discharge Guard with Safety Cut out.

(Option for machine)

Where the Mixer Mincer is supplied on extended legs as a higher loading point machine, the machine may be supplied without the standard lid. In

this instance the machine may also have steps that will be interlocked

with a safety switch and the machine will only operate when the steps have been raised and secured in the UP position to prevent access to the

mixing bowl and feedscrew. If the machine is fitted with the optional hopper grille/guard, it must be pushed to the far outside edge of the

hopper before the machine will function.

1.6.1 HAND CONTROL OPERATION

Refer Appendix E, Drawing 4000AS07 – Page 50: Control Panel. This

drawing shows the locations of the buttons and their intended use.

• PRESS the MIX button - only the Mixing Paddle will operate. . -

The Mixing Paddle incorporates automatic forward and reverse

mixing functions and rotation is set at approximately 15 seconds in each direction

• PRESS the MIX-MINCE button ONCE. The Mixing Paddle and

Feedscrew Drive Shaft will operate in the anti-clockwise direction

– on SPEED 1.

• PRESS the MIX-MINCE button AND HOLD IN FOR 3 SECONDS -

!



the Mixing Paddle and Feedscrew Drive Shaft will operate in the

anti-clockwise direction – on the higher SPEED 2.

1.6.2 SAFETY SWITCH FUNCTION CHECK.

CAUTION

• LIFT the lid slightly to check the safety cut-out - Both the Mixing Paddle and Mincer Drive Shaft will STOP.

CAUTION

• Open plate discharge guard slightly to check the safety cut-out –

Both the Mixing Paddle and Mincer Drive Shaft will STOP.

CAUTION • Lower the optional inspection steps (if fitted) from the raised position

to check safety cut-out - Both the Mixing Paddle and Mincer Drive

Shaft will STOP. Note: The machine might also be fitted with in an Interlocked hopper

safety grille/guard. In some instances this can negate the need for

safety interlocked inspection steps or platform. CAUTION

If fitted, slide the interlocked hopper safety grille/guard towards the

centre of the hopper to check the safety cut-out - Both the Mixing

Paddle and Mincer Drive Shaft will stop.

When satisfied that all safety features are functioning correctly the

machine should now be electrically isolated (Refer Section 1: Method of

Isolating the Machine) and the machine cleaned and sanitised prior to

being placed into production. ( Refer Section 5.4, page 18: Cleaning and Disinfection).

Although the machine is now ready for operation, PLEASE

READ THE OPERATING SAFETY INSTRUCTIONS

FIRST!



Section 2 – OPERATING SAFETY INSTRUCTIONS Mixer Mincers are by nature potentially dangerous machines.

2.1 Before operating the Machine, the operator MUST follow these instructions:-

• REMOVE all jewellery from wrists and fingers.

• TURN BACK and secure cuffs and loose clothing.

• CHECK that the rotation of the feed screw drive shaft is anti-clockwise when viewed from the front of the barrel, BEFORE the Knives and Plates

are installed.

• EXERCISE CARE when handling the cutting knives. These can be very

sharp and if handled incorrectly may cause personal injury. It is recommended that steel mesh gloves be worn when handling or cleaning

cutting knives.

• CHECK that the knives and plates are assembled correctly.

• CHECK that the locking ring is tensioned correctly - Refer Section 3.1.1,

page 10: Machine Assembly. • WEAR eye and ear protection at all times, as a minimum.

• NEVER leave machine unattended whilst in operation.

• ISOLATE the machine from the electrical supply before leaving the machine.

• ISOLATE and LOCK OUT the machine from the electrical supply before an electrician removes any covers or makes any adjustments. (All operator serviceable components are located

externally, away from potential dangers.) • REPORT all machine or equipment faults immediately to a responsible

person or your supervisor.

2.2 Passers-by should never talk to and/or distract the operator whilst the machine is operating

2.3 It is recommended that Mixer Mincers should only be operated by

authorised persons over the legal age who have been properly trained and made aware of the relevant dangers and safety precautions. It is advised

to post a notice to this effect and also advise other people of the dangers

of distraction to the operator. A suggested notice is illustrated below.

THIS MACHINE SHOULD ONLY BE OPERATED BY SUITABLY TRAINED

PERSONS OF THE REQUIRED LEGAL AGE OR BY PERSONNEL WHO HAVE DEMONSTRATED RECOGNISED PRIOR TRAINING.

DO NOT DISTRACT THE OPERATOR !

2.4 NEVER sit or stand on any part of the Mixer Mincer.

2.5 NEVER use the Mixer Mincer for anything other than its intended purpose.

!

!

!



2.6 WARNINGS

Failure to follow these operating instructions may result in severe injuries being sustained by the operator or attendant.

• Severing of limbs or other injuries may occur if trapped between the Mixing Paddle and Bowl.

• Severing of fingers may occur if inserted into Plate Holes

• Should the Mixer Mincer be moved unsafely, it may topple over and strike or trap the operator or attendant and serious injuries

may be sustained.

• Closing of the Hopper cover or lid can create hazards of crushing,

shearing or entanglement to fingers or hands.

• If the machine is fitted with a loading device such as a hoist,

hazards generally associated with loading devices being installed

with Mincing Machines are; trapping or crushing from ascending and descending movement of the lifting arms and product

container. Also hoist drive elements and (where used) pulleys,

chains or wire ropes present a hazard of drawing-in, shearing, crushing or entanglement of fingers or hands.

• DO NOT process Bone, Hard Gristle or Deep Frozen product,

through the Series 4000, 4200 or 4300 Mixer Mincers, as this will

cause damage to the machine and cutting set. Frozen flaked product, bone or hard gristle applications are only recommended

when using the Thompson Meat Machinery 4200 Frozen Model.

!



Section 3 – MACHINE ASSEMBLY 3.1 Mincer System Assembly

3.1.1 Single Cut System (Standard system)

• Insert Mixer Grinder Feed Screw and ensure it engages over drive shaft square.

• Insert Knife and then the Plate.

• Fit Lock Ring and rotate in a clockwise direction. DO NOT over tighten the Lock Ring. DO NOT USE A HAMMER TO HIT THE LUGS, AS THIS WILL

CAUSE DAMAGE TO THE LOCK RING AND BARREL. Please use the tightening spanner supplied and tighten to hand tight only. Over tightening WILL cause premature wear and tear and damage the Knife

and Plates.

CAUTION: NEVER ATTEMPT TO REMOVE THE LOCK RING WHEN THE

MACHINE IS IN OPERATION. SERIOUS PERSONAL INJURY AND/OR MACHINE DAMAGE MAY RESULT.

3.1.2 Alternative Cutting Systems

3.1.2.1 Double Cut System with Pre-Breaker Plate (Style A).

When this system is used without a support spider positioned

after the final hole plate, Thompson Meat Machinery strongly

recommends the use of a Jopp Pre-Breaker Plate with a support bearing.

• Insert Mixer Mincer Feed Screw.

• Insert Pre-break Plate (Kidney shape) (Scalloped side of plate facing

feedscrew) OR “O” plate with bearing • Insert the secondary Knife.

• Insert the finish (second) Hole Plate.

• Fit Lock Ring as instructed in section 3.1.1 above.

3.1.2.2 Double Cut System with Support Spider (Style B).

• Insert Mixer Mincer Feed Screw.

• Insert Primary Knife • Insert Primary Coarse Hole Plate – e.g. 40 mm.

• Insert Double Sided Knife

• Insert Finish (second) Hole Plate

• Insert Support Spider.

• Fit Lock Ring as instructed in section 3.1.1 above.

!



3.2 Knives and Plates

• Follow the knife manufacturer’s instructions regarding correct fitting and

usage of the knife.

NOTE: Unless the Interlocked Plate Guard has been fitted, use a

maximum sized hole plate of 8mm. Using a plate with holes

greater than 8mm in diameter can result in SERIOUS injury.

• The Plates should be re-ground when necessary according to the amount

of usage. Worn Plates prevent a clean cut and may cause damage to the

Knife and Plate. For safety reasons, it is imperative that plates are not ground to a thickness below 5 millimetres.

• Knives MUST be changed before wearing down to the level of the knife holder.

• Vibration from the machine's operation will cause the screws holding the

Blades on the Knives to loosen. It is advised that they be checked and

tightened each time the machine is stripped and cleaned.

3.3.1 4000 Paddle Removal

• To remove the paddle – (refer Illustration I - page 43.)

• Remove the “end float assembly” from the machine by unscrewing the knurled lock screw (refer item A, Illustration I - page 43) and rotating

the whole assembly anti-clockwise (refer item B, Illustration I - page

43). • Then pull the end float assembly off the paddle shaft.

• Pull the paddle back from the locating drive socket, back through the hole for the “end float assembly”.

• Then tilt the ribbon through approx 45° and pull the paddle upward

from the mixing bowl.

3.3.2 4000 Paddle Installation – (reverse of above)

• Place paddle into mixing bowl at approx 45° installing in to the end

float assembly hole first. • Then lower the paddle in to the horizontal position and locate into the

slotted drive socket. • Replace the end float assembly onto the paddle shaft – push into place

on shaft and rotate clockwise to end stops.

• Lock into place by the knurled locking screw.

3.4.1 4200 Paddle Removal Read this instruction in conjunction with drawing: 4200AS-020 – page 57.

• Loosen lock nut (item 8) on the end float adjustment set screw and then undo the set screw by two or three turns.

!



• Remove the four M8 set screws (item 6) together with their spring

washers (item 5).

• Withdraw the end float body (item 4) which incorporates the end float bush. If the end float body doesn’t pull out, try using the paddle to

push the end float body out.

• The paddle must be moved towards the barrel so that it can be

disengaged from the square drive. By carefully rotating and tilting the paddle a position will be found which allows the paddle to be lifted out

of the bowl. Lifting heavy objects should always be done with the

correct lifting equipment and with due consideration to local

regulations.

3.4.2 4200 Paddle Installation – (reverse of above)

• Again, find an position for the paddle which will allow it to be lowered into the bowl. The shaft end will initially need to be inserted into the

end float housing which is part of the machine body and then reversed back over the square drive. Make sure that the paddle’s square drive

is fully home on the drive shaft.

• With the brass end float block inserted into the end float body/bush, refit this assembly to the machine. This assembly should slide home

with minimal effort. If the housing is prevented from sliding completely home, then it will be necessary to slacken off the adjusting

set screw (item 9).

• With the end float body in place, refit the four M8 set screws and spring washers and tighten them.

• Use the adjusting screw to take up any float in the paddle. No float

should exist, however, there should also be no thrust applied to the

paddle, i.e. only the free play should be eliminated. • Use the lock nut (item 8) to lock the adjusting set screw (item 9) in

place.

3.5.1 4200F and 4300 Paddle Removal Refer to drawings 4200AS-020 – page 57 and 4300M2-010 – page 58.

• When satisfied that the machine is safely electrically isolated, begin by removing the rear panel. Take care not to seize any of the M5 set

screws when removing or replacing them. If this happens, re-tap the

offending hole and replace the set screw. Place the rear panel out of

the way in a safe place.

• With the cover removed the two gearboxes are visible, the top motor gear unit drives the paddle. It is not necessary to remove this unit as

the shaft can be shifted back far enough to be disengaged from the

paddle drive square. In preparation for removing the paddle begin by supporting its weight.

• Referring to drawing 4200AS-020 – page 57, prevent rotation of the M12 central adjusting set screw (item 9) and unlock its lock nut (item 8). Remove them both and store them. Next, remove the four M8 set

screws (item 6) along with their M8 spring washers and store them. A sliding hammer may then be fitted with an M12 screw and inserted into



the vacated hole of the adjusting set screw; this can then be used to

extract the end float body. Sometimes a tug on the paddle will be

sufficient to eject the end float body, however if this fails then the method described above must be used. The end float body assembly

and bush can then be removed and stored out of the way.

• Referring to drawing 4300M2-010 – page 58, locate the tab washer

and lock nut (item 7) and (item 8), respectively at the rear of the gearbox. Bend the engaged tab of the tab washer up to disengage it

from the lock nut. Use a suitable C spanner to loosen the lock nut.

Remove the lock nut, tab washer and drive shaft washer (item 6) and

store them. The 60 nominal size circlip will be visible in the hollow

shaft of the motor gear unit. Use an internal set of circlip pliers to remove the circlip. The drive shaft can now be slid back; this can be

achieved by reinstalling the lock nut on the shaft and levering the shaft backwards.

• The paddle can now be lifted (with the correctly rated equipment) out

of the machine by firstly pushing it forward and then tilting it upwards and finally lifting it out of the bowl. It may be necessary to rotate the

shaft so that the front paddle blade is at the bottom.

3.5.2 4200F and 4300 Paddle Installation – (reverse of above)

• Refitting the paddle is essentially the opposite of removal. Lower the

paddle (with the correctly rated lifting equipment) end first into the bowl. Guide the end of the paddle shaft into the hole vacated by the

end float assembly housing. The paddle may need to be rotated so the

front blade is at the bottom. Lower the back of the paddle and push the drive shaft forward to engage the drive square.

• Reinstall the 60 nominal size circlip, drive shaft washer, tab washer

and lock nut. Tighten the lock nut and bend the tab most closely aligned with one of the lock nut slots over to secure the lock nut.

• Push the end float housing assembly into place and fix it with the four M8 set screws. Insert the M12 set screw and adjust it to take up any

axial movement of the paddle then lock in place with the M12 nut. Do

not place a load on the paddle, only take up any free movement.

• The rear panel can then be refitted and the machine reconnected to its electrical supply.



Section 4 – Operation

THIS MACHINE SHOULD ONLY BE OPERATED BY SUITABLY TRAINED PERSONNEL, OF THE REQUIRED LEGAL AGE, OR BY PERSONNEL WHO

HAVE DEMONSTRATED RECOGNISED PRIOR TRAINING.

4.1 PRIOR TO STARTING

• Ensure the machine and all components have been Sanitised. (Refer

Section 5.4, page 18 : Cleaning and Disinfection). • Ensure that ALL safety checks mentioned in

Section 2 , page 8: Operating Safety Instructions have been fulfilled and the operator has fully read that section of the manual.

• Ensure that the feedscrew is rotating in the ANTI-CLOCKWISE direction

(Refer Section 1.5,.page 6). • If a plate with holes larger than 8mm is to be used, check that the

Discharge Guard is fitted. • Connect and turn the power supply ON. Test the operation of the Safety

Cut-out Switches ( Refer Section 1.6.2, page 7: Safety Switch Function

Check.) • Ensure that the Feedscrew, Knife, Plate and Lock Ring are assembled

correctly. Refer Section 3.1 & 3.2, pages 10 and 11

• Ensure that the paddle is correctly inserted. Refer Section 3.4, page 11

4.2 LOAD THE MACHINE BOWL

• Ensure the food product is clear of all foreign materials, i.e. metals, etc.

• Load the food product into the machine. Please consider your local

Health and Safety laws to ensure these are adhered to if the bowl is

loaded manually. DO NOT exceed the maximum capacity of the machine. Bowl capacities listed in Section 8.2, page 23 are to be used

as an indicative figure only and are based on whole muscle beef product

at +2° C. ( 30 Degrees F )



4.3 STARTING

The Thompson Mixer Mincer offers two (2) starting alternatives.

4.3.1 MIXING ONLY

Will mix contents of bowl which may include meat and other additives. The Thompson 4000 Series Mixer Mincers have a reciprocating mixing

action and the mixing paddle will automatically change direction.

4.3.2 MIXING - MINCING

This activates both the Mixing Paddle and Feedscrew simultaneously. • Press the MIX-MINCE button ONCE. The Mixing Paddle will

activate and the Feedscrew drive shaft will operate in the anti-clockwise direction – on SPEED 1.

• PRESS MIX-MINCE button AND HOLD IN FOR 3 SECONDS - the

Mixing Paddle will activate and the feedscrew drive shaft will operate in the anti-clockwise direction – on the higher SPEED 2.

REPORT ANY FAULT(s) IMMEDIATELY TO AN AUTHORISED PERSON FOR

RECTIFICATION.

!



Section 5 – MAINTENANCE

5.1 GEAR UNIT MAINTENANCE

Every 3000 Machine hours or every 6 months Check the Oil

Minimum every 3 years Change the oil

Refer to Section 8.4 – page 24 for lubrication capacities and grades. Please note these quantities are only approximate and the oil should be filled to the level

indicated on the gearbox.

5.2 ELECTRICAL SYSTEM MAINTENANCE

Only trained and qualified electricians are permitted to carry out

electrical maintenance work on the Mixer Mincer. This includes, but is

not limited to work on motors, the control circuit, the safety circuit, manual control devices such as buttons and switches and any other item

involved in the flow of electric current.

To avoid voiding your warranty, it is strongly recommended

that only Thompson Meat Machinery or their authorised dealer undertake maintenance work on Thompson machine(s).

Any other person(s) should have written authorisation from Thompson Meat Machinery prior to undertaking the service or repair work.

MAINTENANCE MUST ALWAYS BE CARRIED OUT WITH THE POWER

SOURCE DISCONNECTED AND THE MACHINE ISOLATED ELECTRICALLY.

Relevant Drawings for Electrical Circuit Refer to Appendix E: Drawings Drawing 4000 AS07 Control Panel.

Dwg 4000W-18 4000, 4200, 4300, 4200F Aust/NZ Wiring Diagram

Dwg 4000W-21 4000, 4200, 4300, 4200F Aust/NZ Invertor Wiring Diagram

Dwg 4000W-22 4000, 4200, 4300, 4200F Aust/NZ Smart Relay Wiring Diagram

Safety circuits and /or fittings are not to be by-passed or rendered ineffective.

All safety devices must be tested daily for complete operational performance and only after these safety circuits have been tested may the machine be placed in

operation.

!



5.3 A GUIDE TO A PREVENTATIVE MAINTENANCE SCHEDULE IS LISTED

BELOW BUT IN NO WAY SUGGESTS THAT MAINTENANCE SHOULD BE LIMITED TO THESE STEPS ONLY !

Recommended Maintenance Task Recommended Frequency

Daily Weekly Monthly or annually

Clean and sanitise machine after use.

•

Check the STOP / START buttons are functioning correctly.

•

Check anticlockwise feedscrew rotation, as shown on the direction sticker near the

barrel.

•

Check all safety limit switches are

operating correctly.

•

Check Knives are sharp and seating

correctly on an evenly ground plate.

•

Check knives & plates are installed

correctly and lubricated.

•

Check worm pin and plate wear.

•

Check feedscrew & barrel for burrs or

sharp edges caused by rubbing due to worn components.

This wear can be caused by a worn worm

pin, worn central plate hole, worn support

bushes or running the feedscrew without a plate or worm pin support.

•

Check plate key wear in cutting head

Every 3 months

Check & maintain or replace if necessary

thrust bearing on the MINCE drive

refer appendix E – Drawing 4000AS-029

Every 12 months

Check gearbox oil – replace if necessary

Every 6 months

Check & replace if necessary RUBBER boots on the stop / start push buttons

Monthly

Lid Counterbalanced Components-parts and springs will need to be checked

regularly and adjusted where necessary. Check springs for corrosion, wear and

creep. (Refer Section 6.5)

Every 12 months

Check Lid Bumper Rubbers for splitting or

distortion. Replace if necessary.

Every 12 months



5.4 CLEANING AND DISINFECTION

BEFORE ANY CLEANING PROCEDURE IS UNDERTAKEN - Electrically isolate the machine from the electrical power

source !

TAKE CARE WITH HOT WATER TO PREVENT INJURY TO SELF OR OTHERS.

Strictly follow the cleaning and disinfectant chemical manufacturer’s directions with regards to chemical concentrations and preventative measures to observe

when making up the solutions. Refer Appendix C – Cleaning Agent MSDS

It is strongly recommended that protective gloves be worn when using cleaning

detergents, disinfectants and during the whole cleaning process.

1. Remove the Lock Ring, Knives, Plates, Paddle and Feedscrew and wash thoroughly using an approved detergent and sanitiser, hot potable water and scrubbing brush. Ensure all product has been removed from the

mincing plate holes and other orifices or apertures. 2. RINSE thoroughly using hot potable water (50° - 60° C) and hang to dry.

3. Using an approved detergent and sanitiser, scrubbing brush and hot

potable water, scrub the Mixing Bowl, Barrel and external surfaces thoroughly ensuring all product residue has been removed.

4. RINSE thoroughly using hot potable water (50° - 60° C).

5. Using an approved sterilized cloth, dry all surfaces thoroughly.



Section 6 – STANDARD WEAR PARTS Apart from keeping the Knives and Plates sharp to ensure clean cutting, there

are other areas that require periodic checking and replacing as follows:

1. The Feedscrew Pin (worm pin) will wear through constant running and

may be replaced by unscrewing the pin anti-clockwise from the feedscrew

end.

2. The Barrel Plate Pin, which stops the Plates from rotating, will need replacing when worn. To remove the plate pin, use a 4mm hexagon key.

3. The 4200, 4300 and 4200F Paddle End Float Adjustment Screw (refer

Appendix D, illustration J - page 44) will need to be checked for normal wear and adjusted accordingly.

4. The 4000 Paddle End Float & Support Assembly – Refer Appendix D, Illustration I – page 43, will need to be replaced when worn.

5. Lid Counterbalanced Components-parts and springs will need to be

checked regularly and adjusted where necessary.

• (See drawing 4000-019) The lid has two pivot blocks supporting it; one is welded to the machine body and the other is bolted to the machine body.

These are known respectively as the fixed and removable Lid Pivot blocks. The lid is counterbalanced by two tightly wound torsion springs. Each

torsion spring has a tail at either end. One end of the spring is keyed into

the lid tube while the other is keyed onto a spindle which can be rotated and locked at any angular position by grub screws in the pivot blocks.

The spindles are locked in place with the springs tensioned to

counterbalance the weight of the lid.

• Start by prying the black plastics plugs out of the fixed and removable pivot blocks. A special socket is required to tension the lid (Part Number

TMN3LTAS). The socket can be rotated by use of an open 24 millimetre

across flat spanner and at the same time with a 12.7 millimetre (½”)

square drive ratchet wrench. The spindles are dimpled and locked in

place by two M8 hexagon socket head grub screws on the removable pivot block and one identical grub screw on the fixed block. Two people are

required to tension the lid. Start with one person holding the lid open. Use

the socket TMN3LTAS to tension the fixed pivot block by resting the ratchet wrench against the body of the machine, with the ratchet set to

prevent the spring unwinding; rotate the socket with the open ended spanner. Undo and remove the two M8 grub screws with a 4 mm across

flat hexagon key. Re-tensioning will most likely require you to apply more

tension, by carefully winding the spindle by rotating the ratchet wrench and then in turn holding it with the open spanner while repositioning the

ratchet wrench. Occasionally lower the lid to test the counterbalance

effect of the spring. Each spring should carry approximately half the load. Once satisfied with the fixed pivot block spring tension use a 6 mm drill to

dimple the spindle. Lock the spindle in place with the M8 grub screw.

• Repeat this process for the removable block spindle. When correctly

adjusted the springs should just counterbalance the weight of the lid. Excessive tensioning of the springs can result in damage to the lid if it



flies open!

6. Lid Stop Bumper Rubbers-check for splitting, compression or distortion.

Replace when necessary.

7. Feedscrew Thrust Taper Roller Bearing - check and maintain or replace when necessary : refer appendix E.- Drawing 4000AS-029.



Section 7 – OPTIONS for the 4000 Series Mixer Mincers

7.1 GU Series MINCER BARREL, LOCK RING AND FEED SCREW.

7.2 Stainless Steel BARREL, FEEDSCREW AND LOCK RING.

7.3 200kg (440 lbs) – AUTOMATIC LOADING HOIST.

7.4 STAINLESS STEEL MEAT CARTON STAND – DISCHARGE.

7.5 VARYING HEIGHT STAND.

7.6 DE-BONE / DE-GRISTLE ATTACHMENT.

7.9 INSPECTION MIRROR

RECOMMENDED PARTS AND FEATURES AVAILABLE;

7.9 FEEDSCREW EJECTOR.

This item is standard fitment on CE compliant machines

Refer Appendix D, Illustration E, F, G & H, - pages 41 & 42



Section 8 – SPECIFICATIONS – Model 4000 415V

8.1 DIMENSIONS



8.2 TECHNICAL SPECIFICATIONS

8.3 SHIPPING SPECIFICATIONS



8.4 LUBRICATION SPECIFICATIONS.

Lubrication Fluid Capacity (approx. only)

Description TMM Part Number Specification

4000 Rossi Mince Input Ass. 4MGMNR R2I 125 UP2A @ 9:1 c/w

4000 SEW Mix Ass. 4MGMXSEW SAF67 DT90 L4 @ 65.63:1 1.5

kW 4P 50Hz

4200 SEW Mix Ass. 4MGMXSEW1 SAF67 DV100 M4 @67.75:1

2.2 kW 4P 50Hz

4300 Rossi Mix Ass. 4MGMXR4 MR31 125 UP2A/112 M4 R61 B8

4 kW 4P

4200F Rossi Mix Ass. 4MGMXR4 MR31 125 UP2A/112 M4 R61 B8

4 kW 4P

SEW - Mixing Motor Gearbox 1.5 Litre

ROSSI - Mixing Motor Gearbox 6.1 Litre

ROSSI - Mincing Motor Gearbox 5.6 Litre

8.5 GREASE SPECIFICATIONS

The following grease is used in Thompson Meat Machinery manufactured

equipment:-

VALVOLINE – FOOD MACHINERY GREASE Used in all areas requiring grease including packing bearings and seals.

Refer to Appendix C for the Material Safety Data Sheet.

OIL GRADES

SHELL Omala 680

MOBIL Mobilgear 636

BP-Energol GR-XP Grade 680

OIL GRADES

BP-Energol GR-XP ISO grade 220

Mobil Mobilgear 600 ISO grade 220

SHELL Omala ISO grade 220

Castrol 220

OIL GRADES

BP-Energol GR-XP ISO grade 220

Mobil Mobilgear 600 ISO grade 220

SHELL Omala ISO grade 220

Castrol 220



8.6 Machine Purpose

The Model 4000 Mixer Mincer is designed to mince fresh or thawed portions of

meat to a maximum weight per portion of approximately 7 kg through an 8mm

size hole plate with subsequent processing down to a 3mm hole plate. The

tempered meat portions can be up to a size approximately 150mm x 150mm x 400mm, at a temperature above -1° C. The same machine also allows for mixing

of processed meat and required meat additives prior to further mincing. It is

recommended to avoid the processing of large thin strips of tough meat such as

from flank portions, as these can jam between the paddle and the bowl wall,

causing the paddle to jam or the mix motor to stall or damage to the bowl or paddle itself. Unusually long strips of dry or sinewy trimmings can wrap around

the paddle arms excessively and then will not be processed through the mincing plate. FROZEN PRODUCT MUST NOT BE PROCESSED on the Standard 4000 machine. (TEMPERED AND FRESH PRODUCT ONLY, TEMPERATURE

APPROXIMATELY –1 TO +4° CELSIUS).

The Frozen models 4200F Frozen machines are designed to process tempered

meat portions or frozen flaked product. The frozen flake can be processed at a temperature above -10° C. It also has the ability to process frozen strips of

approximate size 50mm x 50mm x 300mm long at a temperature above -6° C.

As for the 4000 Machine above, it is recommended to avoid the processing of

extremely dry or sinewy thin or long strips to prevent pieces jamming between

the paddle and bowl or wrapping around the paddle arms.



Section 9 – RISK ASSESSMENT PROCEDURE

The risk of injury through continuous use of this machine can be minimized by adherence to the safety instructions contained within this

manual.

The Thompson machine has been methodically designed to maximise operator

safety without compromising the machine’s endurance.

Thompson Meat Machinery continually research to improve the contents of our

manuals and further develop our machines.

Aspects of our research are;

• Independent assessment of hazards and risks.

• Intensive in house testing and continuous audit of all aspects of

design and manufacture.

• On site testing and audit of systems.

• Feedback for development has been received from:- o Operators.

o End users (management and owners).

o Suppliers and agents.

o Independent and experienced people within the industry.

As a part of occupational health and safety procedures within a

workplace, it is also necessary for you, as the owner or operator of the machine, to conduct and record your own risk assessment

prior to using this machine.

!



SECTION 10 - COPYRIGHT

All users of this specification and the drawings exhibited hereafter are

reminded that copyright exists in all Thompson Meat Machinery

publications. Except where the Copyright Act otherwise allows, no part of this publication may be reproduced, stored in a retrieval system in

any form or transmitted by any means, without prior permission in

writing from Thompson Meat Machinery.

Requests for permission should be directed to Thompson Meat

Machinery or a registered agent. Where such requests relate to the

reproduction of the whole or a substantial part of any Drawing, permission will be conditional on the appropriate documentation being

submitted.



28

Section 11 – TROUBLE SHOOTING GUIDE

PROBLEM POSSIBLE CAUSES REMEDIES

Machine will not start using the push button. 1. Safety switch open 1. Check that the safety interlocked

and /or the machine lid is closed.

2. Check incoming power supply. 2. Connect if disconnected.

3. Main circuit breaker open. 3. Reset Circuit Breaker.

4. Control circuit fuse blown. 4. Replace main supply fuses.

5. Safety switch faulty. 5. Replace safety switch.

Feedscrew stops during processing. 1. Contactor overload. 1. Machine will reset after a few minutes.

2. Unsuitable product (i.e. No frozen 2. Thaw product.

product to be used).

3. Unsuitable hole plate or product size. 3. Change hole plate or reduce product

Mixing paddle stops during processing. 1. Contactor overload 1. Will reset after a few minutes.

2. Unsuitable product (i.e. No frozen 2. Thaw product.

Product to be used).

3. Bowl capacity exceeded. 3. Remove some product.

4. Faulty relay or contactor. 4. Circuit should be checked

Ingredients are not mixing thoroughly. 1. Insufficient mixing time. 1. Allow more time.

2. Not following dry ingredient supplier’s 2. Follow supplier’s instructions.

recommendations for use.

Product appearance not visually pleasing. 1. Cutting knife blunt. 1. Change Blade(s).

2. Mincing hole plate worn. 2. Sharpen hole plate.

3. Knife and plate set incorrectly fitted. 3. Refit knife and plate set correctly.

Knife and/or plates wearing excessively 1. Lock ring too tight. 1. Loosen lock ring.

A L S O T R A D I N G A S E . L . S A M M O N & C O � � � L E A D I N G M A N U F A C T U R E R S O F M E A T P R O C E S S I N G A C H I N E R Y

134 Magnesium Drive, Crestmead Brisbane, Qld. 4132 Australia ��Phone 61 (7) 3803 6643 3803 6643 3803 6643 3803 6643 ��Fax 61 (7) 3803 6635

All correspondence to be addressed to: PO BOX 2163, Crestmead D.C. Qld. 4132 Australia

Email [email protected] ��ABN 44 680 698 556 Page: 29 -

Appendix A – CE Declaration

DECLARATION OF CE CONFORMITY We,

THOMPSON MEAT MACHINERY 134 Magnesium Drive, Crestmead, Queensland

Australia 4132.

Ph: 61 7 3803 6643

Fax: 61 7 3803 6635

Declare that the product:

THOMPSON 4000 Series MINCER MIXER Complies with the requirements of:

DIRECTIVES:

MACHINERY DIRECTIVE 98/37/EC Low Voltage Directive 73/23/EEC, 93/68/EEC. Electromagnetic Compatibility Directive 89/336/EEC, 92/31/EEC.

STANDARDS: The product complies with the following European standards:-

EN 12331:2003 Food processing machinery – Mincing Machines – Safety and

hygiene requirements

The technical file is maintained at:

Thompson Meat Machinery 134 Magnesium Drive Crestmead Queensland Australia 4132.

Signed:

……………………………………….... Rodney C. Sammon, Chief Executive,

Thompson Meat Machinery,



APPENDIX B: - Material Safety Data Sheets

1. Detergents & Disinfectants Cleaning Agent Specifications



2. MATERIAL SAFETY DATA SHEETS - LUBRICANTS



Appendix C - Illustrations

DIRECTIONAL ARROW

For checking correct direction of Feedscrew rotation.

Illustration A



SAFETY SENSORS

Location of Magnetic Safety Sensors on LID

Illustration B

Comment: Replace this

photograph with a photograph of a

4000 series machine.


photograph with a photograph of a 4000 series machine.



“WARNING” LABEL

ON ALL MIXER MINCERS - REGARDING RISK TO FINGERS.

Illustration C



DISCHARGE GUARD WITH SAFETY INTERLOCK CUT OUT

Magnetic Safety Interlock Switch

Illustration D



FEEDSCREW EJECTOR Ejector Actuating Lever



4000 MODEL REMOVABLE PADDLE END FLOAT ASSEMBLY

A

B

Illustration I

Illustration J


photograph with a photograph of a

4000 series machine.


photograph with a photograph of a 4000 series machine.

.



PADDLE END FLOAT ASSEMBLY 4200 / 4200F /4300 Models

Mounting Bolts – M8 x 1.25 – 4 off

Paddle Adjustment Bolt – M12 x 1.75

Illustration J

APPENDIX D: TECHNICAL DRAWINGS





A

B

1

1

2

2

3

3

4

4

5

5

6

6

7

7

8

8

A A

B B

C C

D D

E E

F F

Thompson

MACH INING TOLERANCE

U .O.S.Above Includ in g To le rance

0 .5

6

120

315

6

30

30

120

315

1000

±0.1±0 .2

±0.8

±0.3

±0.5

THOMPSONMEAT MACHINE RY

Title:

Part Number:

Drawn by: Date:

Scale: Fil e :

31/08/2006Bruce Price

4000GA-001

NTS 4000GA-001.idw

AAAA2222

PARTS LIST

ITEM QTY DESCRIPTION PART NUM

1 1 4000 Lid Assembly 4000AS-018

2 1 Paddle Shaft Assembly 4000-122

3 1 Plate Guard Assembly 4000AS-032

4 1 4000AS-053

5 1 End Float Assembly 4000AS-022

6 1 4000 Series Aus. Mince Gear box

Assembly

4000AS-027

7 1 4000M2 (All machines) Motor Gear

Unit To Body Ass

4000AS-038

8 1 Small Side Inspection Cover 4000-024

9 1 Rear Inspection Cover 4000-028

10 1 Large Side Inspection Cover 4000-027

11 45 M5x0.8 S/S Set screw 12 long SSHM512

12 45 M5 S/S Shake proof washer WSPM5

13 1 End Cap IRB22

14 1 M8x1.25 Hex Socket Grub Screw

304 S/S 16 lg

SGM816

15 1 Rubber Door Stop 4MGBRDS

16 1 WFDM618

17 1 M6x1.0 Hex head set screw 20 long SSHM612

A

B

Typical Panel Fastener

11

12

6

10

7

1

2

5

4

9

8

3

Lid Stop

15

16

17

13 14



3

3

4

4

5

5

6

6

7

7

8

8

A

B

C

D

E

F

MAC HINING TO LERANCE

U.O .S.

Abov e Inclu din g To lera nce

0. 5

6

12 0

315

6

3 0

3 0

120

3 15

1 00 0

±0 .1

± 0.2

±0. 8

±0. 3

±0. 5

Ti

P

Dra

S

AAAA2222

ITEM QTY

1 1 Ross

2 1 Minc

3 7 M14

lg

4 1 Ross

5 1 Ross

6 1 50x9

3221

7 1 3000

Was

8 1 50 N

9 1 4200

10 1 M40

11 1 M40

1

2

3

4

7

8

6

5



3

3

4

4

5

5

6

6

7

7

8

8

A

B

C

D

E

F

MACHI NING TOLERANCE

U. O.S.

Abo ve In clud ing Tole ra nc e

0.5

6

1 20

31 5

6

30

30

1 20

31 5

10 00

± 0 .1

±0 .2

± 0.8

± 0. 3

± 0. 5

AAAA2222

I TEM

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

1

2

6

8

2

3

12

11

10

7

5

13

14

16

15

9



3

3

4

4

5

5

6

6

A

B

C

D

MACHINING TOLERANCE

U.O.S.

Above Including Tolerance

0.5

6

120

315

6

30

30

120

315

1000

± 0.1

±0.2

±0.8

±0.3

±0.5

Title:

Par t Number:

Drawn by :

Scale:

4000 MM End

John Hardy

4

1:1

AAAA3333

ITEM QTY DES

1 1 4000 Mixer/ Grinder Body

2 1 End Float Assembly

3 1 Non Reversing Knob

2

3



3

3

4

4

5

5

6

6

7

7

8

8

A

B

C

D

E

F

MAC HINI NG TO LERANC E

U.O .S .

Abov e In clu ding Tole ra nce

0 .5

6

12 0

315

6

3 0

3 0

1 20

3 15

1 000

± 0 .1

±0 .2

± 0.8

± 0. 3

± 0. 5

AAAA2222

I TEM QTY

1 1

2 4

3 4

4 1

5 1

6 1

1

5

6



3

3

4

4

5

5

6

6

7

7

8

8

A

B

C

D

E

F

MACHINI NG TOL ERANCE

U.O.S .

Abo ve I nclu ding Toleran ce

0 .5

6

12 0

31 5

6

30

30

1 20

31 5

10 00

± 0.1

±0. 2

±0 .8

±0 .3

±0 .5

AAAA2222

I TEM QTY

1 1

2 4

3 4

4 4

5 1

6 1

7 1

8 2

9 2

10 1

11 1

12 1

13 1

14 1

15 2

16 1

17 1

18 1

19 4

20 4

1

2

3

4

5

6

7

8

9

12

11

10

20

19

14

13

15

16

18

17



3

3

4

4

5

5

6

6

7

7

8

8

A

B

C

D

E

F


U.O .S .


0 .5

6

12 0

315

6

3 0

3 0

1 20

3 15

1 000

± 0 .1

±0 .2

± 0.8

± 0. 3

± 0. 5

AAAA2222

I TEM QTY

1 1

2 1

3 4

4 4

5 41

2



3

3

4

4

5

5

6

6

7

7

8

8

A

B

C

D

E

F

MACHINING TOLERANCEU.O.S.Above Including Tolerance

0.5

6

120315

6

3030

120315

1000

±0.1±0.2

±0.8

±0.3±0.5

AAAA2222

ITEM QT

1 1

2 1

3 4

4 4

5 1

6 1

7 1

8 1

9 1

10 1

1

3

4

5

6

2



3

3

4

4

5

5

6

6

7

7

8

8

A

B

C

D

E

F


U.O .S .


0 .5

6

12 0

315

6

3 0

3 0

1 20

3 15

1 000

± 0 .1

±0 .2

± 0.8

± 0. 3

± 0. 5

AAAA2222

I TEM QTY

1 1

2 1

3 1

4 1

5 4

6 4

7 1

8 1

9 1

4

3

1

2

5



EXPLODED ISOMETRIC VIEW

3

3

4

4

5

5

6

6

A

B

C

D

MACHINING TOLERANCE

U.O.S.

Above Including Tolerance

0.5

6

120

315

6

30

30

120

315

1000

± 0.1

±0.2

±0.8

±0.3

±0.5

Title:

Part Number :

Drawn by:

Scale:

4200F & 430

Gear box Ass

John Hardy

1:4

AAAA3333

ITEM QTY DESCRIPTION PART NUMBER FILE NAME

1 1 Rossi 125 Mixer Shaf t 4300- 146 4300- 146. iam

2 1 MR3I 125 UP2A/ 112 M4 i=75.3:1 4MGMXR4US 4MGMXR4US. ipt

3 1 WEG motor 4kW 4Pole A FL Mtd 220V 60Hz WEG4K4PAUS WEG4K4PAUS.ipt

4 1 60 NS Internal Circlip to DIN 472 CCLP60 CCLP60.ipt

5 1 Rossi Mince Feed Screw Shaft Key 4200- 144 4200- 144. ipt

6 1 4200 MM Drive Shaf t Washer 4200- 141 4200- 141. ipt

7 1 M40 Lock Nut Tab Washer TWAW08 TWAW08.ipt

8 1 M40x1.5 Lock Nut KM08 NRLKM8 NRLKM8.ipt

9 1 Mincer Flange - Gearbox Side MCH4MNFGR 4000- 170. ipt

10 7 M14x2 Hex socket head screw 40 Long SCSM1440 SCSM1440.ipt

9

10

2

3

7

8

6 4

10

10

10

10

10

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