Strong Manufacturing FillerMate User manual

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Type: Fillermate
Model Number:
Serial Number:
Strong Manufacturing Company, Inc.
P.O. Box 8068
2301 University Drive
Pine Bluff, Arkansas 71611-8068
Phone: [phone]
Fax: [phone]

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Owner’s Manual
For The
Strong Manufacturing Company, Inc.
FillerMate
Strong Manufacturing Company, Inc.
P.O. Box 8068
2301 University Drive
Pine Bluff, Arkansas 71611-8068
Phone: [phone]
Fax: [phone]

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Table of Contents
Preface 4-5
I. Safety 6-10
A. Electrical 6
B. Machinery and Guards 7-8
C. Material Pump and Hose 8
D. Mixer 9
E. Water 9-10
F. Catwalk 10
II. Strong-Mate Mixer 11
III. Strong-Master Pump 12-14
A. Packing Chamber 13-14
B. Dismantling and Installing Pump Drive 14
IV. Machine Installation 15-17
A. Location of Machine 15
B. Connecting Electrical Power 15-16
C. Connecting Water 16
D. Test Electrical Controls 17
V. Machine Operation 18-20
A. Mixing and Pumping Batches 18-20
VI. Clean-Up 21-22
A. Machine Clean-Up 21-22
B. Clean-Up of Material hose 22
VII. Machine Maintenance 23-25
A. Mixer 23
B. Pump 23-24
C. Material Hose 24
D. Water System 24
E. Electrical System 24-25
VIII. Trip Preparation Checklist 26
IX. Troubleshooting 27-29
X. Optional Equipment & Suggested Parts List 30-31
XI. Drawing List 32

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Preface
The Strong Fillermate Tank Filling System (see Drawing #86000614) is specially designed for mixing
and pumping Strong’s specifically formulated materials for use in the steel fuel tank industry. Strong’s
premixed material is the optimum mix for filling the annulus between concentric steel walled tanks
because:
1. The perlite rich premix is extremely effective in producing an insulating barrier that is more than
adequate to pass a standard two-hour fire rating test.
2. Mechanized blending at Strong insures precisely measured ingredients, thereby allowing the
customer to produce consistent mixes from pallet to pallet.
3. After setting, this special material is porous, which allows the absorption of leaked fuel, should
any escape the inner tank.
4. Excess water in a mix can seep from the mix and rust the tank walls. Special additive in the
Strong premix eliminate bleeding of water, reduce the amount of original water needed for
mixing, and at the same time, increase pumpability of the material slurry.
5. Should any questions arise regarding materials of machine operation, Strong Manufacturing
Company’s technical or engineering department can answer questions in a timely manner.
With its patented double drum mixer, the Strong Fillermate mixes materials quickly and thoroughly with
minimum degradation of lightweight aggregates. The special mixer also promotes air entrainment within
the mix to maximize material yields.
The Strong Fillermate utilizes a progressive cavity pump that also prevents damage of fragile mix
ingredients. The pump is capable of pumping in forward and reverse directions. Pumping in reverse is
handy when the operator need to relieve hose pressure. Reverse can also be used to pull material back out
of the annulus should an air pocket at the top of the tank be desirable.

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Power is supplied to the mixer and pump via electrical gear motors. Standard units operate at 230 VAC.
However, for particular applications some units are designed to operate at 460 VAC. The intent of this
manual is to promote the best use of the Strong Fillermate by providing component description, operation
and maintenance procedures, a troubleshooting guide and most importantly, safety instructions.
This operator’s manual has been prepared assuming it will be mixing and pumping premixed materials.
Due to the many other materials, it is capable of mixing and pumping Strong MFG. is unable to provide
instructions for all products.
The manual should be read thoroughly and understood by everyone responsible for the operation and
maintenance of the machine. With proper care and maintenance, the Strong Fillermate will provide its
operators long and dependable service.
Extra copies of this manual and other literature are available from Strong Manufacturing for a nominal fee
of $30. However, the safety section of this manual can be obtained free of charge.
To obtain additional manuals or if questions arise concerning the Fillermate System, please call or write:
Strong Manufacturing Company, Inc.
P.O. Box 8068
2301 University Drive
Pine Bluff, Arkansas 71611-8068
Phone: [phone]
Fax: [phone]

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Important General Safety Information
The Strong Fillermate machine was specifically designed to mix and pump special pre-blended material
slurries. It is also capable of mixing and pumping other materials blended on site. In addition to the
usual hazards of machinery, several special hazards are involved in these operations. Please read and pay
close attention to the following SAFETY INFORMATION.
A. Electrical
1. Read all instructions and safety literature for electrical components prior to connecting
power.
2. Only a qualified electrician should be allowed to perform and service the electrical system on
this machine.
3. Never remove any covers from the electrical components without first isolating and locking-
out the source electricity to the machine.
4. While the machine is not in use and/or at the end of each day, the machine’s red disconnect
knob should be turned to the off position and locked.
5. Before unlocking the red disconnect knob or reconnecting power to the machine, always
check to make sure that the pump and the mixer control switches are in off position and all
guards are in place.
6. Use only the correct voltage that your particular machine is equipped for. Standard machine
is 230 volts, Three Phase AC. Some special machines are designed to operate on 460 VAC.
7. A charged fire extinguisher designed for 230 VAC use on electrical fires should be kept near
the machine at all times. (Class BC, Dry Chemical)
8. Throw electrical disconnect and lockout before final wash-down of exterior or main electrical
cabinet.
9. Always keep main electrical cabinet closed and tightly sealed.

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B. Machinery and Guards
1. Read all “WARNING” and “CAUTION” signs before starting machine.
2. Never operate machine with worn or loose parts, or with parts needing replacement
3. Warning: Do not remove mixer guard or grate or put hands or tools in mixer at any time
without shutting down the power supply and locking it in the off position. When cleaning
mixer at end of day’s operation and washing out loose materials removed during cleanup,
replace the mixer inlet grate before reconnecting or restarting the power supply. Failure to
observe this warning may result in severe bodily injury including eye injury, loss of sight,
loss of limbs, cuts, bruises or possibly death.
4. Before unlocking electrical disconnect knob make sure that all guards and covers are back in
place. The guards provided with this machine consist of the following:
•Mixer Chain Guard –Covers chain and sprockets that drive the mixer.
•Mixer Inlet Grate –Covers top of mixer inlet
•Hopper Grate (Or Sub-Grate) –Fits in bottom of wet material hopper to cover
flighting on pump drive shaft
•Coupling Guard –Horseshoe shaped guard that covers the coupling between the
pump drive assembly and gearbox.
5. Never Operate the mixer or pump under any excessive load causing the electrical system to
overload.
6. Never wear long hair or loose clothes around rotating machinery.
7. Never place hands, arms, tools, etc. through grates or guards.

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8. The machine should be kept as clean as possible. Material should not be allowed to build up
on warning signs, instructions, gauges, etc.
9. Guards are designed for specific purposes and should never be altered in any way.
10. Machines set on casters should always be blocked in place to prevent machine from
movement during operation.
Caution: Failure to observe the preceding warnings can result in severe bodily harm, including
eye injury, loss of sight, loss of limbs, cuts, bruises, electrical shock or possibly death.
C. Material Pump and Hose
1. Do not disconnect material hose with hoses under pressure. Always run pump in reverse
until hose becomes soft before disconnecting it. Failure to do so could result in material
blowing out under pressure and striking someone causing bruises, cuts, breaking of limbs or
possible loss of sight if material enters eye.
Note: When pumping in reverse, be sure that material is flowing back into the hopper as
evidenced by the materials level in the hopper rising. Watch the discharge hose to avoid
collapsing in and causing the pump to run dry. Running the pump dry can damage the stator
in just a few seconds.
2. Examine material hose at the beginning of each shift. If cuts, bubbles, or any other weak spot
is noticed the hose should be replaced. Check all couplings to be sure they are tight and
properly latched.
3. Never stick hands, arms, tools, etc. through the pump hopper grate.
4. Never remove pump hopper grate with power disconnect in the “ON” position. Turn the
disconnect switch to the “OFF” position and lock it out.

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D. Mixer
1. Never stick hands, arms, tools, etc. through the mixer inlet grate or discharge door.
2. Always lock and tag electrical power disconnect off before removing mixer grate. Replace
the grate before reconnecting power.
3. Warning: The mixer safety kill switch is connected to the mixer and detects the presence of
the mixer grate. This switch should never be removed, dismantled, or hindered in any way.
The switch should be checked regularly to assure proper operation. This switch is designed
to stop mixer rotation in the event the mixer grate becomes accidently dislodged.
4. Lock the electrical power disconnect OFF before doing any work on the mixer.
Caution: Failure to observe the preceding warnings can result in severe bodily harm, including
eye injury, loss of sight, loss of limbs, cuts, bruises, electrical shock or possibly death.
5. Always wear safety glasses or other eye protection when operating the machine, dust
particles become airborne and could get into the eyes causing severe irritation or even
permanent loss of sight.
6. Never wear long hair or loose clothes around the mixer as they may be caught between
paddle blades. The winding motion of the paddle can pull a person into the mixer.
E. Water
1. Never connect water to machine, if incoming water line pressure is over 150 PSI.
2. Always flush water lines prior to connecting to machine. Debris in the line may cause
damage to the water meter. Excess air in the line may also damage the water meter.

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3. Use only water that is suitable for drinking.
4. Disconnect water from machine at end of shift; drain water meter and water lines, if a
possibility of freezing exists.
Cleaning, Repairing, Servicing And Adjusting Prime Movers, Machinery And Equipment
Section 3314 –General Industry Safety Orders
Machinery or equipment capable of movement shall be stopped and the power source de-
energized or disengaged, and, if necessary, the moveable parts shall be mechanically blocked or
locked to prevent inadvertent movement during cleaning, servicing or adjusting operations unless
the machinery or equipment must be capable of movement during this period in order to perform
the specific task. If so, the employer shall minimize the hazard of movement by providing and
requiring the use of extension tools (EG extended swabs, brushes, scrappers) or other methods or
means to protect employees from injury due to such movement. Employees shall be made
familiar with the safe use and maintenance of such tools by through training.
Caution: Failure to observe the preceding warnings can result in severe bodily harm, including
eye injury, loss of sight, loss of limbs, cuts, bruises, electrical shock or possibly death.
F. Catwalk
1. Never sit, stand or climb on handrail.
2. Never operate machine without either the optional pallet rack or standard handrail in place.
3. Never stand on catwalk without it being bolted securely to the floor. Without the legs being
bolted down, the catwalk may tend to be unstable and tip backwards.
4. Never let empty bags, hoses, etc., pile up on catwalk as these may become tripping hazards.

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Strong-Mate Mixer
Drawing #386000620
The Strong-Mate Mixer is a completely innovative idea in mixers, designed for mixing most varieties of
cementitious materials. The mixer is designed to give a maximum amount of agitation, and complete
dispersement of the particulate ingredients and admixtures in as short a mixing cycle as is possible.
To accomplish this, two inter-connected fixed drums are attached and include two self-wiping, ribbon
paddles that counter-rotate. The mix is brought to the center where it gets an EXTRA ORDINARY and
VIOLENT mixing action –but does not “beat” the mix as is the case with the conventional type paddle
mixers. The amount of mixing time to bring the mixture into a completely homogenous mix under
normal conditions is about 30 seconds. With longer mixing times the yield of a mix can actually be
increased over 100%.
The mixer should be thoroughly cleaned after each day’s use to prevent a buildup of materials on blades
and walls of the mixer. Power is supplied to the mixing paddles by a 5 horsepower, 3 phase, A.C. electric
motor.
The mixer has a set of packing chambers with rings of packing at either end of the paddle blade shafts to
prevent water and the mix from getting into the flange bearings. One fitting, on each of the flange
bearings, is for greasing the seals inside. THESE FITTINGS ARE LOCATED ON TOP OF THE
BEARING HOUSING AND MARKED “GREASE TWICE DAILY”. These should be greased every
four hours of operation and at the end of each day’s operation. Enough grease is injected to show at the
end of the packing house inside the mixer after the cleanup operation. This ensures that any materials that
have worked past the seals is discharged out and cannot harden inside and prevent the sealing action
necessary to protect the shaft bearing.
Grease the fittings on the sides of the bearing housing every 150 hours of operation. These fittings are
provided for greasing the race of the bearings which are prepacked at the factory. Too much grease here
can shorten the life of the bearing more than not greasing it at all.
Caution: Do not remove mixer guard or put hand in mixer at any time without disconnecting electrical
power and locking it in the off position. When cleaning mixer at end of day’s operation and washing out
loose materials removed during cleanup. Replace the mixer inlet grate before reconnecting power.
Failure to do so could result in severe bodily injury.

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Strong-Master Pump
Drawing #86000616
The Strong-Master pump consists of three principle parts, the pumping elements, the suction housing for
material storage and the drive assembly to transfer power to the pumping elements.
The pumping elements for the Fillermate consist of a #80 rotor and stator connected to the suction
housing. This rotor-stator combination is capable of producing 400 PSI pressure when new. Pressure of
this amount will not be encountered during normal operations, UNLESS a “plug” in hose occurs. If a
plug does occur, stop the pump immediately. Run the pump in reverse to relieve the hose pressure. Find
the “plug” in hose. Remove and clean the plugged section of hose.
As the pump is operated, the rotor will wear, causing the pressure to drop and discharge rate to reduce.
Should either rotor or stator has excessive wear, it will shorten the life of the other component
considerably. Worn parts cause “slippage” within the pumping elements which accelerates the wear.
Generally, the stator wears first.
It is not critical which end of the stator is screwed into the pump hopper. To prolong the stator life,
reverse ends when stator wear in noticed. This is indicated by a substantial reduction of flow out of the
end of the material hose. Eventually, the rotor will wear also. Rotor wear consists of chrome missing
from the lobes of the rotor. When this occurs, replace the rotor. Worn rotor will result in reduction of
stator life by one-half or more. Never use a new stator with worn-out rotor. When wear is excessive, the
material flow from the hose will decrease and become intermittent. When flow breaks, a small puff of
vapor may be released. At this point, the rotor and stator should be examined and one, or both, replaced if
wear is observed.
To remove the stator, loosen the “U” bolt clamp and unscrew the stator with a pipe wrench. The stator
can then be screwed out of threads by rotating the stator slowly while holding backward pressure on the
pipe wrench. To replace a stator, lubricate the inside of the stator and outside of the rotor with glycerin or
soap. Using a pipe wrench hold forward pressure against the stator and screw it on to the rotor and into
the pump housing. Holding pressure against the discharge end of the stator may be required. Do not use
the machine to thread stator into housing. This must be done by hand. Damage to threads could occur if
attempt is made to thread stator into housing by use of the machine.
The suction housing (See Drawings #86000370 and #86000617) has the materials holding hopper welded
to it. A connecting rod connects the rotor to the drive shaft at hub inside the suction housing.

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The connecting rod has auger flighting welded to it to keep materials agitated and fed to the pump during
operation. These parts which operate in the cement slurry environment, are subject to severe wear. The
connecting rod should be inspected for excess wear at pin holes every 40 hours of operation. It is easily
done when rotor is removed as one end of connecting rod is exposed. The wear at the rotor end is usually
greatest so that it is not necessary to remove other end unless pin holes can be used when wear is
excessive on one set. When both sets of holes are worn, the drive shaft hub should be replaced.
Connected to the suction housing is the drive assembly (see Drawing #86000615) which houses the
packing chamber/chrome sleeve, and drive shaft bearings. The bearing housing is pregreased at the
factory and should not require additional lubrication more than once a year.
The standard power supply for the standard Fillermate pump is a 7 ½ horsepower, 230-460 VAC, 3 phase,
A.C. electric gear motor.
A. Packing Chamber
The Strong-Master #80 pump features a packing chamber (see Drawing #86000615) specially
designed to handle cementitious slurries.
The packing chamber consists of a set of specially prepared packing and one lantern ring. These
stationary rings seal against the rotating drive shaft that has been hard chrome plated to resist
wear. To maintain the sealing pressure required, a grease fitting and a conventional packing
gland are utilized.
The packing chamber must be kept well-greased. This should be done every four hours of
operation and at the end of each operational day. This will prevent water and mix from entering
the chamber and setting up.
The packing gland is used to maintain a uniform packing pressure as the rings wear. There is
enough adjustment for one full ring of packing. When the gland has bottomed out against the
chamber, an additional ring should be added.
When the packing chamber continues to leak after greasing and gland adjustment, the original
rings are too badly worn or dried out and will not seal. Remove the gland and all of the rings.
Replace with compete new set as shown on the pump drawing. The lantern ring and chrome
plated drive shaft usually will not need replacing, but they should be inspected and cleaned. If
the holes in the lantern ring are stopped up with dry material, they should be cleaned as grease

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will not reach the packing and rapid wear of the packing will occur. The chrome on the drive
shaft should be inspected for wear and cleaned or replaced. Excessive grooving or lack of
chrome indicates a need to replace the drive shaft.
B. Dismantling and Installing Pump Drive
Disconnect and lock0out electrical power source. Disconnect wires at electric motor (make a
note regarding where the wires were attached). Remove connecting rod pin in drive hub.
Remove four 3/8 inch bolts holding bearing housing to suction hopper. Entire unit will now lift
clear of suction hopper. There is approximately 1/16 inch clearance all around between the drive
collar and the center hole into the suction hopper and plate. Set-up concrete may block passage
of drive collar through housing.
To install a new unit, reverse the above procedures, paying particular attention to the following:
Pack drive collar with Esso Nebula EP2 or equivalent grease. On the bearing housing is a raised
boss which fits into a counter bore in the suction hopper bolting face. Examine both of these
sections for burrs. Remove with flat mill file. Make sure all foreign matter is removed from all
mating surfaces. Wipe with grease after cleaning. Tighten the four housing bolts up alternately,
so that housing faces contact securely all the way around. Reconnect connecting rod pin and
reconnect wires to the motor according to the notes you took above.

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Machine Installation
A. Locating Machine
1. Care should be taken to locate machine on level ground.
2. Caster on bottom of skid should be blocked to prevent rolling during machine operation.
3. Machine should be located near a charged fire extinguisher.
4. Machine should be located where excess water from wash-down and normal operation will
run off and not leave a hazardous walking surface.
B. Connecting Electrical Power (see Drawing #86000621)
The electrical power required for the 430 Fillermate machine is 230 volts, three phase, A.C.
Special machines are supplied with a 460-230 control voltage transformer and must operate on
460 volts.
Warning: Only a certified electrician should be allowed to perform electrical work on this
installation.
1. The plant’s main electrical disconnect should be thrown to the OFF position and locked
before beginning any work on the machine.
2. Before connecting hot leads to machine, make sure that all guards are installed properly on
the machine and that all switches are in the OFF position.
3. Connect the machine’s main power supply cord to an existing electrical power supply. The
three power leads should be connected as shown in Drawing #86000621.
4. Route wires to the machine so they are not a hazard to workers operating around the machine.
5. Make sure that wires are connected to the terminals securely and that all wire fittings on
cabinet are tightly sealed.

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Warning: Improperly sealed wires can allow water to enter the cabinet causing the possibility of
electrical shock.
Danger: This machine should never be operated or sprayed with water without sealing the
electrical disconnect box. The metal key supplied with the machine should always be used to
lock and seal the machine’s electrical disconnect box before clean up begins. Rotating the lock
counter clock-wise, by use of this key will seal the box and prevent water from contacting
electrical components inside the box.
DO NOT TURN THE MIXER OR PUMP ON YET
C. Connecting Water
Note: The following procedures should be adhered to before attempting to start the mixer or
pump.
1. In order to flush air and debris from the incoming water line, turn the water on before
connecting it to the Fillermate water system.
2. Turn the water line off.
3. Connect the water line to the fitting on the bottom of the water system.
4. Open the wash-down faucet and water inlet valve to allow excess air to escape.
5. Turn incoming water back on until water flows through the two ports.
6. Open mixer door an allow water to flow into wet material hopper.
7. Open hopper trap door so that this water and any excess debris can be emptied.
8. Close the hopper trap door and place 10 more gallons of water in the hopper.

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D. Test Electrical Controls
1. All guards should be in place before turning any component of machine on.
2. TEST THE PUMP FIRST. Make sure there is water in the hopper. When the pump control
switch is set to FORWARD the water level does not drop and bubbles come from the back of
the rotor/ stator, stop the pump IMMEDIATELY, the incoming electrical leads have been
installed backwards.
3. Only, after the pump operates correctly in FORWARD and REVERSE should the mixer
controls be tested. With controls in the ON position the mixer should turn approximately 50
RPM.

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Machine Operation
The General Safety Information section of this manual should be studied carefully by everyone working
around this machine before it is operated. This machine should never be operated or serviced without all
safety guards in place and operating correctly.
Danger: Never stick hands, arms, tools, etc. into the mixing chamber either through the inlet grate or
discharge door with electrical power connected to the machine.
A. Mixing and Pumping Batches
During the mixing operation, the wash down hose can be used to remove any material that
adheres to the mixer grate or paddles. Do not remove the mixer grate. Adequate room for clean-
up is provided through the mixer grate openings.
When using material that has not been pre-blended, add water to mixer, add admixture if
required, spreading evenly over entire length of mixer, add cement, add aggregate. *All material
should be added slowly and evenly to prevent excessive mix times and prevent lumpy material.
Dumping ingredients without spreading evenly may affect mix consistency.
Mix 2 to 3 minutes or until proper density is achieved.
1. Reset water meter to zero.
2. Turn the mixer ON.
3. After making sure the mixer door is closed, open the water inlet valve to allow water to flow
into the mixer. The amount of water required for a batch of material is specified by material
vendor. Place all of the specified amount of water in the mixer except 1 or 2 gallons. These
should by saved to do final adjustments on the mix after the material has been added.
4. Place dry premixed material in the mixer one bag at a time, adding the last bag slowly. Mix 2
to 3 minutes. Adjust water as necessary. Open door and dump, close door, wash down, add
water. NEVER place dry material in the mixer before the majority of specified water has

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entered the mixer or without the mixer paddles turning. Doing either of these two operations
will cause extreme loading of the mixers electrical motor and power train.
5. After all bags have been emptied into the mixer, add the remainder of the after slowly until
the correct material consistency is obtained.
6. When the mixer is thoroughly blended and air entrained (2-3 minutes after last bag of
material is dumped), the mixer door should be opened to allow the mixed material to gump
into the pump hopper.
7. The mixer should be left running continuously. The mixing action of the paddle blades will
force remainder of mixed material out of the discharge door.
8. After all material is discharged to the holding hopper, close door, spray with wash down hose
& nozzle, begin mixing a new batch (Step #1).
9. Turn the pump control switch to FORWARD. The material level in the hopper is designed to
a specific volume that will allow continuous operation of the mixer. As one batch is mixed
another is being pumped. However, before the pump hopper is completely empty, the batch
in the mixer should be discharged to keep the pump from running dry. If for any reason the
required mixing time is greater than the required pumping time, turn the pump controls to
OFF before the pump runs completely out of material. Running the pump dry can cause
damage to the stator in a matter of seconds.
10. The hose and hopper should be monitored periodically to make sure that the hose is not
plugged. If the level in the hopper stops falling, the material hose becomes very firm and no
material is flowing from the end of the hose, the hose is plugged. Turn the pump to
REVERSE immediately until the hose becomes soft again.
Caution: Only after the pump has been reversed and the hose is soft again should the hose
be uncoupled and the plug removed.
11. If a void is desired at the top of the tank’s annulus, this is easily accomplished. First, fill the
tank completely using the standard procedure. Next, place the pump in reverse to suck
material back from the tank. Make sure that material is continuously flowing back to the

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holding hopper, or else the pump will run dry and cause damage.
12. With the application of a few of Strong’s optional Tank Filling Valve Assemblies, operators
can fill multiple tanks. This assembly connects to a threaded port at the base of the tank and
allows the operator to quick connect the material hose to the tank bottom. After the tank is
filled, the valve on the assembly is closed to prevent material leakage and the material hose is
disconnected. The hose is ready for use on another tank and the valve assembly is left on the
tank until the material sets. After the material takes its initial set, the valve assembly can be
removed and reused on the other tanks.
Caution: Always wear safety glasses or other eye protection while operating machine.