Western 500 User manual

500
600
X500
WARRIOR
WARRIOR
X500
WARRIOR
600
X600
WARRIOR
500
Warrior Shotcrete Pump
OPERATOR'S MANUAL

2
TABLE OF CONTENTS
4 WARRANTY INFORMATION
6 SAFETY
6 Safety Warnings
6 PersonnelQualications
7 Safety Regulations
8 GENERAL TECHNICAL DESCRIPTION
8 Control Panel
10 Outrigger Controls
11 OPERATION
11 Principles of Operation
11 Flatpack Assembly
12 Hydraulic System
14 Operating Procedures
17 MAINTENANCE
23 TROUBLESHOOTING

3

The following individual, who has signed below, hereby acknowledges receipt of this manual on behalf
of the purchaser of the shotcrete pump.
Model:
Machine Serial No.
Sold To:
Name:
Title:
Signature:
Date:
After signing for this manual, please mail the manual back to the following address.
Western Shotcrete Equipment, Inc.
3026 Scott Lane
West Haven, UT 84401
NOTE! Warranty void until Western Shotcrete Equipment, Inc. receives the signed Signature Page.
Warranty Information

5
WARRANTY
Western Shotcrete Equipment, Inc. warrants each new shotcrete pump sold by it to be free from
defects in material and workmanship under normal use and service for a period of twelve (12) months
from the date of delivery to the rst retail purchaser.
Western Shotcrete Equipment is not responsible for failures resulting from accident, owner or operator
abuse or neglect, improper repair, modication of standard parts or the use of parts not authorized by
Western Equipment.
This warranty does not apply to normal maintenance service or to normal replacement of certain
machine parts such as concrete cylinders, valve mechanisms, o-rings, seals, delivery systems, etc. which
are subject to normal wear.
Western Shotcrete Equipment’s sole obligation under this warranty must be to cause the repair or
replacement without charge or granting of a credit reimbursement, at its discretion, through its
warranty processing procedures, for any defective part of a concrete pump sold by Western Shotcrete
Equipment when returned prepaid to an authorized concrete pump dealer appointed by Western
Shotcrete Equipment or a point designated by Western Shotcrete Equipment. Determination of
defect must result from the exclusive examination of the part by Western Shotcrete Equipment or the
authorized dealer.
Western Shotcrete Equipment does not warrant components or accessories which bear the name of
another company, such being subject to the warranties of their respective manufacturers.
Western Shotcrete Equipment will not be responsible for travel or transportation expenses, rented
equipment, outside contractor’s fees or unauthorized repair shop expenses.
Western Shotcrete Equipment assumes no liability for loss of use or any direct, indirect or
consequential damages of any kind in respect to the use or operation of concrete pumps sold by
Western Shotcrete Equipment or any equipment or accessories in connection therewith.
THIS WARRANTY IS THE SOLE WARRANTY BY WESTERN SHOTCRETE EQUIPMENT FOR CONCRETE
PUMPS. THIS WARRANTY IS EXCLUSIVE AND IS IN LIEU OF ALL OTHER WARRANTIES EXPRESSED
OR IMPLIED AND THERE IS NO IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR A
PARTICULAR PURPOSE.
Western Shotcrete Equipment does not authorize any person or company to assume for it any other
warranty obligation in connection with the sale of the Western Shotcrete Equipment product. Any
enlargement or modication of this warranty by a dealer or other selling agent must become the
exclusive responsibility of such dealer or selling agent

6
Safety Warnings
WARNING
Do not attempt to operate this equipment without
a thorough understanding of the operating,
maintenance, and safety considerations contained
in this manual. To prevent damage to equipment
and or injury to you or other personnel, these
instructions must be carefully followed.
WARNING
Diesel is extremely flammable and is explosive
under certain conditions. Work in a well-
ventilated area with the engine stopped. Do not
smoke or allow flames or sparks in your working
area or where diesel is stored.
WARNING
If the engine must be running to perform
maintenance, make sure your workspace is
well ventilated. Never run the engine in an
enclosed space. The exhaust contains poisonous
carbon monoxide gas that may cause loss of
consciousness and lead to death.
WARNING
Use dry nitrogen gas only to pressurize the
accumulator bladder. Never use compressed air.
The use of an unstable gas such as compressed
air can cause a fire or explosion resulting in
serious injury or death.
WARNING
California Proposition 65 Warning:
Diesel engine exhaust and some of its
constituents are know to the state of California
to cause cancer, birth defects, and other
reproductive harm.
PersonnelQualications
Introduction
Western Shotcrete Equipment, Inc. Warrior
Shotcrete Pumps are high-pressure, hydraulic-
powered pumps for shotcreting or pumping of
concrete. This manual describes the operation,
maintenance, and safety considerations that must
be followed. Close attention to these details by
the operator and maintenance personnel are
necessary to ensure a minimum of problems while
striving for maximum productivity and safety.
Prior to pump operation an operator must be
thoroughly familiar with the equipment and its
operation so that he or she can operate it in a safe
manner. His or her eligibility to operate the pump
must be based on the following qualifications.
Qualications
Only experienced operators, or trainees under
the direct supervision of an experienced operator,
must operate the equipment. No unauthorized
person should be permitted to assist or remain
in the immediate vicinity of the machine while it
is in operation or during the performance of any
maintenance, inspection, cleaning, repair, or in
preparatory operations.
Individuals who cannot read and understand the
signs, notices, and operating instructions that are
part of the job must not operate the machine.
Individuals who are not familiar with the operating
instructions, have not received some on-the-job
supervised training, or are not familiar with the
signal codes used at the construction site must
not operate the machine.
Anyone under the age of 21 years must not
operate the machine.
Anyone with seriously defective eyesight or
hearing and/or physical or mental impairment
must not operate the machine. (Such as epilepsy
or heart disease) This should be verified annually.
The machine must not be operated while the
operator is eating, drinking, reading, talking on a
phone, or is more that six feet distance from the
controls.
An operator who has asked to be relieved
because he or she feels physically or mentally
unfit must not operate the machine.
Safety

7
Machine must not be operated at any new site, or
at the start of a new shift, until a visual inspection
is made of the condition of the equipment.
The operator must report and damage, defects,
problems, or accidents to his/her work supervisor
and next shift operator.
Safety Regulations
All personnel operating, transporting, assembling,
or maintaining a Warrior Shotcrete Pump should
understand and comply with the following safety
regulations:
Anyone near the unit must wear appropriate
clothing (NO loose clothing, neck ties, rings,
open-toed shoes) and protective equipment
(e.g. hard hat, safety goggles, hearing protection,
and close-toed shoes) required by Federal,
States, local, and job site regulations. [[Hearing
protection OSHA requirements are listed in "29
CFR Ch. XVII Section 1910.95 Occupatoinal Noise
Exposure," which can be found at www.osha.gov]]
Do not operate a malfunctioning unit or if it has
not been leveled and stabilized.
Before use, check machine's operating condition.
Never open hopper grate cover while operating
pump. Though Warrior Shotcrete Pumps are
equipped with a trigger sensor to shut off
machine when grate is opened, it may not work,
and the operator is in danger off contacting
moving parts in hopper.
Never enter the hopper grate with any part of
your body while the machine is on.
Do not stand on hopper grate.
If the hopper needs repairs, ensure the machine
is OFF and the accumulator pressure reads
ZERO. The system uses a hydraulic accumulator
which contains a stored charge of high pressure
oil to shift the S-tube. Stop engine, turn ignition
key to OFF, and wait 10-15 seconds until the
accumulator pressure gauge reads zero.
Make sure decals and operations instructions are
legible.

8
General Technical Description
Control Panel
Emergency Stop Button (1)
Push this button in case of emergency. It will cause the
machine to terminate all functions.
Manual Regen Switch (2)
Switch enables operator to perform a manual regen
via Powerview monitor. Not required for normal
machine operation.
Safety Switch Override (3)
Switch bypasses hopper safety switch in case of
emergency or switch failure. Switch must never be
used for operating purposes.
Aux Lights (4)
Switch used for optional hopper lighting package.
Aux 2 (5)
Switch used for optional functions.
Hydraulic Fluid Overheat Alert (6)
Light illuminates when the hydraulic fluid temperature
exceeds the normal operating range (>180°).
FLOW CONTROLENGINE SPEED
CIRCUIT
ACTIVE
FAST
SLOW
SAFETY
SWITCH
OVERRIDE
E
M
E
R
G
E
N
C
Y
0 6000
0 6000
3
6 7
8 8
9
10 11 12
14 15 16 17
18
19
13
1
2
4 5
Circuit Active Light (7)
Light illuminates when hopper safety sensor is
engaged when grate is closed and hydraulic circuit is
powered.
Cycle A/B Light (8)
Light illuminates to show which drive cylinder is active.
PowerView Display (9)
Multifunction display provides information such
as engine speed, active regeneration, exhaust
temperature, diesel exhaust fluid level, error codes,
and service reminders.
Hopper Screen Vibrator Switch (10)
Activates the optional hopper screen vibrator if
equipped.
Pump Forward/Reverse Switch (11)
Switch is used for forward or reverse pumping.
Forward is normal pumping operation.

9
Pressure Test Switch (12)
Must be up in the Pump position for normal operation.
In the Pressure Test position, the pump will make one
reverse stroke, stop, then the main hydraulic system
will go to maximum pressure.
On/Off/Remote Switch (13)
Turns the pump on and off at the Control Panel. When
in the Remote position, the pump can be turned on
and off with a Remote Control Cable.
Diagnostics Connection (14)
Plug used for troubleshooting machine errors.
Ignition Switch (15)
Two positions: OFF and ON. On allows the engine to
start. Off shuts off the fuel to the engine.
Engine Speed (16)
Sets the engine speed. Push the level up for more RPM
or down for less RPM to set the engine speed.
Flow Control (17)
Sets the hydraulic pump output and thus the concrete
pumping output. Push the lever up for more flow and
down for less flow or volume.
Pumping Pressure (18)
Gauge indicates hydraulic system pressure in psi.
Note: this is hydraulic fluid pressure not actual pump
outlet pressure.
Swingtube Pressure (19)
Gauge indicates stored hydraulic pressure within the
swingtube in psi.

10
Hydraulic Jackstand Levers
Control the extending/retracting
of the machine support stands.
Remixer Forward/Reverse Lever
Shifts the remixer motor between
Forward, Reverse, or Neutral.
This control lever is detented to
remain in position selected by the
operator. This lever is normally
in the Forward position so that
concrete will be drawn from the
walls of the hopper and pushed
into the material cylinders.
General Technical Description
Outrigger Controls