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

11
Principles of Operation
The Warrior is a hydraulically operated concrete
pump that is designed to pump wet concrete
through a system of pipes and hoses. Normal
operation is controlled at the control panel.
A diesel engine drives the main hydraulic pump.
The hydraulic pump powers the two hydraulic
cylinders, which drive the two delivery cylinder
pistons. A swingtube automatically shifts from
one delivery cylinder to the other to provide a
continuous flow of concrete through the system.
During the pumping cycle, the continuous flow of
concrete is accomplished as one of the hydraulic
cylinders which has the delivery cylinder open
to the hopper retracts, it pulls the piston of the
delivery cylinder. At this point, the concrete is
drawn into the delivery cylinder from the hopper.
When the fully-retracted position is reached, the
proximity switch sends a signal to the swingtube
shift valve. The swingtube then shifts to the
loaded delivery cylinder. The hydraulic cylinder
extends and the delivery cylinder piston pushes
the concrete through the swingtube, out the
discharge and into the delivery line. The cycle is
repeated to provide an uninterrupted concrete
flow.
The flat pack seen in the following illustration
performs the following functions, (1) cools the
delivery pistons and piston rods, and (2) rinses the
inner wall of the delivery cylinders.
Flat Pack Assembly
The Flat Pack is made up of the hopper,
swingtube, concrete cylinders, hydraulic cylinders,
water box.
WARNING
The operator must carefully determine that the
hopper is clear of personnel and/or equipment
before engaging the Remixer.
The operator must carefully determine that
personnel and/or equipment are clear of the
jack stand feet before extending the hydraulic
jackstands.
Operation
Hydraulic Fluid Level and Temperature Gauge
Never operate the pump when oil level is below
the Low Level mark. Inspection of oil level
periodically during operation and at shutdown
is considered good operator awareness. This
will protect against accidental loss of oil. With
the motor running, the proper level should be
between the low and high mark on the gauge.
Normal range of oil temperature is 100°-160°F.
Oil temperature of less than 50°F is in the
cautionary range. The machine should not be
operated at full output until the oil temperature is
above 50°F, otherwise hydraulic pump damage
may occur. Oil that is below 10°F should be
preheated to 50°F ideally but at least to 20°F prior
to starting the engine.
Diesel Fuel Safety
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
California Proposition 65 warning:
Diesel engine exhaust and some of its
constituents are known to the state of California
to cause cancer, birth defects, and other
reproductive harm.

12
Hydraulic System
Hydraulic Fluid Precautionary Measures
Avoid prolonged breathing of vapor, mist, or gas.
Workers should wash exposed skin several times
daily with soap and water.
Hydraulic Fluid First Aid
• Eye contact: Flush eyes with plenty of water
for several minutes. Get medical attention if
eye irritation persists.
• Skin contact: Wash skin with plenty of soap
and water for several minutes. Get medical
attention if skin irritation develops or persists.
• Ingestion: If more than several mouthfuls of
hydraulic fluid are swallowed give two glasses
(160 oz) of water. Get medical attention.
• Inhalation: If irritation, headaches, nausea,
or drowsiness occurs, remove to fresh air.
Get medical attention if breathing becomes
difficult or respiratory irritation persists.
Note to Physician: High-pressure injection of
material can cause severe injury. Failure to
debride the wound of all residual material can
result in disgurement, loss of function, or may
require amputation of the affected area.
HydraulicfluidFire
In case of fire use water spray, dry chemical, or
carbon dioxide. Water may cause frothing. Use
water spray to cool fire-exposed containers.
Operation
The Western Shotcrete Equipment Warrior
Shotcrete Pump has two 6” x 42" (85401) chrome
plated concrete pumping cylinders powered by
the 4” x 39” hydraulic main drive cylinders.
The main pump is an axial piston pump (L), which
generates the main oil flow. Flow from this pump
is directed through a flow control valve (B) then
into the Cycle block. The Cycle block (Anodized
Gold) houses four cartridge logic valves (C)
and one relief valve (D) and is located on top
center of the hydraulic fluid tank (83650). The
cartridge logic valves are required to duplicate
the functions of a spool type four-way directional
valve. By controlling the opening and closing of
each valve, four different flow paths are obtained.
The Logic valves are opened by venting the pilot
oil from the main pump to the tank through the
solenoid actuated pilot cycle valve (A).
Operation
The timing circuit (P) is the oil that is on the rod-
end side of the main cylinders. The oil from the
rod side on cylinder A when extending is forced
through the crossover tube located on the bottom
side of the cylinder next to the water-box and
causes the cylinder B piston to retract. While the
cylinder B piston is retracting, a constant flow of
make-up oil is supplied by bypass oil from the
cylinder A piston, thus overfilling the B cylinder.
This overfilling ensures that the cylinder B ram
will be fully retracted and ready to deliver a full
stroke. As the retracting piston reaches the end
of its stroke. It passes a crossover port.
When this occurs, the overfill oil is exhausted
through the crossover line and check-valve then
into the end cap, through the Cycle block and into
the tank. When the cylinder B ram starts to extend
it retracts the cylinder A ram in the same manner.
Note: Should the rams become out of sync simply
put the machine in pressure test mode. Through
the water-box window, observe the retracting
ram. When the ram has fully retracted, toggle
the Pressure Test switch to the normal (Pumping)
position.
The secondary pump is a tandem gear pump.
The pump is mounted piggyback style on the
main pump. The 1st stage pump (M) charges the
accumulator. (Q) Flow from this pump is directed
through the Control block to the accumulator. (Q)
The Control block houses the unloading/relief
valve (F) and the unloading/check valve (E). The
solenoid operated accumulator dump valve (K)
must be energized by the PLC in order for the
accumulator to retain a charge. This is so that the
accumulator will automatically discharge when
the machine is shut down.
Note: The Western Shotcrete Equipment Warrior
Shotcrete Pump’s, frame No.109 and higher
are equipped with this automatic accumulator
discharging system that will discharge the
accumulator if the ignition key-switch is in the off
position, if the electrical system loses power, or
if the hopper grate is opened-NOT if the engine
stalls. (i.e. Engine runs out of fuel, is manually shut
off, etc.) The operator should not rely solely on this
system: he or she must use extreme caution when
working around the hopper.

13
The accumulator (Q) charge is directed through
the pilot operated directional valve (H) then into
the swingtube-actuating cylinder. (R) The pilot
operated directional Valve is controlled by pilot
oil from the solenoid operated pilot control valve
(G), The solenoid operated pilot control valve is
controlled by the PLC.
The 2nd stage of the tandem gear pump (N)
powers the Remixer motor (S) and/or the jack
stands. (T) The oil from this pump (N) is directed
through the hand operated triple spool valve
with a built-in relief valve (U) then to the Remixer
motor (S) and/or the jack stands. (T) The oil is then
routed to the hydraulic fluid storage tank through
the oil cooler and the 10-micron filter.
The system has two electrically powered
proximity sensors* (V) that send a signal to the
PLC when the cylinder piston has reached the
end of its stroke. The PLC also receives signals
from the operator control panel. The PLC then
automatically controls the switching of the
solenoid operated pilot cycle valve (A) and the
solenoid operated pilot control valve (G) to pump
a smooth flow of concrete in forward or reverse
depending on the operators input.
Valves
Setting the main relief valve 83301 (Sun RPGC-
FCN):
• Loosen locking nut with a 9/16” wrench.
• Turn adjuster all the way out.
• Start engine, place in pressure test mode, turn
pump on and observe main hydraulic pressure
gauge.
• Turn adjuster in until the pressure gauge stops
climbing. (It should stop climbing when it reaches
the pump setting at 3800 psi.)
• Turn adjuster In an additional 1/2 turn and
tighten locking nut.
Setting the Unloader/Check valve 83410 (Sun
QCDB-LAN) and the Unloader/Relief valve. 83411
(Sun RVCA-LAN):
• Loosen locking nuts with a 9/16” wrench.
• Screw top valve (Unloader/Check-83410)
adjuster all the way in using a 3/16” hex key.
• Screw the bottom valve (Unloader/Relief-83411)
adjuster all the way out.
• Start engine and observe accumulator pressure
gauge.
• Screw the bottom valve (Unloader/Relief)
adjuster in until the accumulator gauge reads
2200~2500 psi.
• Screw the top valve (Unloader/Check) adjuster
out until the pump unloads then turn out an
additional 1/4 turn. You can tell when the pump
unloads by three ways:
a) Listening for a slight clicking noise in the
Unloader/Relief valve.
b) Hearing the engine work less.
c) Seeing the accumulator charge hose relax.
• If you have difficulty determining when the pump
unloads, place a 4000# gauge in-line at the pump
output. When the pump unloads the gauge will
drop from 2500 psi to near 0 psi.
• Tighten locking nuts.
• Test operation by shifting S-Tube with
the Forward/Reverse switch and observing
Accumulator gauge. The pump should promptly
charge the Accumulator to 2300~2500 psi and
then unload.
Accumulator
WARNING
Use dry nitrogen gas only to pressurize the
accumulator bladder. NEVER use compressed air.
The use of compressed air or any other unstable
gas can cause a fire or explosion resulting in
serious injury or death.
An accumulator stores hydraulic pressure. This
hydraulic pressure is potential energy since it can
change to kinetic energy.
The Warrior Shotcrete Pump is equipped with a 1
gallon bladder type accumulator (83500) rated @
5000 psi maximum.
A bladder type accumulator consists of a synthetic
rubber bladder inside a metal shell: the bladder
contains the nitrogen gas. As hydraulic fluid enters
the shell, gas in the bladder is compressed. Gas
pressure decreases as fluid flows from the shell.
When all fluid has been discharged, gas pressure
attempts to push the bladder through the outlet.
But, as the bladder contacts the poppet valve at
the outlet, flow from the shell is automatically shut
off.
Since the charged accumulator is a source of
hydraulic potential energy, stored energy of an
accumulator can be used to develop system
flow when system demand is greater than

14
pump delivery. This is the case for the S-Tube
valve actuator circuit. Since the actuator cycles
infrequently, a small displacement pump (33701)
is used to fill the accumulator over a period of
time. When the moment arrives for the S-Tube
valve to operate, a directional valve (83402)
is shifted downstream and the accumulator
delivers the required pressurized flow to the 2.5”
x 5” actuator (83708). Using an accumulator in
combination with a small pump in this manner
conserves peak horsepower. For instead of
using a large pump/motor to generate a large
horsepower all at once. The work can be evenly
spread over a given time period.
Operating Procedures
Positioning of the shotcrete pump will, of course,
differ from job to job. The operator must determine
how close the machine can be placed to the work
location while still providing good access to ready-
mix trucks. After a relatively flat location is found,
the outrigger legs must be extended to isolate the
machine’s road suspension from the weight of the
loaded hopper.
WARNING
The operator must carefully determine that
personnel and/or equipment are clear of the jack
stand feet before extending the hydraulic jack
stands.
Start up
An important part of pumping is the proper
lubrication of the pipeline and/or hose system at
the start of the pour. More downtime has been
caused by inattention to this detail than any other
reason.
First, the hopper must be wetted. Then a rich,
sloppy grout must be introduced to the hopper
and slowly pumped into the pipeline system. The
grout should be a 1:1 sand/cement mix about
the consistency of thick soup. It coats the pipeline
system ahead of the concrete mix and prevents
packing or bleeding of the material to be pumped
when it is introduced to the line.
The amount of grout depends on the length of
line and its diameter. The minimum is 5 to 6 cubic
feet for short runs of small diameter line. It can be
a cubic yard or more for several hundred feet of 5”
line. Experience will indicate the proper amount,
Operation
but it is always safer to have too much rather than
too little.
A small amount of grout should be kept in the
hopper and blended with the mix to provide a
transition into the pumping operation.
Before turning the pump on, push the Flow-Control
lever down to a minimum level. This will set the
hydraulic pump output to minimum. Use the
throttle control to set the engine speed to about
1800~2200 rpm. Make sure that the Forward/
Reverse switch is set to “FWD” and the Pressure
Test switch is set to “Pumping”. Turn the pump on
by setting the pump switch to the “ON” position.
Slowly push the Flow-Control lever up to increase
the pumping rate. As the mix is starting to flow
through the line careful attention must be paid
to pump pressure to see If a plug or blockage is
forming. Only after this should the pump speed be
increased to the planned operation rate.
Note: The Warrior shotcrete machine is designed
to develop a theoretical pressure of 1870-psi at
the discharge outlet of the machine. Although
the average pumping pressure will normally be
somewhat less than the maximum, remember that
the pressure on the concrete is a 2.25 to 1 ratio to
the hydraulic pressure gauge on the control panel.
For example, when the hydraulic pressure gage
reads 2000-psi. ( 2000 /225 = 889 ) The actual
concrete pressure at the 5” outlet flange is 889 psi.
The transport system must be capable of
withstanding the maximum pumping pressure
of 1870 psi. (Check with the manufacturer on
products not supplied by Western Shotcrete
Equipment.)
Pressures are highest at the pump’s 5” outlet flange
and reduce uniformly to zero at the discharge
end of the transport line under normal pumping
conditions.
WARNING
If a dry-pack or blockage does occur in the
delivery system, pressures up to 1870-psi will
be developed and contained within the entire
delivery system from the pump to the point
of pack or blockage. USE extreme cautionary
procedures under these conditions.

15
WARNING
It is the responsibility of each pump owner/
operator to check with the manufacturer of the
delivery system pressure capability that is not
supplied by Western Shotcrete Equipment. Failure
to observe these guidelines can result in serious
personal injury and/or damage to equipment.
Western Shotcrete Equipment recommends only
the usage of shouldered or heavy-duty pipeline
system, hose, and clamping devices that are
specifically designed for high-pressure concrete
pumping applications.
Clearing a Dry Pack
When a block or dry-pack occurs in the delivery
system, the pumping pressure gauge will reach the
maximum 4200-psi. Immediately switch the pump
off. Switch the swingtube from forward to reverse,
pump at least two or more strokes in reverse to
relieve the pressure from the dry-pack back to the
concrete pump. Shut the pump off.
WARNING
It is possible there will still be pressure contained in
the delivery system. Extreme caution must be used
when opening the clamping devices on any part of
the delivery system.
Warn all persons in the immediate area of this
danger. Clear the area of persons prior to opening
the clamp and protect eyes and body while opening
clamp.
After the dry-pack has been cleared and the
reducer, pipeline, and/or hose system restored,
return the swingtube to forward. Start the pump up
at a low volume rate until a steady flow of material is
being pumped.
WARNING
Never attempt to clear a pack in the transport
system with pump pressure.
Shut Down & Clean up
It is very important that the operator knows and
follows the correct procedure for cleaning the
machine. Because there are moving parts in the
hopper, the operator must use caution when
cleaning the machine. The operator MUST USE
EXTREME CAUTION when using his or her hands
to clean in the hopper area. When it is necessary to
clean out the hopper or swingtube, the operator
must shut down the engine and carefully determine
that the accumulator has discharged. The operator
must also warn anyone that may assist him in
cleaning the machine.
Clean the machine in the following manner:
1) Pump the remaining material out of the hopper
until it is half empty, and then turn the pump off.
2) Add enough water to the material in the hopper
to make a thin slurry.
3) Switch the swingtube to reverse and turn the
pump on. The reverse pumping will cause the water
to mix with the material to form a thin slurry.
4) Pump the slurry through the line followed with
water.
5) Remove and thoroughly clean the hopper clean-
out door.
6) With the pump turned on and in reverse
pumping, turn a water hose into the discharge
outlet. This will draw water into the concrete
cylinders and push rock and sand out through the
hopper door.
7) Before cleaning the inside of the hopper the
operator must shut down the engine and carefully
make sure that the accumulator pressure is
fully discharged. Check that the accumulator is
discharged in the following manner:
a) With the engine shut down, turn the ignition key-
switch to the on position.
b) Turn the pump switch to the on position.
c) Repeatedly switch the swingtube from reverse to
forward until the swingtube no longer shifts.
8) Clean the hopper out using a stiff brush and
water.

16
Operation
WARNING
THE OPERATOR SHOULD NEVER PUT HIS OR HER
HANDS IN THE CYLINDERS!
9) Start the engine and turn the pump on.
Cycle a few times to make sure there is no material
left in the cylinders.
10) With a bent rod or broom handle remove
any build up of material.
11) Clean the clean-out door opening. The
clean door and opening must have a good seal.
(Not leak water) If the seal is not good the pump will
suck air through it instead of concrete- resulting in
partially filled material cylinders.
12) Lubricate the pump module at these five
locations:
a) Flange Bearing.
b) S-Tube shift Cylinder Base.
c) S-Tube shift Cylinder Yoke.
d) Remixer Housing.
e) Outlet Flange.
It is important to lubricate the pump module after
clean up. This pushes out water, cement, and other
contaminants before they can harden. Failure to
lubricate the pump module properly even once
will cause premature wear and or damage to the
machine resulting in expensive downtime.

17
Maintenance
Hydraulic Oil Tank
Hydraulic Oil: AW-68 Oil
X500, 500, 600: 60 gallons
Service Interval: Every 1000 hours or 1 year.

18
Oil/Filter Change Intervals
Engine Oil: 15W-40
API Service: CJ-4, CI-Plus, CI-4, CH-4, SN A
Service Interval: Every 500 hours or 5 months.
Maintenance

19
Diesel Tank and Prime

20
DEF Tank
Maintenance