INSTRUCTION

MANUAL
PC20
ELECTRIC

ALLENTOWN SHOTCRETE TECHNOLOGY, INC

421 SCHANTZ ROAD
ALLENTOWN, PA. 18104
800-553-3414
610-398-0451
Fax 610-391-1934

INSTRUCTION
MANUAL
PC20
ELECTRIC

ALLENTOWN SHOTCRETE TECHNOLOGY, INC

421 SCHANTZ ROAD
ALLENTOWN, PA. 18104
800-553-3414
610-398-0451
Fax 610-391-1934

WARNING
DO NOT ATTEMPT TO OPERATE
THIS EQUIPMENT WITHOUT A
THOROUGH UNDERSTANDING OF THE
OPERATIONAL, MAINTENANCE AND SAFETY
CONSIDERATIONS CONTAINED IN
THIS TECHNICAL MANUAL.

TO PREVENT DAMAGE TO
EQUIPMENT AND/OR INJURY TO YOURSELF
OR OTHER PERSONNEL, THESE
INSTRUCTIONS MUST BE
FOLLOWED CAREFULLY.
A COPY OF THIS MANUAL SHALL ACCOMPANY THE UNIT AT ALL TIMES.

FOR PARTS AND SERVICE PLEASE

CALL OUR TOLL FREE NUMBER

PARTS: 800-553-3414 Ext. 214

SERVICE: 800-553-3414 Ext. 213

For best assistance, please have the equipment

Model and Serial Numbers available at time of
inquiry.
The Model Number and Serial Number are
available on the equipment Data Tag attached to
the frame of the equipment.

Record the following information on this equipment

below:
Model No. ________________________
Serial No. ________________________
Date Purchased ___________________

TABLE OF CONTENTS PC20 ELECTRIC

PAGE
INTRODUCTION

SECTION I - SPECIFICATIONS
DATA TAG

1-1

SECTION II
OPERATIONAL SAFETY ..
OPERATOR QUALIFICATIONS ..
RESPONSIBILITY OF EMPLOYERS AND OWNERS ..
PRINCIPLE OF OPERATION .
HYDRAULIC SYSTEM - INTRODUCTION ..
HYDRAULIC COMPONENTS ..
HYDRAULIC SYSTEM .
OPERATOR CONTROLS .
HYDRAULIC TANK .
INTERLOCK SAFETY SYSTEM .
DAILY SAFETY CHECK
SET-UP OF EQUIPMENT
OPERATION OF EQUIPMENT
START UP PROCEDURE
FUNCTIONAL CHECK .
LUBRICATING THE MATERIAL DELIVERY LINE
PRECAUTIONS DURING OPERATION
CLEARING MATERIAL PLUGS ..
CLEAN UP. ..

2-1
2-4
2-5
2-6
2-7
2-8
2-9
2-10
2-13
2-14
2-15
2-15
2-18
2-18
2-19
2-20
2-21
2-24
2-25

SECTION III - MAINTENANCE

MAINTENANCE INTERVALS ..
WEAR PARTS REPLACEMENT & ADJUSTMENT
PROXIMITY SENSOR ADJUSTMENT .
RECOMMENDED LUBRICANTS .
TROUBLESHOOTING ..
ELECTRIC SCHEMATICS .

3-1
3-3
3-7
3-8
3-10
3-14

SECTION IV - PARTS CATALOG

MATERIAL PUMP
REMIXER ..
HARSH MIX HOPPER ..
OPERATOR CONTROLS
MICROPROCESSOR .
HYDRAULIC SCHEMATIC .
HYDRAULIC SYSTEM COMPONENTS .
MISCELLANEOUS COMPONENTS
SAFETY DECALS .

4-1
4-5
4-7
4-9
4-11
4-12
4-13
4-14
4-16

INTRODUCTION
The Allentown Powercreter pump is a high-pressure, hydraulically powered piston pump
for the mixing, pumping, or spraying of concrete, grout, mortar, and refractories. This
manual describes the operation, maintenance, and safety considerations that must be
followed. Close attention to these details by the operator and maintenance personnel is
necessary to assure a minimum of problems while striving for maximum productivity and
safety.

Pump operation is dependent on the pumpability of the material to be pumped.

Pumpability can be defined as the combination of physical properties - of both the
material and pump - which determine if the material will flow into the inlet chamber of
the pump and can therefore be discharged. The physical properties of the material
which, in varying degrees, determine its pumpability are: water content, size of
aggregate and gradation, slump, viscosity, density, presence of reinforcing fibers, and
the presence of additives that improve pumpability or influence set time. The Allentown
Shotcrete Technology sales department will provide application assistance to determine
the Powercreter that best suits your application needs. Call 1-800-553-3414.

Prior to pump operation, the operator must be thoroughly familiar with the operation of
the equipment so that it can be used in a safe manner. After the operator has gained
experience in the safe operation of the equipment, he or she can work toward high
volume concrete placement. For the safe operation of this equipment, the qualifications
for, and the conduct of the operator, should be as described in Section 2.

SPECIFICATIONS
The specifications for this unit with all applicable data are provided on the units DATA
TAG, usually located inside the motor starter box.

1-1

OPERATIONAL SAFETY
Any person assigned to operate, troubleshoot, maintain or repair the Allentown pump,
must be thoroughly familiar with the operating and safety instructions. Your safety and
the safety of others are at all times very important. To work safely, you must
understand the job you do. If in doubt, use extreme caution and obtain assistance from
trained personnel.
The Allentown pump is constructed with safety features for operating personnel,
however, construction features alone cannot ensure complete safety. Safe work
practice, observance of O.S.H.A. regulations, specific work methods and procedures,
timely maintenance and an alert, well-trained operator are all factors contributing to safe
operation. In order to highlight the situations which have historically been the cause of
accidents, the information in this manual addressing safety is preceded with a graphic
symbol to identify the principal hazard. Within the frame of the graphic symbol, the
following signal words indicate the likelihood of occurrence and the degree of potential
injury or damage. If in doubt about this classification, assume the worst case since
some hazards, which are minor at the time of occurrence, can develop into hazards with
a severe degree of potential injury or damage.

SIGNAL WORD

LIKELIHOOD OF OCCURANCE

DEGREE OF POTENTIAL
INJURYOR DAMAGE

DANGER

Will occur if warning is ignored.

Severe

WARNING

Can occur if warning is ignored.

Severe

CAUTION

Will or can occur if warning is ignored.

Minor

Various hazards and their usual causes are described below and shown with the
associated graphic symbol. The graphic symbols associated with any of the signal
words are repeated throughout this manual when the likelihood of the hazard exists.
The symbol provides an index permitting reference to this section for a more extensive
discussion of the hazard.

2-1

Never open or remove the hopper grate when the pump is in

operation. It protects against contact with moving parts that are
capable of amputating the fingers or hand. Serious injury can
occur.

The hydraulic system of the Allentown pump operates under high

pressure. A pinhole type leak can form a fine stream of hydraulic fluid,
which can penetrate skin, fill a large area under the skin, and cause
serious infection. This hazard can be avoided by keeping the body
parts away from the surfaces of pressurized hydraulic hoses. Feeling
with hands for the source of leaks is generally the cause of accidents
from this hazard.

The mechanical linkage located on the side of the mixer, opposite

the dump control valve, positions the mixer grate when the mixer is
dumped. Because of the relative motion of this link, the mixer drum
and the hopper produces a scissors movement which can pinch
anything in its path. Confirm that this area is clear of all personnel
when operating the mixer. Severe bodily injury can occur to any
body member pinched.
Reliable operation of this equipment is dependent on proper
operation, scheduled cleaning, and maintenance. Failure to follow
instructions can result in accelerated wear or equipment failure.
During operation, repair, or troubleshooting, problems may arise that
seem singular but may be due to several causes. The information in
this manual should be used to assist in the safest and best manner to
operate the pump. Use caution and safe methods in the repair and
operation of the equipment.

2-2

The rapid release of a blocked hose can cause a material hose to whip
or move abruptly with potential injury to personnel. Do not attempt to
dislodge a blockage with increased or continued pumping pressure.
Dislodge the blockage as instructed in the Clearing Material Plugs
section of this manual. Only trained personnel should be permitted to
handle the material hose.

The hydraulic system of the Allentown pump operates under high

pressure. Fluid at high pressure will discharge at a high velocity if the
hydraulic system is opened to atmosphere by venting, loosening of
flange bolts, removing fittings, etc., when the power source is operating.
Until discharged, the accumulator has a stored charge of oil under
pressure that operates the swing tube cylinder. Stop the motor of the
material pump and allow sufficient time for the accumulator to
discharge. Confirm discharge by checking the pressure gauge, which
should read 0 PSI. When removing fittings or removing any hydraulic
component, wear safety goggles and cover the joint from which
hydraulic fluid will discharge, using a large cloth to absorb and
discharge the fluid. If hydraulic fluid gets in the eyes, flush with a
generous amount of clean water and consult a physician.
In the case of a blocked material line, never open any of the couplings
in the material delivery line without first reversing the pump and
pumping backward to remove pressure in the system. Discharge can
propel particles at high velocity, capable of eye damage. If eye
protection is not worn, serious eye injury can result.

Never put hands in the lubricating wash box when the pump is
operating. Oscillating linkage can amputate the fingers or hand.
Severe injury can result. Never work on any part of the pump that is in
motion while the motor is running. Take time to stop the motor and turn
off/disconnect power supply.

2-3

OPERATOR QUALIFICATIONS
Before operation, the operator must be thoroughly familiar with the equipment and its
operation so that he can operate it in a SAFE manner. His eligibility to operate the
equipment must be based on the following qualifications:

1. Equipment must be operated only by experienced operators or trainees under

the direct supervision of an experienced operator. Unauthorized personnel
must not be permitted to assist or remain in the immediate vicinity of the unit
while it is in operation or during the performance of any maintenance,
inspection, cleaning, repair, or start up operations.
2. Individuals who are not familiar with operating instructions, have not received
on-the-job supervised training, and are not familiar with the signal codes used
at the construction site must not operate equipment.
3. Individuals who cannot comprehend the signs, notices, and operating
instructions that are a part of the job must not operate equipment.
4. Equipment must not be operated by anyone under the age of 21 years.
5. Equipment must not be operated by anyone with seriously defective eyesight
or hearing, or anyone with physical or mental impairment (such as epilepsy,
heart disease, or progressive neuro-muscular deterioration). Physical and
mental qualifications must be verified by a physical examination at least
annually.
6. Individuals under the influence of alcohol or drugs shall not operate this
equipment.
7. Equipment must not be operated while operator is eating, drinking, reading, or
is more than six feet distance from the controls.
8. An operator who has asked to be relieved because he feels physically or
mentally unfit must not operate equipment.

2-4

RESPONSIBILITY OF EMPLOYERS AND OWNERS

As an owner or employer using this equipment, it is your responsibility to ensure that the
operator is qualified, has read this manual, and has received training in the safe
operation of the Allentown pump, and the safe work practices for the job to be
accomplished. It is also your responsibility to provide for regularly scheduled
preventative maintenance and repair of the pump by trained repair personnel using only
parts supplied by Allentown Shotcrete Technology. Modification of any part of this
pump can create a new safety hazard. If the pump is modified or rebuilt it must be done
under the direction of the Allentown Shotcrete Technology Factory. No field
modification of the pump is permitted, unless authorized in writing by Allentown
Shotcrete Technology.

It is further the responsibility of the owner or employer to train the operating personnel in
all the specific requirements, government regulations, safety regulations, safety
regulation of the product liability insurance company, precaution, and work hazards
which exist in a work situation and ensure that all involved take the necessary
precautions and safety measures. Only a trained and qualified operator who abides by
safe work practices can avoid accidents.

2-5

PRINCIPLE OF OPERATION

MATERIAL PUMP

THE MATERIAL PUMP

The material pump consists of a receiving hopper and two material pumping cylinders
and pistons that are driven by two hydraulic cylinders and a swing tube valve. A
continuous flow of material through the delivery line is produced by the sequential
operation of the two material pistons with the swing tube. The swing tube shifts
between the two material cylinders under a controlled electronic/hydraulic sequence to
direct the flow between the two material cylinders, the hopper, and the discharge outlet.
The swing tube allows one material cylinder to be directly open to the hopper on the
suction stroke, while simultaneously the other cylinder is directly connected through the
swing tube to discharge. At the end of the piston travel the direction changes and the
swing tube is shifted to direct the material flow from the other cylinder to discharge.

2-6

THE HYDRAULIC SYSTEM PC20 ELECTRIC

INTRODUCTION
The PC20 has a three pump hydraulic system. The first pump, which is the first main
pump coupled to the electric motor, is a variable displacement piston pump. This pump
powers the hydraulic pumping cylinders. These cylinders are controlled through a
directional valve, which is operated from the processor controls. The processor controls
gets signals from the proximity switches that are located in the wash box. Each
retracted stroke of the hydraulic pumping cylinder will signal the processor controls to
switch direction. The next two pumps are mounted directly to the first pump. This is a
double gear pump. The first section of the gear pump supplies oil to the accumulator
manifold, which powers the hydraulic cylinder that operates the switch of the swing
tube. The second gear pump operates the hopper remixer motor. A single spool valve
located off the hydraulic reservoir operates the blending paddles. For the hydraulic
component P/Ns, please see the Hydraulic Schematic with its parts list in this manual.

GEAR PUMP
FOR REMIXER

GEAR PUMP FOR

ACCUMULATOR MANIFOLD

2-7

MAIN PUMP FOR

PUMPING CYLINDERS

HYDRAULIC SYSTEM COMPONENTS

PROXIMITY SENSORS

PROPORTIONALLY CONTROLLED
PUMPING VALVE WITH MANUAL
OVERRIDE CONTROL HANDLE

HYDRAULIC OIL COOLER,

THERMOSTATICALLY CONTROLLED

RETURN FILTER
WITH GAUGE

REMIXER CONTROL
VALVE

PRESSURE
SWITCH

ACCUMULATOR

ACCUMULATOR MANIFOLD
ASSEMBLY
FILLER BREATHER CAP

SWING TUBE HYDRAULIC CYLINDER

2-8

HYDRAULIC SYSTEM
PUMPING CYLINDERS
The two hydraulic cylinders are linked by means of a cross over loop system. This
cross over loop is located on the rod side of the cylinders. As one cylinder is pumping,
powered from the piston side, the oil on the rod side is being forced out over to the other
cylinders rod side, thus forcing the other cylinder to retract. See Fig. 1. When the
cylinder that is being retracted meets with the proximity sensor, which is detected by the
piston adapter, the system will switch and run the opposite way. To ensure that there is
equal and full travel of both cylinders, there are four check valves located internally of
both cylinders (two/cylinder) which add oil to the side that is being pushed back to make
certain a full retraction is made. These check valves prevent short stroking.

ACCUMULATOR (SWING TUBE) CIRCUIT

The hydraulic cylinder switching the swing tube is powered through an accumulator
assisted circuit. When the Pump Motor/Mixer button is pressed, the main pump motors
will turn on sequentially. Ten seconds after the electric motor/diesel engine starts, the
manifold On/Off Valve closes to charge the accumulator to a preset pressure. Once this
pressure is reached, which is determined by a pre-set pressure switch, the system will
hold this pressure by means of a check valve that is in the manifold. The On/Off Valve
will switch, sending oil back to the tank. At this point, the system will hold and wait for
the first response from the processor signaling to switch. After switching, the system
will recharge, hold, and wait for the next signal. When the machine is turned off a Dump
Valve in the manifold will slowly discharge the pressure from the accumulator back to
the tank. There should be no pressure reading on the gauge.
Note: while the charged accumulator circuit is holding for its signal, and that response
takes a long period of time, it is common for the system to turn on and off to recharge
the accumulator to its preset pressure. The pressure switch has a differential pressure
setting of 100 to 200 psi.

2-9

OPERATOR CONTROLS

9
1

10
11

17

12
16

15

14

13

2-10

OPERATOR CONTROLS

1.

Pressure test Switch This switch must be in the Pump position for normal
operation. If held in the Pressure Test position, the pump will make one stroke,
stop at the fully extended stroke, and the pump will be at maximum pumping
pressure with the flow control fully open.

2.

Start/Stop Remote Switch This switch will turn the pump on or off at the Control
Panel or, when in the Remote position, the pump can be turned on or off using
the remote control cable. In an emergency the remote can be overridden by
placing the switch in the center Off position.

3.

Forward/Reverse Switch The Forward/Reverse switch is used for manual

forward or reverse pumping. Forward sends material out; reverse will pull
material back or relieve line pressure.

4.

Manual Cycling Switch This switch provides a manual override of the automatic
cycle of the pumping cylinders. Each time the switch is toggled the material
pump goes through alternate strokes of the material cylinders, overriding the
proximity sensors. In the event of a failure of the automatic cycle control circuit
during pumping operations, the switch will permit manually controlled pumping.

5.

Potentiometer (Flow Control Dial) This dial controls the output of the material
pump. To adjust the output, slowly turn the dial clockwise to increase output and
counterclockwise to decrease output.

6.

Hour Meter Displays the number of hours of pump operation.

7.

Main Power Indicator This indicator lights when there is power to the system.
The main disconnect has been switched to the on position.

8.

Phase Reversed Indicator This indicator lights when the start motor button is
pressed and the incoming power phase lines are reversed in hookup. This will
indicate that the electric motor will be trying to run in reverse.

9.

Control Power On and Indicator By pressing the On button, the

microprocessor for the pump will become energized and its indicator light will
come on. It takes approximately five seconds for the microprocessor to become
energized.

10.

Emergency Stop Pushing on the palm button shuts down the system and,
consequently, all power to the motor. To restart the pump the switch must be
reset by pulling the knob out.

2-11

OPERATOR CONTROLS

11.

Pump Motor Start, Stop, and Indicator Pressing the Start button will start the
electric motor that powers the pumps, which, in turn, operates the
accumulator/swing tube circuit and the flow control/pumping rams circuit. To turn
the pump off, press the Stop button. The indicator light will then turn off.

12.

Manual Lube Switch Pushing this button will operate the automatic lubrication
device and activate the preset lube cycle. This manual button is to be used at
the end of the day after the equipment has been cleaned or during operation
when the auto lube is in between its automatic cycle.

13.

Remote Control Socket The remote control cord is plugged into this socket. In
order to avoid unintentional operation of the machine, set the material pump
switches that are located on both the operator control box and the remote to the
neutral positions prior to any switchover from local to remote and vice versa. The
same applies to connection and disconnection of the remote control.

14.

Pump Pressure Gauge This gage will indicate the pressure to pump the
material when the Pump Start Switch is held in the start position. The resulting
material pressure is a function of the diameters of the pistons of both the
hydraulic and material cylinders. See Figure 2 and the pumps data tag for
maximum material pressure.

15.

Accumulator Pressure Gauge This gage indicates the pressure of the Swing
Tube Manifold and the Pilot Valve.

16.

Fault Indicator Light This light will illuminate when the remixer grate is lifted and
the safety locking pin is pulled out. This will shut down pump operations. After
closing the grate and pushing in the pin, the accumulator will recharge and the
pump will be ready for production in a few seconds.

17.

Stroke Counter The stroke counter counts the number of strokes of the material
pump and has a reset to zero button.

2-12

HYDRAULIC TANK

Oil Level Gauge

Temperature Gauge

Hydraulic Reservoir Oil Level Gauge Never operate the pump when the oil level is not
visible in the sight tube. Periodic inspection of the oil level during pump operation and
after shut-down is a recommended practice. This will protect against accidental loss of
oil. When the pump is running the oil level should be at mid-point in the sight glass.

Hydraulic Oil Temperature Gauge The normal range of the hydraulic oil temperature is
100 F to 160 F. Oil temperature of less than 50 F is in the cautionary range. The
material pump should not be operated at full output until the oil reaches temperatures
above 50 F as hydraulic pump damage may occur. Oil that is below 10 F should be
preheated by running the motor with the material pump turned off.

2-13

INTERLOCK SAFETY SYSTEM

The purpose of the Interlock System is to prevent operation of the swing tube if the
hopper grate is opened.
The interlock is achieved with a two position, normally open limit switch that is activated
by a roller plunger. In the normal running position this switch is held in the closed
position by the Locking Pin. When the grate is closed and the pin is pushed in and
locked, normal pump operation can take place. Pulling out the pin in order to open the
hopper grate will open the limit switch and shut down pump operations. After closing
the grate and pushing in the pin, the accumulator will recharge and the pump will be
ready for production in a few seconds.
Before adding material to the hopper, turn on the pump and verify that the limit switch is
operating properly. DO NOT operate the pump if this switch is not functional. It should
be repaired or replaced immediately. DO NOT attempt repairs with the diesel engine
running.

WARNING the rotating components in the hopper can cause

severe bodily injury. Do not operate this equipment without the
safety interlock system operational.

Limit Switch
Locking Pin
ITEM
1
1

QUANTITY
1
1

PART NUMBER
14311
03318

DESCRIPTION
LIMIT SWITCH
LOCKING PIN

2-14

DAILY SAFETY CHECK OF EQUIPMENT

1. Equipment must not be operated at any new site or at the start of a new shift until
a safety check is made of the condition of the equipment.
2. Equipment must have a sign-off sheet attached to the unit where an operator can
report any damage, defects, problems, or accidents to the next shifts operator
and work supervisor.
3. Confirm that the unit has received scheduled lubrication. See Maintenance
Intervals in this section. Inspect the wash box to ensure it contains a lubricant.
4. Walk around the unit and inspect for damaged or missing parts. All safety
devices and provisions to protect against accidents such as warning labels,
decals, safety guards, etc. must be in place. Do not remove or alter any of these
items and replace any which are missing or defective. Safety Decals will be
replaced free of charge. See the parts section of this manual. Visually inspect
air and hydraulic hoses for indications of leaks or damage. Confirm that no
foreign objects are in the hopper or lubricating wash box that would interfere with
operation.

SET-UP OF EQUIPMENT Locating the Equipment on the Jobsite

1. Locate the material pump on the most level ground possible.
2. Prior to placing equipment, check the condition of the soil. Keep sufficient
distance from excavations or slopes.

SET-UP OF MATERIAL DELIVERY LINE

1. It is the responsibility of each pump owner/operator to check the material delivery
system pressure capacity with the manufacturer if these components are not
supplied by Allentown Shotcrete Technology. Failure to observe these
specifications can result in serious personal injury and damage to the equipment.
Allentown Shotcrete Technology recommends the use of only shouldered or a

2-15

Heavy Duty pipeline system, hose and clamping devices that are specifically
designed for material pumping applications. Allentown Shotcrete Technology
has connection packages available for the material pump which contain
couplings, reducers, material hose, air hose, nozzles, tips, and clean-out balls.
Contact our sales department for additional information.
2. The inside diameter of the material pumping pipeline must be at least three times
the size of the largest aggregate in the mix, and, with some difficult mixes, four
times the size. For example, a difficult mix must have a three inch line to pump
3/4 inch aggregate material. The larger the line diameter, the less pump
pressure will be required, or a higher output rate can be achieved with a large
line at the same pressure.
3. Ideally, using the same size pipeline as the size of the material cylinder will allow
very low pressure pumping at long distances. From a practical standpoint, the
larger the line, the heavier and more difficult it will be to set up, place, and clean
up. Utilize as little reduction as possible in the line. Additionally, long reducers
use less pump output pressure than short reducers.
4. The material delivery line should be set up using a minimum of rubber hose since
rubber hose has three times the resistance to material flow as compared to steel
pipe. One length of rubber hose at the discharge end of the delivery system will
provide flexibility for changing the discharge point and provide the capability to
bend the hose for downhill pumping.
5. The most direct line from the material pump to the placement site should be
used.
6. Clamp type flanges should be clean and have seals that will retain the slurry in
the delivery line.
7. Horizontal pipelines must be adequately supported. Support the pipeline
attached to the pump outlet. If the material system crosses rebar, support the
pipe/hose so that it does not contact the rebar.
8. If the jobsite has a vertical material delivery system, the vertical pipeline should
be anchored to the building every ten feet of height.

2-16

9. Place the hoses or pipe in sufficient length to reach the farthest delivery point. It
is easier to remove sections than to add additional sections after pumping has
begun.
10. Material will flow with less back pressure through pipe than through hose. Bends
in the hose or elbows in the delivery line will require more pressure. These
conditions should be taken onto consideration when laying out the delivery
system.
11. Vertical and downhill pumping are more difficult than horizontal pumping.
Vertical pumping requires higher pumping pressure while downhill pumping can
cause separation of the material which may result in a blockage in the material
delivery line.
12. When laying pipeline, utilization of as few elbows and reducers as possible is
recommended.
13. Replace any worn or damaged hoses, pipeline, or couplings immediately.
14. In hot and/or dry weather, pre-soak the hose in water to avoid absorption of
moisture from the pumped material.
15. Spray a release agent such as WD-40, Form Oil, or Kleen Kote on all accessible
parts that will be in contact with the pumped material to ease clean up after
operation. Do not use diesel fuel as this has a negative effect on the hopper
seals as well as other components.

2-17

OPERATION OF EQUIPMENT
Connecting AC Power to the Pump
The electrically powered Powercreter Pump can be supplied with a power cable to
connect to a power supply. Have a qualified electrician install the cable between the
motor control box and the power supply in accordance with local code. Hookup with an
undersized power cable will limit power to the machine which can result in reduced
performance and/or damage to the motor and control box. When the disconnect switch
is in the on position, the green indicator light for the main power should be lit. If the red
Phase Reversed light comes on when the Motor Start button is pressed, immediately
turn off the machine. The electrician must switch two wires of the three phase power at
the power supply. In order to preserve the integrity of the motor starter panel, do not
interchange wires in the motor starter panel.
WARNING: Contact with High Voltage can result in serious personal
injury or death.

1.
2.
3.
4.

Confirm the daily safety check has been performed.

Verify that the pan mixer grate is lowered and in place.
Confirm that the Emergency Stop button is reset by pulling outward.
With the disconnect switch of the motor starter box in the on position, confirm
that the green indicator light for the main power on the control panel is lit. If the
red indicator lamp labeled Phase Reversed is lit when the motor start button is
pressed, two wires of the three phase power must be interchanged. See the
Connecting AC Power to the Pump in the previous section.
5. Push the Control Power start button. The green indicator should light. This will
energize the microprocessor.
6. Wait at least five seconds then press the Motor Start button.

NOTE: Once the system is running, the accumulator system will automatically
charge after about ten seconds. Once charged, there should be a
reading on the accumulator pressure gauge of the preset psi charge. If
this does not happen, shut down motor and follow start up procedure
again.

7. In cold weather starts, let the pump run until the hydraulic oil temperature
reaches at least 50 F. Once the oil reaches this temperature, pump operation
can continue.

2-18

FUNCTIONAL CHECK
Once the motor is running and all conditions are ready to start production, a functional
check of the equipment and any optional accessories should be performed prior to
adding material to the hopper.

1. Check to assure the accumulator is charged and holding the preset pressure.
This pressure setting is recorded on the equipments data tag.

NOTE: It is common for the accumulator system to recharge periodically when

the pump is at idle. A slight internal hydraulic leakage within the system
is normal. Once the pressure deviates more than 100 to 200 psi, the
system will automatically recharge.

2. Check the swing tube oscillation. Toggle the Forward/Reverse switch to assure
that the swing tube moves freely.

CAUTION: Make sure that there are no objects in the hopper prior to
switching the cylinder.

3. To check the pumping cylinders:

Turn the pumping speed potentiometer dial to the 2 position.
Toggle the Pump Start switch and observe for automatic oscillation of
the pumping cylinders.
Toggle the Manual Pumping switch to confirm that the manual override
will function each of the pumping cylinders.
4. Actuate the remixer valve. Observe for the rotation of the remixer blending
paddles.
5. Turn on the pan mixer paddles using the pan mixer start switch. Raise the pan
mixer grate to confirm that the grate cut-out switch is operational. This switch
should stop the mixer rotation when the grate is lifted.
6. If there is an optional accelerator pump being used, make sure it is primed and
ready for operation. See the accelerator pump manual for start up instructions.

2-19

LUBRICATING THE MATERIAL DELIVERY LINE

An important prerequisite of pumping is the proper lubrication of the pipeline or
hose system at the start of the pour. Failure to lubricate the material delivery line
will contribute to the plugging of the line, resulting in excessive downtime to
clear plugs.

The choice of lubricating agents is dependent upon the physical properties of the
material being pumped. Contact the Allentown Shotcrete Technology parts department
for line lubricant.

First wet the hopper with lubricating agent and then slowly pump the lubricating agent
into the pipeline system. This will provide a smooth coating in the pipeline system
ahead of the material to be pumped while preventing bleeding and cracking of the
material. The amount of lubrication required will depend on the length of the line, the
line diameter, and the pumpability of the material being pumped. 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 large diameter line. Experience will indicate the proper amount
to be used although it is always safe to have too much rather than too little.

Once material is added to the hopper and begins to flow through the line, the hydraulic
pressure gauge and the flow from the material line should be monitored to ensure that a
plug or blockage is not forming. Only after pressure and flow are stable should the
pump speed be increased to the planned operating rate.

2-20

PRECAUTIONS DURING PUMP OPERATION

1. The operator and nozzleman must always wear eye protection and hard hats.
2. Do not operate the Allentown Shotcrete Technology pump without the hopper
grate mounted firmly in place. Never stand on the hopper grate or place any
parts of the body into the hopper while the motor is running.

WARNING: Failure to follow these precautions can result in serious

personal injury or death.

3. In the event of downtime during material placement, it may become necessary to

stop pumping. During these periods, the material should be moved every 10
to15 minutes. One method to move material is to reverse the pump and convey
backwards two or three strokes and then turn the material off for 10 to 15
minutes and then pump forward two or three strokes. If delays continue and the
material starts to set, it may become necessary to clean out the material delivery
system and the material pump. Experience with each application will determine
how long material can be safely held in the system before it becomes necessary
to clean out the delivery system and the material pump. If shut down periods
exceed 2 to 3 minutes, turn off the motor between moves to prevent separation
of the mix in the hopper due to vibration. Separation of the mix in the hopper can
cause a blockage in the delivery line when pumping is resumed.
4. When pumping long distances or stiff mixes, expect less volume than with
shorter lines and wetter mixes. Water leaking from hose coupling gaskets can
cause separation of the mix in the material line and subsequent blockage at that
point. Damaged hoses with internal restrictions can also cause blockages.

2-21

6. The maximum material pressure is a function of the maximum hydraulic pressure

and the areas of the hydraulic and the material cylinders. (See Fig. 2). Maximum
pressure is only obtained under a no flow condition. Average pumping pressure
will normally be somewhat less than the maximum. Pressures are highest at the
material pump outlet and reduce uniformly to zero at the discharge end of the
material pipeline under normal pumping conditions. Do not kink the material delivery
hose. If the hose is kinked during material placement or if a dry pack or blockage
does occur in the material delivery system, the flow of material will be stopped and
pressure will build up to maximum in the material delivery system to the point of the
blockage. If a plug has formed, follow the instructions in the Cleaning Material
Plugs section.

7. Downhill pumping can be difficult on some jobs. When the pump is stopped the
material can flow slowly in the material line and cause the hose to collapse. A plug
can form at the point of hose collapse. To prevent this, the hose can be kinked off
at the discharge while the pump is stopped. This will prevent the gravity flow. The
use of stiffer mixes when pumping downhill will also avoid gravity flow.
2-22

8. When pumping vertically up along the side of a building (above 40 ft.), installation
of steel pipe securely fastened at intervals of 10 feet to support the pipe column
is recommended. 90 long radius pipe sweeps should be installed at the top and
bottom of the steel line. A 25 ft. (or shorter) section of hose off the pump should
be used while the balance of the horizontal distance to the vertical line should be
pipe. This type of installation has been proven satisfactory on many jobs where
material is being pumped to heights in excess of 100 feet.
9. When using snap couplings with gaskets to join hoses, they should be washed
and cleaned after each use. Dip both the couplings and the gaskets into water
prior to use to permit easier installation.

If the delivery system is blocked for any reason, or

the line kinked at the start-up or during the pump
operation, the pump pressure could straighten out
the kink or force out the blockage. The rapid
surge of material could cause the line to whip or
move in such a manner that it may cause injury to
personnel.

10. A slight pulsation of the delivery hose near the pump will always be noticeable.
Excessive pulsation near the pump is normally due to higher than average line
pressure caused by stiff, harsh mixes or extremely long pumping distances. The
use of hoses with a larger internal diameter than specified in the Set-Up of
Equipment section will reduce the line pressure.
11. In order to reduce the line pressure, a slight amount of water may be added to
the mix. The use of an admixture may also help. (See the Admixture section in
this manual.)

2-23

CLEARING MATERIAL PLUGS

The probable causes for material plugs are:

Attempting to pump a mix that is not pumpable. See Introduction.

Failure to clean up after a previous pour. See Clean Up at End of Pour.
Poor pipeline set-up. See Set-Up of Material Line.
When a blockage occurs in the material delivery system, the pumping pressure gauge
will reach the maximum of the hydraulic system and the material will not flow from the
material line. To clear the plug:

Immediately stop the pump.

Switch the swing tube from Forward to Reverse.
Switch the pump to Start and pump two strokes in reverse to get the pressure at
the plug back to the material pump.

Switch the pump to Forward and observe if the plug is dislodged. If material is
flowing, slowly increase the volume to the desired output. If material is not flowing,
repeat the previous steps several times.

If Reverse pumping did not dislodge the plug, stop the pump and walk along the
hose until the point of blockage is found. The hose will be soft immediately past the
blockage. Elevate the hose at that point with the blockage hanging down. Shake or
hit the hose with a rubber mallet until the blockage is broken up.

Switch the pump to Forward and observe if the plug is dislodged. If material is
flowing, slowly increase the volume to the desired output.

If none of the above methods are effective in dislodging the plug, rotate the
section of line containing the plug end for end or replace the section with a clean
section of line.
Even after pumping in reverse, it is possible for sections or all of
the material in the delivery line to be under pressure. Clear the
immediate area of all personnel and wear eye and body
protection prior to opening any flanges. Open any clamps with
caution to slowly discharge any pressurized material. Start the
pump at a low volume rate until a steady flow of material is
being pumped.

2-24

CLEAN UP AT END OF POUR

Clean the pump as follows:
1. With the pumping speed set low, 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 hopper to make a thin slurry.
3. Place the Forward/Reverse switch to the Reverse pumping mode and turn the
pump on. The reverse pumping will cause the water to mix with the material and
form a thin slurry.
4. Switch the pump to Forward and pump the slurry through the line followed with a
mixer-load of water.
5. Open the hopper clean out door.
6. With the pump turned on and in Reverse pumping mode, turn on a water hose
and run water into the discharge outlet. This will draw water into the material
cylinders and push rock and sand out through the open hopper door.
CAUTION: Do not insert hose nozzle or hands into outlet while engine is
running.
If material remains in the hopper, turn off the pump. A solenoid
operated dump valve built into the accumulator circuit will
automatically discharge the circuit when the power is turned off.
Check the pressure gauge to ensure that it reads zero psi.
There are moving parts in the hopper and lubricating wash box.
The operator and any assistant must know and follow the correct
procedures and use caution when cleaning the pump. DO NOT
put hands or tools into hopper, outlet, or lubricating box while the
power is on. Use the clean out tool supplied with the pump to
clean the outlet and swing tube area.
7. Repeat steps 2 through 4 if material remains in the hopper.
8. If the machine will be left at the jobsite unattended, it should be secured from
unauthorized use or movement.
9. Life of the internal seals of the remixer shaft is extended by cleaning thoroughly.
After cleaning at the end of the day, apply lubricant to the surfaces that come into
contact with material to inhibit corrosion and act as a release agent to ease
removal of subsequent material buildup.
10. Restart the pump and grease the remixer, the pan mixer, and the material pump
seals. This should be done while the paddles and swing tube is in operation to
work out any grout that has passed by the seals during operation.

2-25

MAINTENANCE INTERVALS
Daily
OPERATION
Diesel Engine - See Engine Manual
Fuel Tank Level
Hydraulic Reservior Level
Hydraulic Leaks
Tires
Brake Lining
Controls & Gauges
Battery
Hydrulic Cylinder Seals
Wear Parts**
Clean up
Operational Safety

Weekly

Monthly 6 Months

Yearly

..X
..X
..X
..X
..X
X
..X
..X
..X
..X
..X

LUBRICATION
..X
Diesel Engine - See Engine Manual
Engine Oil Filter Change*
..X
Engine Oil Level
X
Electric Motor Bearings
X
Wheel Bearings
..X
Material Pump Main Shaft
..X
Material Pump Outlet
..X
Mixer/Re-mixer Seal Housings
..X
Mixer/Re-mixer Bearings
Hydraulic Oil Filter*
..X
Hydraulic Oil Drain, Clean Tank
..X
Lubrication Washbox
..X
Mixer Pivot Bearings
..X
Mixer Gear Box Oil
*-First 50 hours of operation . Every 200 hours thereafter
**-Interval dependant on use and severity of material pumped.

3-1

WEAR PARTS REPLACEMENT AND ADJUSTMENT

1. Swing Tube Adjustment The initial adjustment of the Swing Tube, Item 19, is
made with the 2-1/4 Nut, Item 15, on the shaft. The locking bolt and retainer plate
mounted to the Swing Arm, Item14, must be removed when adjustments are made.
After the initial adjustment, the cutting ring, Item 20, in the swing-tube will automatically
adjust for wear. The cutting ring has a rubber expansion band, Item 21, between the
body of the swing tube and the diameter of the cutting ring. For proper sealing and
operation this rubber must be compressed the correct amount. The correct adjustment
is made by tightening the 2-1/4 nut on the shaft, rotating the nut one flat at a time.
When the cutting ring contacts the wear plate continue adjustment by 1 or 2 flats of the
nut. Install the retainer plate and locking bolt to lock the nut adjustment in place. There
should be a minimum of 0.015 gap between the swing tube extension, Item 24, and the
Outlet Body, Item 25. NOTE: Additional adjustment will be required when failure of the
cutting ring to seal on the wear plate, Item 4 is observed. Attempts to reduce leakage by
excessive torque on the nut will accelerate wear of these parts with negligible reduction
in leakage.
NOTE: (2) Outlet seals, Item 26, and Wear Band, Item 27, must be in place when the
adjustments are made.
2. Outlet Seals, Item 26, and Wear Band, Item 27, O-Ring, Item 28 Always replace
the outlet seals, o-ring, and wear band whenever wear parts are replaced. Replace
these components by removing the outlet body. Remove the (6) mounting bolts and
install two bolts in the threaded jacking bolt holes located at 12 and 6 oclock on the
outlet flange to back it out of the hopper. Clean the outlet body, swing tube extension,
and the hopper piloted area thoroughly before reassembling. Wipe grease on the
swing-tube extension and inside the outlet body prior to assembly. The hopper pilot
should be coated with a lubricant or anti-seize compound before assembly.
3. Wear Plate, Item 4 and Cutting Ring, Item 20 The abrasives in pumping materials
and friction of the cutting ring sliding across the wear plate result in constant wear of
these parts. The loss of pumping pressure should result in a thorough inspection of
these parts. Replace the wear plate and cutting ring whenever deep grooves of wear
develop, causing loss of sealing between the two surfaces. The inability to maintain a
seal will allow the fines of the mix to be discharged back into the hopper, resulting in lost
pumping pressure. The mounting surface must be clean and flat to assure proper
performance of the new wear parts.
4. Material Cylinders, Item 6 The material delivery cylinders have a hard-chrome
internal finish for excellent abrasion resistance and provide a smooth sealing surface for
the piston cups. Inspect the internal chromed surfaces for wear. A worn cylinder will
exhibit feathering of the bright chrome into a dull gray surface. The loss of the chromed
surface will reduce the sealing characteristics and accelerate the wear of the piston
cups. Exercise care when cleaning the material cylinder ends before installing a new
wear plate. Do not trap hardened grout between the two surfaces. Accidental chipping
or cracking of the chromed surface will result in premature failure. Replace the o-ring
seals in both the valve body and washbox every time the cylinders are removed or
replaced.
3-3

5. Replace Piston Cups, Item 31, and Wear Band, Item 16 Due to the abrasiveness
of materials pumped, it will be necessary to periodically replace the piston cups and the
piston wear bands. Symptoms of worn piston cups are: excessive accumulation of
cement passed into the washbox, lubricating fluid leaking from the wash box into the
hopper, overnight, or loss of wash box lubricant when pumping. Replace the piston
cups through the hopper as follows:
a. Drain and clean the washbox.
b. Piston cup removal can be done through the hopper top. The hopper can also

be unbolted and removed with the appropriate equipment.

c. Start the motor. On the operator panel, put the Forward/Reverse switch in
Reverse and toggle the Pump Start/Pump Stop switch between start and stop to
activate the accumulator circuit.
d. With the motor running and pumping speed at low volume (set on 2), switch the
pump to start and hold the pressure test switch on until the piston is fully
extended to the hopper and stops. Turn the pump switch to stop. Check to see
that the piston head that is forward is not covered by the swing tube.
e. If the swing tube is in front of the forward piston head, turn the Pump Start/Pump
Stop switch on momentarily and move the Forward/Reverse switch to the
opposite position to reposition the swing tube.
f. Stop the motor. Lock out and tag the operator controls.
g. The accumulator dump valve will automatically discharge the accumulator
pressure; the gauge must read zero.
Never work in the hopper when the pump power source is operating or the
accumulator circuit is pressurized. Severe injury can result from
inadvertent actuation of moving parts. For your protection, take time to
stop and disable the motor power system and confirm the accumulator
pressure gauge reads zero before putting hands in the hopper.
h. The piston bolts, Item 65, and the piston cup plate, Item 32, should be able to be
seen and felt in the material cylinder. Chip away any material on and around the
bold head.
i.

Using an air impact gun, remove the 3/8-24 bolts with a 9/16 socket.

j.

Start the motor and turn the pump switch to start for 2-3 seconds. This will retract
the cylinder rod and piston adapter from the piston cup.

k. Turn the Pump Start/Pump Stop switch to stop and disable the power source.

3-4

l. Using a punch or blunt object, tap the bottom of the piston cup, Item 31, until it
turns side-ways in the material cylinder. It can now be easily removed.
m. Using an air impact gun and 1-1/8 socket, remove the 3/4-16 x 2-1/2 long bolt
that holds the piston adapter to the cylinder rod. Remove the steel piston
adapter, Item 33, and clean thoroughly.
n. Start the motor and turn the pump switch to start. Toggle the manual pumping
switch to bring the ram forward in the material cylinder where the piston cup was
just removed.
o. To install the new piston cup, first place the piston adapter with the piston wear
band on the hydraulic cylinder rod and attach with the 3/4-16 x 2-1/2 long bolt
coated with a generous amount of anti-seize compound. Install the two 3/8
alignment studs into the piston adapter. Grease the piston cup and tap it into the
material cylinder, aligning onto the studs. Do the same with the faceplate and
reinstall the 3/8-24 x 1-1/2 long bolts and lock washers.
p. Repeat all the above steps to change the opposite piston cup.
q. Always inspect all parts for wear and damage whenever working on the pump.
Early detection of problems will save time and money.
r. When both piston cups have been replaced, fill the wash box with lubricant.
Never cycle the pump without lubricant in the wash box
and water or pumpable material in the hopper. This will
cause damage to the piston cups. If it is necessary to
stroke the pump dry, always do it very slowly. Excessive
friction will cause heat and damage the piston cups.

6. Material Cylinders, Item 6 The material delivery cylinders have a hard chrome
internal finish for excellent abrasion resistance and provide a smooth sealing surface for
the piston cups. Inspect the internal chromed surface for wear. A worn cylinder will
exhibit feathering of the bright chrome into a dull gray steel surface. The loss of the
chromed surface will reduce the sealing characteristics and accelerate the wear of the
piston cups. Exercise care when cleaning the material cylinder ends before installing a
new wear plate. Do not trap hardened grout between the two surfaces. Accidental
chipping or cracking of the chromed surface will result in premature failure.

3-5

MIXER SHELL

SET SCREW

MIXER SHAFT
4

RE-MIXER SEAL REPLACEMENT

The inner seal of the seal housing is exposed to severe operating conditions and
eventually will require replacement. The function of the grease filled seal housing is to
prevent solid particles from entering the flanged ball bearings. The seals need to be
replaced when they can no longer retain grease in the Seal Housing, thus permitting
eventual premature bearing failure.
IT IS RECOMMENDED TO GREASE THE SEAL HOUSINGS AFTER EVERY DAYS
USE. THIS WILL HELP FORCE ANY FOREIGN MATTER OUT OF THE HOUSING
WHICH MAY HAVE WORKED PAST THE SEAL.
TO REPLACE THE SEALS IN THE HOUSING:
1. Remove the chain sprocket (See page 4-5).
2. Securely prop the mixer shaft inside the mixer to keep the shaft axially centered.
This is done to prevent seal damage during re-installation.
3. Remove the Flanged Ball Bearing (Item 1), and Seal Housing (Item 2).
4. Remove the Seal (Item 3) and O-ring (Item 4).
5. Clean the Seal housing and Mixer Shaft end of material build up.
6. Inspect Flanged Bearing for operation and clean or replace if required.
7. Grease the end of shaft and insert New Seal (Item 3).
8. Install new O-ring (Item 4) in Seal Housing, then insert Housing onto shaft.
9. Install Flanged Bearing.
10. Lock shaft in position with set screws in the inner race of the Flanged Bearing.
11. Fill the Seal Housing with grease until grease comes out of the seal.

3-6

PROXIMITY SENSOR ADJUSTMENT

The Powercreter material pump is delivered with factory set proximity sensors.
However, after maintenance or replacement of components, readjustment may be
required. The proximity sensor adjustment should be made in the Forward pumping
condition.
To adjust the sensors:
1. With both sensors assembled as shown in the pictures above, adjust the body of
the sensor to ensure the maximum gap is between the sensor and piston adapter.
2. From the operator control panel, start the pump power. With the pump in the
Forward mode, switch to Pressure Test to retract one material cylinder piston to
end of travel. Shut down motor but retain power to the control circuit.
3. Adjust the gap between the sensor and the piston adapter. The set dimension
should be between 1/16 (0.062) and 3/32 (0.093).
4. Repeat step 2, except after switching to Pressure Test, toggle the manual pumping
switch to retract the other material cylinder piston. Repeat step 3.
5. Restart the motor and start the pump to confirm that the pump cycles automatically
with the new sensor adjustments.

3-7

RECOMMENDED LUBRICANTS
LUBRICATION / WASH BOX
Fill the Lubrication/Wash Box to the top of the cylinder rods. There are three
recommended lubricants:
1. Water is commonly used. Using only water will give the shortest life of piston
cup wear.
2. Soluble oil and water mix will improve the life of the piston cups.
3. Oil only, as compared with water only, will almost double the life of the piston
cups. Oil greatly reduces the drag friction between the material cylinder and
pistons. This can be used oil, drain oil, vegetable oil, or any type of
inexpensive oil. Oil is recommended in freezing weather conditions.
HYDRAULIC TANK
Fill the hydraulic tank to the mid-point of the tank level indicator. Use clean SAE 5W-20
Hydraulic Oil which is formulated for operation over a wide temperature range. This oil
contains anti-wear and anti-foam additives and contains rust and oxidation inhibitors for
internal protection. Use the following typical test data if selecting an equivalent.
Low Temp. Pumpability test Pass

Viscosity
cSt @ 40 C 23-27

Foam Test .. Pass

cSt @ 100 C ..5.4

Rust Test Pass

Viscosity index 155

Total Acid No .. 0.6

API g Gravity @ 60 F ...31.2

Zinc, % by weight ....0.06-0.07

Flash point ...370 F

ISO Viscosity Grade ...370 F

Pour Point -45 F

SAE Grade 5W-20

GREASE FITTINGS
Use Multi-Purpose E.P. No. 2 grease, except with electric motors
MIXER AND REMIXER LUBRICATION
Pillow block bearings, flange bearings, and the seal housings should be maintained full
of grease and lubricated daily. Factory lubricant is NLGI Grade 2 lithium 12
hydroxystearate base grease.

3-8

LUBRICATION - ELECTRIC MOTOR

Motors with grease fittings should be lubricated every 6 months. Add 1.0 cubic inches
of lubricant to 20 and 30 HP motors. Add 1.5 cu.in. of lubricant to 40 HP and above
motors. Use the following recommended lubricants:
Shell Oil Company - Dollum R
Chevron Oil - SRI No.2
Texaco Inc. Premium RB
Lubrication Procedure:
1. Clean the area around the grease fitting and remove the protective cap.
2. With the motor warm and stationary, add the recommended volume as listed
above, and run the motor for 20 minutes.
Note: All used petroleum based lubricants should be recycled in accordance with
environmentally safe methods.

3-9

TROUBLESHOOTING
Diesel engine
will not start..

Diesel engine
slow to start or
running rough

Electric motor
will not start..

Pump makes one

stroke, but will not
cycle.

Confirm E stop is reset by turning the knob clockwise.

Make certain remixer grate is down and the safety lockout pin
is pushed in.
Check fuel, prime if necessary.
Battery voltage must be 10VDC or greater for controller to
operate and supply power to open the fuel shut off.
Dirt or water in fuel. Change filter and clean tank if
necessary.
Check battery voltage, alternator output, battery cables are
clean and tight, and controller box cable is connected.
Check continuity of ignition circuit through the engine
temperature switch, fuel shut off solenoid, ignition switch,
operator panel connector, and bulb of alternator indicator.
Starter fault, repair or replace.
Refer to engine manufacturers manual, local engine
manufacturer service center, or contact Allentowns service
department.

Clean or replace fuel injectors.

Refer to engine manufacturers manual, local engine
manufacturer service center, or contact Allentowns service
department.

Confirm power wiring, see Set Up of Equipment

Check the motor starter box for blown fuses.
Confirm E-Stop is reset by pulling knob outward.

If pump will cycle with manual pumping switch, adjust the

sensors. See Sensor Switch Adjustment
If pump will not cycle with manual pumping switch, refer to
Material Pump Does Not Cycle in this troubleshooting guide.

3-10

TROUBLESHOOTING
Material pump
does not cycle

Flow control must be open.

The accumulator system did not charge on start-up.
Confirm Pumping / Pressure Test switch on the operator
control panel is in the Pumping position.
Confirm Pump Start / Pump Stop switch on the operators
control panel is in the Pump Start position.
Proximity sensors or sensor cables - adjust or replace. See
Sensor Switch Adjustment.
Switching or continuity fault with Pump Start/Pump Stop or
Pressure Test switches.
Directional control valve requires cycling voltage to the
solenoid coil and continuity in the coil winding.
Confirm the main hydraulic pumps will maintain pressure.
Confirm the pumping circuit relief valve and the swing tube
relief valve is set in accordance with specifications on the units
data tag.

Stroke is short..

Sensors require adjustment. See Sensor Switch Adjustment

Pumping cylinder seals worn and require replacing.
The check valves must seal in the checked flow direction for
the stroke adjustment circuit to maintain full stroke. Clean or
replace.

Both material pump

cylinders stroke
forward under
pressure test

Faulty check valve. Clean or replace.

Accumulator pressure
builds slow
Swing tube circuit pump worn and needs replacing
Accumulator bladder leaks and needs replacing.

3-11

TROUBLESHOOTING
Swing Tube does
not swing .

Confirm Pump Start/Pump Stop switch on operator control panel is

in Pump Start position.
Confirm relief valve is set as specified on the data tag.
Confirm voltage, circuit and coil continuity, and the spool is
shuttling on the Swing Tube directional control valve.
Confirm the dump valve located in the swing tube manifold is
working properly.
Confirm the accumulator nitrogen pre-charge is set per the
pressure setting listed on the data tag.
Swing tube circuit pump is worn and needs replacement.
Mechanical bind. Check freedom of rotation of the main shaft and
outlet to s-tube extension. Also check torque of the 2-1/4" main
nut.
Confirm that there are no foreign objects or hardened material in
the hopper obstructing travel of the swing tube.

Swing tube
out of timing ..

Swing Tube
slow shifting ..

Material Cylinders
stroke but do
not build pressure

Confirm accumulator is pre-charged per data tag.

Swing tube cylinder seals leak and need replacing.
Confirm accumulator circuit relief valve is set per data tag.
Swing tube cylinder seals leak and need replacing.

Worn wear plate, cutting ring, and/or piston cups. See Wear Parts
Replacement or Adjustment.
Confirm that the relief valve is set per the pressure specified on the
data tag.
Swing tube out of timing. Confirm accumulator precharge and
swing tube cylinder seals for wear.
Pumping cylinders seals are worn and need replacing.
Main hydraulic pump is worn. Replace pump if the case drain line
is producing excessive oil. Consult factory prior to replacement to
confirm condition of the pump.
3-12

TROUBLESHOOTING
Fluctuating pumping
pressure

Worn wear plate, cutting ring, and/or piston cups. See

Wear Parts Replacement or Adjustment.
Pumping cylinders seals are worn and need replacing.

Slurry in the
Lubrication/Wash
Box

The piston cups and/or the material cylinders are worn and
need to be replaced. See Piston Cups.

Confirm the relief valve is set per the pressure specified on

Adjustment of flow
the data tag.
control valve does not
change material
Main hydraulic pump is worn. Replace pump if the case
pump speed
drain line is producing excessive oil. Consult factory prior
to replacement to confirm condition of the pump.

3-13

MATERIAL PUMP MODEL 20

ITEM
1

QUANTITY
1

PART
NUMBER
33120

33118

WASHBOX, SHP MODEL

33122

COVER, WASHBOX

33233

WEAR PLATE, CAST

33134

DOOR ASSEMBLY, CLEAN-OUT

33030

MATERIAL CYLINDER

33022

FLANGE ADAPTER

33021

O-RING

33136

TIE ROD

10

33270

RETAINER PLATE, SEAL - 4 BOLT

11

32642

SEAL, MAIN SHAFT

12

32454

MAIN BUSHING, FLANGED

13

33060

WEAR BAND

14

32479

SWING ARM

DESCRIPTION
VALVE BODY

15

32022

16

32470H

HEX NUT, 2 1/4-12 TH'D

17

32271

RETAINER PLATE

18

32457

OILITE BUSHING

19

33125

SWING TUBE, KEYED

20

33232

CUTTING RING, CARBIDE INSERT

21

33123

EXPANSION BAND, RUBBER

22

33029

O-RING

23

32655

LOCKWASHER, WEDGE, 5/8"

24

33019

S-TUBE EXTENSION

25

A507199

TAIL PIPE HOUSING, 4" HD

26

A505885

OUTLET SEAL

27

A510807

WEAR BAND

28

32221

PLUG, WASHBOX

29

33229

SWING TUBE CYLINDER

30

33063

PISTON, MATERIAL CYLINDER

MAIN SHAFT, KEYED

31

33052

PISTON CUP

32

33058

RETAINER, PISTON CUP

33

33237

HYDRAULIC CYLINDER, PUMPING - SHP

34

32641

KEY, 5/8" SQUARE

35

32458

HANDLE GRIP (NOT SHOWN)

36

82001

GREASE FITTING

37

11480

CYLINDER CLEVIS PIN, 3/4" STN STL

38

33223

BAFFLE, WASHBOX

4-3

MATERIAL PUMP MODEL 20

ITEM
39

QUANTITY
2

PART
NUMBER
32145

40

11489

WEAR SLEEVE

41

33134

DOOR WELDMENT

42

33023

DOOR GASKET

43
44

4
1

45

46

47

HEX HEAD BOLT, GR.5, 3/4-16 X 2 1/2

48

HEX NUT, GR.8, 7/8-14 TH'D

49

LOCKWASHER, 3/4"

50

51

52

53

FLAT HEAD CAP BOLT, 5/8-11 X 3

54

HEX NUT, 5/8-11

55

LOCKWASHER, 5/8"

56

HEX HEAD BOLT, GR.5, 3/8-16 X 1

57

SOC. HEAD CAP BOLT, 3/8-16 X 1 1/4

58

SET SCREW, CONE PT., 1/4-20 X 3/8

59

HEX HEAD BOLT, GR.8, 3/8-24 X 1 3/4

60

LOCKWASHER, GR 8, 3/8"

61

"E" STYLE RETAINING RING

62

LOCKWASHER, 3/8"

63

BELLEVILLE WASHER, 5/8"

64

DESCRIPTION
PROXIMITY SWITCH

FLAT HEAD CAP SCREW, 5/16-18 x 1

HEX HEAD BOLT, 1/2-13 X 2
LOCKNUT, 1/2-13
33145

33190

HINGE PIN

HEX HEAD BOLT, F911, 5/8-11 X 2 1/2

HEX HEAD BOLT, GR.8, 5/8-11 X 3

33638

A510302

HEX HEAD BOLT, F911, 1/2-13 X 2 1/2

O-RING

4-4

PC20 STANDARD REMIXER HOPPER COMPONENTS

EXPLODED VIEW

4-5

PC20 STANDARD REMIXER HOPPER COMPONENTS

ITEM
1

QUANTITY
1

PART
NUMBER
03298

03305

SEAL HOUSING

03310

SEAL

03311

SEAL, O-RING

03272

MAIN SHAFT

09201

HYDRAULIC MOTOR

11059

FLANGE BEARING

32519

TORQUE ARM

04014

PADDLE ARM

10

04055

MIXING PADDLE, 14", RH

11

04056

MIXING PADDLE, STRAIGHT

12

04054

BOTTOM SCRAPER

13

04061

RUBBER SCRAPER

14

04062

MIXING PADDLE, 14", LH

15

03277

LIFTING ARM, (FOR OPTIONAL MIXER)

16

11488

WEAR SLEEVE, 2"

17

FHCS, 1/2-13 x 2-1/2

18

LOCK WASHER, 1/2"

19

HEX NUT, 1/2-13

20

LOCK WASHER, 3/8"

21

HEX NUT, 3/8-16

22

FLAT WASHER, 3/8"

23

HEX HEAD BOLT, 3/8-16 x 1-1/4

24

HEX HEAD BOLT, 5/8-11 x 1-3/4

25

LOCK NUT, 5/8-11

DESCRIPTION
MIXER GRATE

4-6

PC20 HARSH MIX HOPPER COMPONENTS

8 ,9

11

13

4-7

PC20 HARSH MIX HOPPER COMPONENTS

ITEM
1

QUANTITY
1

PART
NUMBER
03288

03293

REMIXER SHAFT

03287

STUB SHAFT, DRIVE END

03310

SEAL

03311

SEAL, O-RING

03305

SEAL HOUSING

11059

FLANGE BEARING

11048

CHAIN

11049

CONNECTION LINK

10

11402

SPROCKET, DRIVEN, 60T

11

11403

SPROCKET, DRIVE, 18T

12

03294

CHAIN COVER (NOT SHOWN)

13

09192

HYDRAULIC MOTOR

14

16

15

04059

SCRAPER, BOTTOM

16

04060

SCRAPER, SIDE

17

FHCS, 1/2-13 x 2-1/2

18

HEX HEAD BOLT, GRADE 8, 1/2-13 x 2-1/2

19

16

HEX HEAD BOLT, GRADE 8, 1/2-13 x 1

20

24

LOCKNUT, 1/2-13

21

DESCRIPTION
STUB SHAFT, IDLER END

FLAT WASHER, 1/2"

11488

WEAR SLEEVE, 2"

4-8

OPERATOR CONTROLS

7, 8

8, 9

10
1

11, 12

22

13
20, 21

19

16, 17, 18

4-9

14, 15

7, 8

OPERATOR CONTROLS

ITEM
1

QUANTITY
1

PART
NUMBER
14031

DESCRIPTION
TOGGLE SWITCH, PRESSURE TEST

14033

TOGGLE SWITCH, ON/OFF/REMOTE

14032

TOGGLE SWITCH, FORWARD/REVERSE

14044

TOGGLE SWITCH, MANUAL PUMPING

14442

POTENTIOMETER, FLOW CONTROL

14027

HOUR METER

14196

LENS, GREEN

14149

PILOT LIGHT

14195

LENS, RED

10

14119

E-STOP

11

14158

BOOT, RED

12

14139

PUSH BUTTON SWITCH, N.C.

13

45019

MANUAL AUTOLUBE BUTTON

14

14159

BOOT, GREEN

15

14140

PUSH BUTTON SWITCH, N.O.

16

14047

CONNECTOR, REMOTE

17

14048

CAP

18

14329

REMOTE PENDANT (NOT SHOWN)

19

30124

PRESSURE GAUGE, 0-5000 PSI

20

14386

PANEL LIGHT

21

14387

LIGHT BULB, 12VDC

4-10

MICROPROCESSOR CONTROLLER

ITEM
1

QUANTITY
1

PART NUMBER
14327

DESCRIPTION
MICROPROCESSOR (SEE NOTE)

NOTE: The microprocessor has a program specifically designed to run this pump. The
pump will not run correctly if the program is not installed by Allentown Shotcrete
Technology. Please contact Allentown Shotcrete Technology if replacing the
microprocessor. If the pump is not functioning correctly contact the Allentown Shotcrete
Technology service department.

4-11

HYDRAULIC SYSTEM COMPONENTS

ITEM
1

QUANTITY
1

PART
NUMBER
09382

35106

DIRECTIONAL CONTROL VALVE, SWING TUBE

32332

COIL, DCV, 12VDC

30124

PRESSURE GAUGE, 0-5000 PSI

32122

ACCUMULATOR

09361

ACCUMULATOR BLADDER

30532

CONTROL VALVE, REMIXER

09201

HYDRAULIC MOTOR, STANDARD REMIXER

09192

HYDRAULIC MOTOR, 15 CU FT REMIXER

09343

MAIN HYDRAULIC PUMP

10

32103

11

33237

12

33229

DOUBLE GEAR PUMP

HYDRAULIC CYLINDER, PUMPING, WITH INTERNAL
CHECKS
HYDRAULIC CYLINDER, SWING TUBE

13

09328

HYDRAULIC TANK

14

09332

RETURN FILTER ELEMENT, IN TANK

15

09406

GAUGE, RETURN FILTER INDICATOR

16

09331

RETURN FILTER ASSEMBLY

17

09311

FILLER BREATHER CAP

18

09335

OIL GAUGE AND THERMOMETER

19

09324

OIL COOLER

20

09711

TEMPERATURE SWITCH

21

09447

MOTOR ASSEMBLY, OIL COOLER

22

32222

CHECK VALVE

23

09303

CONTROL VALVE, 12VDC, REMIXER GRATE CUTOUT

24

35094

ACCUMULATOR MANIFOLD

25

09292

CHECK VALVE

26

09291

RELIEF CARTRIDGE

27

09306

COIL, CONTROL VALVE, 12VDC

28

09294

ON/OFF VALVE, SWING TUBE

29

09294

DUMP VALVE, SWING TUBE

30

09333

PRESSURE SWITCH

31

32416

DAMPENING HOSE, PRESSURE SWITCH

DESCRIPTION
PROPORTIONAL VALVE, PVG-32

4-13

MISCELLANEOUS COMPONENTS

11

9
6

7
10

4-14

MISCELLANEOUS COMPONENTS

ITEM
1

QUANTITY
1

PART
NUMBER
55049

A-FRAME JACK

14135

WIRE HARNESS

01037

SAFETY CHAIN

01393

LUNETTE EYE

14300

BREAKAWAY SWITCH

14071

TAIL LIGHT

01204

FENDER

01330 & 01368

01411

OUTRIGGER, MANUAL

10

01216

HITCH PIN

11

55050

TOP PLATE, A-FRAME JACK

12

30535

13

09358

CONTROL VALVE, OPTIONAL HYDRAULIC OUTRIGGERS

HYDRAULIC CYLINDER, OPTIONAL HYDRAULIC
OUTRIGGERS

DESCRIPTION

TIRE & RIM

4-15

SAFETY DECALS
Safety deals must be in place at all times. Missing or illegible decals will be
replaced free of charge upon request.

P/N 07001

P/N 07006

P/N 07101

P/N 07099

P/N 07102

P/N 07105

P/N 07106

4-16

P/N 07108

Models 94012, 94024

CHASSIS LUBE ELECTRIC GREASE PUMP
Series "C"
OWNER/OPERATOR MANUAL

Do not use pump without pressure relief valve.

SPECIFICATIONS
Electrical Requirements
Model 94012 ...................
Model 94024....................
Enclosure Rating.............

12 VDC @ 3.5 amps

24 VDC @ 2 amps
IP 6K9K- Protected from water
sprayed in all directions.
On Time ........................... 2 minutes minimum 30 minutes
maximum in 2 minute
increments
Off Time ........................... 1 hour minimum 15 hours
maximum in 1 hour increments
Pump Output ................... 0.171 cu. in./min (2.8 cc/min)
Outlet Connection............ 1/8" NPT (female)
Maximum Recommended
Operating Pressure .....
3600 psi (248 bar)
Reservoir Capacity.......... 122 cu. in. (2000 cc)
Lubricant.......................... Greases up to NLGI grade 2 (
depending on the operating
temperature and type of
lubricant)
Temperature Range........
-13 F (-25 C) to +158 F
(+70 C)
Pressure Relief Valve ........ 4000 psi +/- 250 psi
(276 bars) +/- (17 bars)

DESCRIPTION
The chassis tube pump is electrically operated and used in a
progressive type centralized lubrication system. The pump
consists of a pump housing, electric gear motor, a timer and a
plastic reservoir with stirring paddle. The high operating
pressure allows the pump to supply lubricant up to NLGI 2
grease.

MOUNTING THE PUMP

Select an easily accessible place of installation which allows
access to the timer and lubricant reservoir filler fitting. The
pump must be mounted vertically on an even surface by
means of two bolts.

TO FILL RESERVOIR
Fill the reservoir through the grease fitting located at the base of
the reservoir, using a hand operated grease pump. Refill
reservoir when grease reaches MIN mark located on the
reservoir. Fill the reservoir up to the MAX mark located on the
reservoir.

TO PRIME SYSTEM
Pump & Supply Line: After reservoir has been filled with
recommended lubricant, loosen the supply line fitting. Operate
the pump until lubricant flows from outlet, then tighten fitting.
Feed Lines: Pre-fill each feed line with lubricant before
connecting to outlet of divider valve and bearing.

Indicates Change

One Lincoln Way

St. Louis, Missouri 63120-1578
(314) 679-4200

DEC - 2003

- Q3
- 2F

Section
Copyright 2003
Printed in U.S.A.

Page

FORM 403301

SYSTEM ACCESSORIES
Description

Qty. Part No.

8 Amp Fuse

241052

8 Amp Fuse Holder

241053

Lighted Manual Sw itch (12 VDC)

241419

Lighted Manual Sw itch (24 VDC)

241484

Remote Manual Lube Pow er Cord

256276

Note: Use loctite 545 when

assembling pressure relief
assemlby (34) to pump element
(32).

Indicates Change

Page 2

Form 403301

ELECTRICAL CONNECTIONS
Connect black power cord as follows:
Red wire connects to 8 amp fuse then
to Battery (+).
White wire connects to Battery (-).
Blue wire connects to ignition switch,
to 8 amp fuse, then to Battery (+).

PARTS LIST
ITEM NO.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
28
29
20
31
32
33
34
35
36
37
38

DESCRIPTION
Reservoir
Hose
Stirring paddle
Washer
Bearing ring
Bearing
0-ring
Intermediate plate
Shim
Snap ring
Inner ring
Eccentric cam
Screw
Washer
0-ring
Pump housing
Closure plug
3 Wire Power Cord/Plug
6 Wire Plug
6 Wire Power/Remote Manual
Lube Cord/Plug (Optional)
Sealing plug
Nipple
Screw
Grease fitting
Printed circuit board
Woodruff key
Radial seal
12 VDC motor
24 VDC motor
Housing cover
Hose
Check valve
Pump element
Gasket
Pressure relief ass'y.
Plug for motor
Grease cap
Adapter for relief assy.
Seal

QTY.
1
1
1
1
2
1
2
1
1
2
1
1
3
3
3
1
2
1
1
1
1
1
10
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1

PART NUMBER/KIT NUMBER

REMOTE MANUAL LUBE
part of Kit 246432
PUSHBUTTON
part of Kit 246433
If a remote manual lube pushbutton
part of Kit 246433
is required, order a 256276 Manual
part of Kits 246433 & 246434
Lube cord/plug (consisting of a
part of Kit 246434
33 ft. cord and plug) and:
part of Kit 246434
246424, part of Kit 246432
for a 12 volt pump, order
246425
241419 - Lighted Manual Lube
part of Kit 246434
Switch
part of Kit 246434
for a 24 volt pump, order
part of Kit 246434
241484 - Lighted Manual Lube
246427
part of Kits 246435 & 246436
Switch
part of Kits 246435 & 246436
part of Kits 246435, 246436 & 246437
246426
246422
256274

256277

256276

246423
226-14105-5
206-13796-7
5050
246420
part of kits 246435 & 246436
part of Kits 246435, 246436 & 246437
part of Kit 246435
part of Kit 246436
246421
not sold
part of Kit 600-26876-2
part of Kit 600-26876-2
part of Kit 600-26876-2
270864
part of Kits 246435 & 246436
242125
304-19614-1

249569

Indicates Change

Form 403301

Page 3

Part no.
Qty.
Description
5050
1 Grease Fitting
242125
1 Grease Cap
246420
1 Printed Circuit Board
246421
1 Housing Cover
246422
1 Closure Plug
246423
1 Sealing Plug
246424
1 O-ring
246425
1 Intermediate plate
246426
1 Pump Housing
246427
1 Eccentric Cam
304-19614-1
1 Adapter for relief assy.
270864
1 Pressure Relief assy.
249569
1 Seal
226-14105-5
1 Nipple
206-13796-7 10 Screw
256287
1 3-w ire pow er cord/plug
256277
1 6 w ire internal plug
256276
1 6 w ire pow er/remote manual lube cord
1 (optional)
246432
Reservoir Kit Contains:
1 Reservoir
1 O-ring
246433
Paddle Kit contains:
1 Hose
1 Stirring Paddle
1 Washer
246434
Bearing & Seal Kit contains:
1 Washer
2 Bearing Ring
1 Bearing
1 Shim
2 Snap Ring
1 Inner Ring
246436
12 VDC Motor Kit contains:
3 Screw
3 Washer
3 O-ring
1 Woodruff Key
1 Radial Seal
1 12 VDC Motor
1 Plug for Motor
246437
Housing Seel Kit contains:
3 O-Ring
1 Radial Seal
600-26876-2
Pump Element Assembly contains:
1 Check Valve
1 Pump Element
1 Gasket

Item No.
24
36
25
29
17
21
7
8
16
12
37
34
38
22
23
18
19
20

1
7
2
3
4
4
5
6
9
10
11
13
14
15
26
27
28
35
15
27
31
32
33

Indicates Change

RETAIN THIS INFORMATION FOR FUTURE REFERENCE

When ordering replacement parts, list: Part Number, Description, Model Number and Series Letter.
LINCOLN provides a Distributor Network that stocks equipment and replacement parts.

Page 4

Form 403301

LIMITED WARRANTYLincoln warrants the equipment it supplies to be free from defects in material and workmanship for one (1) year
following the date of purchase. If equipment proves to be defective during this warranty period it will be repaired or
replaced, at Lincolns discretion, without charge provided that factory authorized examination indicates the equipment to
be defective. To obtain repair or replacement, you must ship the equipment, transportation charges prepaid, with proof
of date of purchase to a Lincoln authorized warranty and service center, within one (1) year following the date of
purchase.

LIMITED 5 YEAR WARRANTY (Series 20, 25, 40 Bare Pumps, Heavy Duty and Golden
Standard Bare Reels)Lincoln warrants series 20, 25, 40 bare pumps, and heavy duty and golden standard bare reels it supplies to be free
from defects in material and workmanship for one (1) year following the date of purchase. If equipment proves to be
defective during the warranty period it will be repaired, or replaced, at Lincolns discretion, without charge provided that
factory authorized examination indicates the equipment to be defective. To obtain repair or replacement, you must ship
the equipment, transportation charges prepaid, with proof of purchase to a Lincoln Authorized Warranty and Service
Center within one (1) year following the date of purchase. Additionally, in years two (2) and three (3) the warranty on this
equipment is limited to repair with Lincoln paying parts and labor only. In years four (4) and five (5), the warranty on this
equipment is limited to repair with Lincoln paying for parts only.
This warranty is extended to the original retail purchaser only. It does not apply to equipment damaged from accident,
overload, abuse, misuse, negligence, faulty installation or abrasive or corrosive material, or to equipment repaired or
altered by anyone not authorized by Lincoln to repair or alter the equipment. This warranty applies only to equipment
installed and operated according to the recommendations of Lincoln or its authorized field personnel. No other express
warranty applies.
Any implied warranties applicable to equipment supplied by Lincoln, including the warranties of merchantability and
fitness for a particular purpose, will last for only one (1) year from the date of purchase. Some jurisdictions do not allow
limitations on how long an implied warranty lasts, so the above limitation may not apply to you.
In no event shall Lincoln be liable for incidental or consequential damages. Lincolns liability on any claim for loss or
damages arising out of the sale, resale or use of equipment it supplies shall in no event exceed the purchase price.
Some jurisdictions do not allow the exclusion or limitation of incidental or consequential damages, so the above
limitation or exclusion may not apply to you.
This warranty gives you specific legal rights. You may also have other rights that vary by jurisdiction.

Form

Page 5