Jacon Shotcrete Operation Manual-Mxprt-109

Operator’s Manual MAXIJET PRONTO
OPERATION MANUAL
&
SPARE PARTS BOOK
MACHINE MODEL: MAXIJET PRONTO

Serial No.: MXPRT-1108-109
Date of Manufacture: 10/2011
Jacon Technologies Pty. Ltd.

24 Egerton Street, Silverwater N.S.W. 2128, Australia
Tel: + 612 9737 9028 – Fax: + 612 9737 9031 – Website: www.jacon.com.au.
- Please understand the Operation Instructions before operating. - 1

CONTENTS
CONTENTS .........................................................................................................................................2
1 GENERAL INFORMATION ....................................................................................................4
1.1 TECHNICAL SPECIFICATIONS ....................................................................................4
1.1 WARRANTY ....................................................................................................................6
1.2 GENERAL DIMENSIONS: ..............................................................................................7
1.3 ELIGIBILITY ..................................................................................................................10
1.4 PLANNING .....................................................................................................................11
1.5 SAFETY PRECAUTIONS ..............................................................................................12
2 DRIVING AND OPERATING INSTRUCTIONS .................................................................14
2.1 DRIVING INSTRUCTIONS: .........................................................................................14
2.2 QUICK OPERATIONS GUIDES ...................................................................................20
2.3 SHOTCRETE BOOM .....................................................................................................23
2.4 SHOTCRETE BOOM WORKING RANGES ................................................................23
2.5 PUMP, BOOM AND NOZZLE OPERATING INSTRUCTIONS .................................24
2.6 SHOTCRETE PUMP OPERATIONS ............................................................................26
2.7 CHEMICAL PUMP.........................................................................................................27
2.8 ELECTROMAGNETIC FLOWMETER ........................................................................29
3 CONCRETE PUMP SPECIFICATIONS................................................................................31
3.1 MIX DESIGN ..................................................................................................................31
3.2 PRIMING THE PUMP ....................................................................................................32
3.3 REMOVING A BLOCKAGE .........................................................................................33
3.4 HINTS ON SHOTCRETING WITH THE ROBOSHOT PRONTO ..............................34
3.5 CLEANING THE PUMP ................................................................................................38
3.6 CLEANING THE PIPELINE ..........................................................................................38
3.7 CLEANING THE PIPELINE WITH WATER ...............................................................38
3.8 CLEANING THE PIPELINE WITH COMPRESSED AIR ...........................................39
3.9 CLEAN-UP......................................................................................................................39
4 MAINTENANCE ....................................................................................................................41
4.1 GENERAL INFORMATION ..........................................................................................41
4.2 ESSENTIAL PART LIST ...............................................................................................41
4.3 LUBRICATION CHART................................................................................................44
4.4 HYDRAULIC CIRCUIT .................................................................................................45
4.5 ELECTRICAL CIRCUITS ..............................................................................................47
4.6 SWINGTUBE ADJUSTMENT AND REPLACEMENT OF PARTS ...........................53
4.7 REPLACEMENT OF THE WEAR PLATE ...................................................................55
4.8 REPLACING THE SWING TUBE.................................................................................57
4.9 SETTING THE PROXIMITY SWITCH ........................................................................58
4.10 ASSEMBLY AND DISASSEMBLY NOZZLE ORBITAL HEAD ..............................59
5 TROUBLE SHOOTING .........................................................................................................64
5.1 ENGINE AND DRIVE UNIT.........................................................................................64
5.2 CONCRETE PUMP ......................................................................................................65
5.3 SWING RAM MOVING SLOWLY:..............................................................................66
5.4 SHOTCRETE BOOM AND ROBOT (NOZZLE) .......................................................67
6 PRESSURE SETTINGS ..........................................................................................................68
6.1 CONCRETE PUMP ......................................................................................................68
6.2 SHOTCRETE BOOM ...................................................................................................69
6.3 STEERING PRESSURE SET AT 200 BAR (PRE-SET). .......................................69

6.4 SERVICE BRAKE PRESSURE SET AT 40 BAR. ...................................................70

6.5 PARK BRAKE PRESSURE SET AT 100 BAR. .......................................................71
6.6 HYDRAULIC COMPONENTS & FUNCTIONS ........................................................72
6.7 TRANSMISSION PUMP (A4VG90) ...........................................................................72
6.8 LOAD SENSING PISTON PUMP A10VO71 ............................................................74
6.9 PISTON PUMP A10VO45 NO.3 .................................................................................75
6.10 PUMP NO.4 ...................................................................................................................77
7 GLOSSARY OF TERMS & THE FUNCTION OF DIFFERENT PARTS ...........................78
8 SPARE PARTS .......................................................................................................................82
8.1 SHOTCRETE BOOM ...................................................................................................83
8.2 NOZZLE ORBITAL HEAD .........................................................................................109
8.3 Oscillating Assembly ..................................................................................................111
8.4 2.5” Nozzle Assembly.................................................................................................113
8.5 2.5” Nozzle Mounting Assembly ...............................................................................114
8.6 Rotary Actuator RA80/180.........................................................................................116
8.7 PUMPING MODULE & HOPPER ASSEMBLY ......................................................117
8.8 CONCRETE DISCHARGE ASSEMBLY .................................................................125
8.9 CHEMICAL PUMP ......................................................................................................127
8.10 Chemical Suction Screen ..........................................................................................129
8.11 Chemical Pump ...........................................................................................................130
8.12 AXLE ASSEMBLY .....................................................................................................132
8.13 Front Axle .....................................................................................................................136
8.14 Front Axle (2) ...............................................................................................................137
8.15 Transmission................................................................................................................139
8.16 Front axle (3) .................................................................................................................142
8.17 Front axle (4)................................................................................................................145
8.18 Front axle (5)................................................................................................................146

1 GENERAL INFORMATION
1.1 TECHNICAL SPECIFICATIONS
DRIVE UNIT
ENGINE: Caterpillar C4.4 Electronic Engine
OUTPUT POWER: 96kw @ 2200 rpm
DRIVING Clark Hurth 4 Wheel Hydrostatic Steering Axles.
TRANSMISSION: Bosch Rexroth Closed Loop Transmission Pump coupled with Dana
2 speed transmission gear box.
SERVICE BRAKE: Hydraulically applied four wheel internal wet disc brakes
PARK BRAKE: Driveline mounted external disc with dual callipers (SAHR).
SPEED: Hi speed: 25km/hr road speed, fully loaded
Low speed: 10km/hr road speed, fully loaded.
SHOTCRETE PUMP Jacon S125
POWERED BY: Hydraulic Load Sense Pump 71cc/ G3 Gear Pump 19cc
CONCRETE CYLINDERS: 125mm Bore with 910mm Stroke
HYDRAULIC PRESSURE MAX: 150 bar
LINE PRESSURE MAX: 47 bar
FEATURES: Dual Circuit Hydraulic System, for Positive Swingtube
Displacement.
Fully hydraulic pilot system with electric instant reverse control on
main cylinders.
Fully Automatic Stroke Adjustment.
RATED OUTPUT: 25 cubic metres per hour
ACTUAL OUTPUT: 0-18 Cubic metres per hour.
VERTICAL HEIGHT: 50 metres.
HORIZONTAL DISTANCE: 180 metres.
HOPPER: Swingtube type 5” to 4” bathtub hopper with Remixer.
(OPTIONAL)
24V Hopper Vibrator.

SHOTCRETE BOOM
TYPE: Triple extension 8.6 metres reach parallel slewing boom

VERTICAL REACH: 9 metres
HORIZONTAL REACH: 7.5 metres
SLEWING ANGLE: Robotic head with 360 degree slew angle
NOZZLE: 360 degree robot rotation
180 degree nozzle tilt
Oscillator on robotic head
Air and Chemical injection at nozzle.
Corded Remote Control Joystick operation.
LOW VOLTAGE ELECTRICAL SYSTEM
SYSTEM: 24 Volt.
LIGHTS: 2 x 65W low beam & 2 x 65W high beam driving lamps
2 x stop/tail lamps at rear
70W orange revolving beacon warning lights
4 x 35W HID work lights fitted to boom
3 x 65W work/reversing lamps at rear
OTHERS
CHEMICAL DOSING: Peristaltic type chemical dosing pump with electronic integration.
Flow-rate and capacity designed to suit the maximum output
required by admixture specifications.
Automatically calibrated electronic controlled chemical dosing
output in conjunction with concrete pump output to a preset dosing
ratio, and will change automatically to be consistent with any
change in concrete pump output.
On Board 1000 litre intermediate bulk container for liquid
chemicals
EXHAUST: Catalytic converter on exhaust system

WHEELS: 300-15 x 20 ply “wide wall” tyres and spare wheel
WASH DOWN SYSTEM: High Pressure Water Wash down with hose and nozzle
CiRP 16/160 PUMP Water hose reel (optional)
CABINS: One cabin.

1.1 WARRANTY
WARRANTY
We guarantee each new machine sold by us to be free from defects in

material and workmanship for six (6) months from date of shipment, but
not to exceed (90) days of service. The obligation under this warranty,
statutory or otherwise, is limited to the replacement or repair at our
Silverwater factory, or at a point designated by us, of such parts as shall
appear to us, upon inspection at such point, to have been defective in
material or workmanship.
This warranty does not obligate us to bear the cost of labour or

transportation charges in connection with the replacement or repair of
defective parts, nor shall it apply to a machine upon which repairs or
alterations have been made by a third party, unless authorised by us.
We make no warranty in respect of trade accessories, such being subject to

the warranties of their respective manufacturers.
We shall, in no event, be liable for consequential damages or contingent

liabilities arising out of the use of, or failure of the machine parts to operate
properly.
No express, implied or statutory warranty other than herein set forth is

made or authorised to be made by us.

1.2 GENERAL DIMENSIONS:

2821
2403
1162
445
425
378
345
13° 17°
Ø840 Ø840
1579 2700 852

5130
6081
2821
2403
1139
445
425
378
345
17° 13°
Ø840 Ø840
852 2700 1579
5131
6081

2076
6073
2812
2403
2000

MAXIJET PRONTO IDENTIFICATION
Model: Serial No.: Date of Manufacture:

MAXIJET PRONTO MXPRT-1108-109 10/2011
Customer: Order No.:
Job No.: MXPRT-109
Carrier model: Maxijet Carrier Serial No.:MXPR-001
Diesel engine: CAT C4.4 (24V) Engine No: 44412768
Front axle: Spicer Dana 278/209 Serial No.: N-HUN-119389
Rear axle: Spicer Dana 278/209 Serial No.: N-HUN-134127
Rim: RIM ASSEMBLY (8.0-15) Serial No.: JSDL-300-15-RIM
Wheel: WHEEL (300-15) Serial No.: JSDL-300-8-278-2
Hydraulic pump group Assembly ASSY No.: JSA-PB393SAS
Hydraulic pump unit 1: A4VG90DA2D2/32R Part No.: JSA-RNO190
Hydraulic pump unit 2: A10VO71DFR1/31R Part No.: JSA-B3067
Hydraulic pump unit 3: A10VO45DFR1/31R Part No.: JSA-B30111,F
Hydraulic pump unit 4: PG3BS19BR Part No.: JSA-79515
Transmision gear box: JSDL-K1025504 Serial No.: N-ITA-710083
Main drive Hydraulic motor: A2FM90/6xW-VAB027 Serial No.: JSA-20065
Concrete pump model: PM-1251070 ASSY No.: PM-1251070-002A
Hopper model: SH-5000 ASSY No.: SH-5000-001B
Shotcrete boom model: JSB-040-NL-A Serial No.: SVB-0711073
Orbital head : OH-6300-002-N ASSY No.: OH-6300-002-N
Chemical pump: CHEM.SP15 COMP. ASSY No.: JSP-SP15-250-C-1
Water pump : D52F002250 ASSY No.: JSP-D52F002250-A

Does this correspond to include GRP 16/160 Pump with hyd motor?

1.3 ELIGIBILITY
• Equipment should only be operated by experienced operators, or trainees under the direct supervision
of an experienced operator, and no unauthorised person shall 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 make ready operations.
• Equipment shall not be operated by individuals who cannot read and understand the signs, notices and
operating instructions that form a part of the job (in the language in which printed).
• Equipment shall not be operated by individuals who are not familiar with the operating instructions,
received some on the job supervised training and are familiar with the signal codes used at the
construction site.
• Equipment shall not be operated by anyone with seriously defective eyesight or hearing and physical
or mental impairment (such as epilepsy, heart disease, or progressive muscular deterioration), and that
this be verified by a physical examination at least annually.
• Equipment shall not be operated while the operator is eating, drinking, reading or is more than two
metres distance from the controls.
• Equipment shall not be operated by an operator who has asked to be relieved because he feels
physically or mentally unfit.
• Equipment shall 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.
• Equipment shall have a sign off sheet attached to the vehicle where an operator can report any
damage, defects, problems or accidents to the next shift operator and work supervisor

1.4 PLANNING
The planning of concrete pumping requirements should commence as early as possible in the
development of any project and should include consultation with the supplier of the concrete.
At appropriate stages consideration should be given to the following points:
• Management plan and risk assessment.

• Site access and equipment position.
• Obtaining authorized and requirements of regulatory authorities.
• Protection and safety of public.
• Procedures for the setting up of the equipment, pipeline and pumping program.
• Personal protective equipment.

• Communication system.
• Weather conditions.
• Emergency procedures.
• Inspection, maintenance and repair.
• Cleaning of equipment and disposal of waste.

1.5 SAFETY PRECAUTIONS

Any personnel assigned to repair, troubleshoot or operate the PRONTO should first be thoroughly
familiar with the operating instructions manual. Your safety and the safety of others is at all times very
important. To work safely, you must understand the job you do. If in doubt, use extreme caution, obtain
assistance from trained personnel.
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 unit.
Unsafe operating practices and improper use of the PRONTO can result in injuries. Observe the following
safety precautions at all times.
• Give complete and undivided attention to the job at hand so that complete control of the unit is
maintained at all times.
• Drive slowly over rough ground and on slopes; keep alert for holes, ditches and other irregularities
that may cause the unit to overturn.
• Avoid steep slopes that may cause the unit to overturn.
• Reduce speed when turning so there is no danger of overturning.
• Always look behind you before backing, if vision is blocked, ensure some one is on hand to guide you
so as not to back in to any obstructions or people.
• Do not allow any persons to ride on the unit at any time during driving or operation.
• Never drive the unit from the cabin without the seat belt correctly secured.
• Never operate the unit in any site without adequate ventilation.
• Do not smoke when handling fuel. Avoid spilling fuel.
• After operating the engine, never touch the muffler, exhaust pipe, catalytic converter, engine or
radiator until they have had time to cool.
• Dress appropriately – wear relatively tight fitting clothing when operating the unit. Loose or torn
clothing can catch in moving parts or controls.
• Never walk underneath the boom whilst in operation.
• Wear an approved safety hat when operating the unit and while in any work area.
• Wear suitable hearing protection if you are exposed to noise which you feel is uncomfortable.
• Wear suitable protective eye wear at all times whilst operating the unit.

• When driving the unit make sure the beacon lights are switched on.
• Never extend any part of the body outside of the driving cabin whilst driving
• Make sure all bystanders are at a safe distance away from the unit before starting the engine.
• Never work on any part of the unit while the engine is running. Take time to stop the engine.
• Hydraulic oil systems can be hazardous. Know the circuit you are repairing, it may have high pressure
and injury can occur. If in doubt, stop the entire unit and allow sufficient time for oil pressure to
disappear from gauges. Use caution when opening the circuits or components. Pressurised oil can
cause severe injury.
• NEVER open any parts of the concrete delivery line system without discharging any built up pipeline
pressure.
• NEVER place hands or any objects into the hopper whilst engine is running. Make sure all hydraulic
pressure has been discharged completely before doing any work in hopper.
UTILISE CAUTIONS AND SAFE METHODS IN THE OPERATION AND REPAIR OF THE
PRONTO, IT PAYS IN MANY WAYS!!!
• NEVER remove the hopper grate cover. It protects against accidental contact with other moving parts
in the hopper.
• NEVER enter the hopper with any parts of your body; it is a DANGER area and bodily injury can
occur, even if the engine is stopped. Reason – the accumulator has a stored charge of high pressure oil
which can throw the swingtube or rotate the remixer blades. If work must be performed inside the
hopper, mechanical disconnection of the hydraulic motor and cylinder that powers the remixer shaft
and swingtube respectively must be done prior to entry. Discharge swingtube accumulator circuit and
stop the engine. Always use CAUTION!!!

2 DRIVING AND OPERATING INSTRUCTIONS
2.1 DRIVING INSTRUCTIONS:

2.1.1 PRIOR TO STARTING THE UNIT, THE FOLLOWING STEPS SHOULD BE CARRIED OUT:
• Check oil and coolant level in the engine. If it is low, do not start until it has been topped up.
• Check the hydraulic oil level. This must be at least half way up the sight gauge when oil is cold.
Again do not start until this is achieved.
• Check the oil level in the lubrication box (water box), it should be at least half full. Do not over fill
as the oil will spill out as the pistons move. Use old hydraulic oil in the lubrication box.
• Grease all joints on the pump and boom. It is very important as parts will fail quickly without
grease.
• Ensure park brake is engaged.
• To ensure boom does not operate on start up, check that the remote lead is disconnected or
switched “off”.
2.1.2 START UP PROCEDURES
To Turn Ignition On
• Battery Isolator Switch turned Off
• Ensure all Emergency Stop Buttons are not Depressed
• Turn Ignition Switch On.
To Start
• Turn Ignition On
• Press Start button
To Drive
• Vehicle must be started
• Remote switch to Manual
• Park brake Released
To Stop Vehicle
• Press Front Stop button (or)
• Press Rear Stop buttons (or)
• Press Radio Remote Stop button (or)
• Turn Ignition Key Off
CAUTION: OBSERVE YOUR SURROUNDINGS FOR HAZARDS AND NEARBY

WORKERS AND SPECTATORS- GIVE DUE WARNING.
CAUTION: SHOULD THE REMOTE CONTROL NOT BE USED FOR A SHORT PERIOD OF
TIME WHILE STILL CONNECTED, ALWAYS SWITCH THE POWER OFF.
THIS WILL REDUCE THE RISK OF ACCIDENTAL STARTUP SHOULD THE
JOYSTICKS BE BUMPED.
WHEN PARKING THE UNIT ENSURE PARK BRAKES ARE ENGAGED

2.1.3 Turn the Isolator Switch to the Right Position.
BATTERY
ISOLATOR
SWITCH
2.1.4 Make sure all EMERGENCY switches are released by turning counter clockwise.
There are 3 Emergency switches.
• One inside the driver cabin on the Front Dash.
EMERGENCY
STOP

• Second Emergency Stop locates at the rear Driver Side Control Panel.
EMERGENCY
STOP
• Third Emergency Stop locates at the rear Passenger Side.
EMERGENCY
STOP

ALT
TRAM Engine
PARK Engine oil
PRESS Run Remote
RANGE Engine throttle
2.1.5 Ignition temp
STEER
Brake
Pressure
PARK
BRAKE
OVER RIDE
1. Turn PV100
IGNITION
SWITCH to
“ON”
2. Push to
start the
engine.
3. Select
TRAM
MODE to go
Park
FORWARD
brake
or
test
REVERSE.
4. Select
LOW/HIGH
RANGE
Rear work light
5. Select mode:
STEERING Head lights
6. Select DRIVE/REMOTE
DRIVE to drive. Top work lights

DRIVER CONTROL PANEL
2.1.6 Acceleration/Deceleration & Service Brake Pedals.
SERVICE BRAKE ACCELERATION

PEDAL PEDAL
Throttle Throttle Switch

Up/Down ON/OFF

2.1.7 Operating Driving Gear Shifter
NOTICE TO OPERATORS. PLEASE READ BEFORE ATTEMPTING TO DRIVE.
DO NOT TRY TO CHANGE SPEED WHILE MOVING AND CHECK FULL ENGAGEMENT
BEFORE MOVING OFF.
ALWAYS SHIFT TO NEUTRAL BEFORE SELECTING GEAR WITH SERVICE OR PARK

BRAKE APPLIED.
THIS UNIT IS FITTED WITH 2 SPEED TRANSMISSION HIGH / LOW with NEUTRAL IN
CENTRE POSITION.

2.2 QUICK OPERATIONS GUIDES
Engage PARK BRAKE Switch to REMOTE
DRIVER CONTROL PANEL

• Start up the engine as per previous instruction.
• Engage PARK BRAKE
• Select “REMOTE” on DRIVE/REMOTE switch.
• Set up Stabiliser Legs, ensure the legs are taking some load and the machine is level.
• Plug the remote control lead into its socket.
• Fit remote harness over shoulders.
• Switch power selector to “ON” position.
Now Boom, Robot, chemical pump and concrete pump can be all operated by the
remote control.
Front & Rear

Stabiliser Valves
– on front of
Driver side

* Boom Up * Extend * Nozzle Forward

* Boom Down * Retract * Nozzle Back
* Slew Right * Tilt Forward * Nozzle Right
* Slew Left * Tilt Back * Nozzle Back
* Oscill ON Fire
Suppression
* Chem Pump Pump

* Scale * Forward
* Reverse
Lancing (If Fitted)

* Reset * Extend
* Stop * Retract
RADIO REMOTE CONTROL

MANUAL BOOM CONTROL
UP RIGHT EXTEND FWD RIGHT
BOOM BOOM BOOM NOZZLE NOZZLE
DOWN LEFT RETRACT BACK LEFT

2.3 SHOTCRETE BOOM

SPRAY HEAD : 0H-6300-002-N.
Model: JSB-040-NL-A
Diesel power by PERKIN 3056TA engine.
Hydraulic Pump: 45cc Load Sense Piston Pump.
Load Sense Control Valve Bank.
Radio remote with Manual Remote for back up.
2.4 SHOTCRETE BOOM WORKING RANGES

2.5 PUMP, BOOM AND NOZZLE OPERATING INSTRUCTIONS

LOCATION OF PRONTO
• Locate the unit where it can be made as level as possible and the hopper as low as possible where
the Ready-Mix Trucks will have easy access to the hopper at all times.
• Try to position the unit so maximum area of shotcrete can be attained with minimum repositioning
of the PRONTO.
PREPARING THE PUMP FOR OPERATION – HOT & COLD CLIMATE CONDITIONS
In cold weather, do not start the pump motor unless the hydraulic oil temperature is -100C or above. Use
electric heaters in the oil tank to heat the oil to -50C. Remember, the hydraulic pumps are connected
directly to the engine shaft and they could be damaged if the oil too cold. Allow the oil warm up to a
minimum of 100C before starting the concrete pumping operation. Cold oil will cause the pumps to
cavitate and cause SEVERE DAMAGE.
Once the unit is parked and ready for pumping operation, set up the boom as follows:
• Ensure Park Brake is engaged.
• Ensure all stabiliser legs are taking some load.
NOTE: Do not try to lift unit off the ground. The legs are only for stabilisation.
• Plug the remote control lead into its socket.
• On the main driving dash select Remote:
• Fit remote harness over shoulders.
• Switch power selector to “ON” position.
Now Boom, Robot, chemical pump and concrete pump can be all operated by the remote control.
CAUTION: SHOULD THE REMOTE CONTROL NOT BE USED FOR A SHORT PERIOD OF
TIME WHILE STILL CONNECTED, ALWAYS SWITCH THE POWER OFF.
THIS WILL REDUCE THE RISK OF ACCIDENTAL STARTUP SHOULD THE
JOYSTICKS BE BUMPED.
HINTS ON OPERATION
• Operate boom smoothly
• Hasty movements will shorten the life of the boom
• Try to locate the unit as close as possible to the job so as to minimise the load on the unit.

PRIMING THE PUMP FOR OPERATION.
Starting the pumping operation requires that a coating of lubricating grout be pumped through the concrete
valve unit and into the line so that the regular concrete mix will flow smoothly. The grout should consist of
two part sand to one part cement, mixed to the consistency of thick soup. The grout coats the line ahead of
the concrete mix to ensure lubrication of the concrete and prevents packing when the line is being filled
during the primary operation.
The amount of grout needed will depend on the length of line and harshness of the material being pumped.
It will generally require about 30 litres to lubricate the system. Experience will indicate that more or less
grout will be required, depending on the length of the line, consistency of the concrete mix and whether
pumping uphill or downhill.
REMEMBER: CONCRETE PUMP PRESSURE CAN BE DANGEROUS
DELIVERY LINE INFORMATION AND SAFETY TIPS
The concrete pump is capable of developing a pressure of approximately 60 Bar (840psi) on the concrete at
the discharge outlet of the pump. However, average pumping pressure will normally be somewhat less
than the maximum.
• The transport system shall be capable of withstanding the maximum pumping pressure of 60 Bar
(840psi).
• Pressure is highest at the concrete pump outlet and reduces uniformly to zero at the discharge end of the
transport line under normal pumping condition.
WARNING: If a dry pack or blockage does occur in the delivery system, pressure up to 60 Bar
(840psi) will be developed and contained within the ENTIRE delivery system from the
pump to the point of pack blockage.
Use cautionary procedures under these conditions.
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 JACON. Failure to
observe these rules can result in serious personal injury and damage to equipment.
• JACON stresses the usage of SHOULDERED delivery systems and clamping devices that are
specifically designed for Concrete Pumping applications. All concrete pumps delivered from JACON
are equipped with this type of delivery system.
• Pumping pressure can be reduced by using a larger delivery system or reducing the pump rate (volume
output).

2.6 SHOTCRETE PUMP OPERATIONS

PRINCIPAL OF OPERATION
PRINCIPLE OF CONCRETE PUMP OPERATION
The concrete pump consists of a receiving hopper, two concrete cylinders and pistons, and a swing tube
concrete valve. A continuous flow of concrete through the dilivery line is produced by the sequence of
operation of the two concrete pistons with the swingtube. The swingtube rocks between the two
concrete cylinders under a controlled hydraulic sequence to direct the flow between the two concrete
cylinders, the hopper and the discharge outlet. The swingtube allows one concrete cylinder to be
directly open to the hopper on the suction stroke, while simultaneously the other cylinder is directly
connected through the swingtube to discharge. At the end of the piston travel the direction changes and
the swingtube is shifted to direct the flow output from the other cylinder to discharge.
The two concrete pistons and swingtube are driven with hydraulic power. Hydraulic pressusre and
flow is alternately applied to the two hydraulic pistons which in turn drive the two concrete piston.
Alternate pressure is applied to the ends of the swingtube throw cylinder.
Hydraulic pressure applied to the piston rod side causes one piston to move forward on the discharge
stroke, while a closed slave loop connecting the piston head ends causes the other piston to move back
on the suction stroke. This reciprocating action is controlled by two impulse valves. These impulse
valves are located on the ends of the master hydraulic cylinder and are hydraulically actuated by the
movement of the piston in the master cylinder. One actuator on the front of the master piston operates
an impulse valve which in turn controls the swingtube hydraulic piston changeover valve (cycle valve).
The second actuator on the rear of the piston operates a second impulse valve to change piston travel
direction and swingtube motion. The control of both pistons, so they maintain an exact, opposed
diagonal relation as they reciprocate, is obtained through two simple by-pass ports in the slave
hydraulic cylinder. As the piston in this cylinder travels back and forth to the ends it will add or
subtract oil from the closed slave loop connection of the piston head areas of each cylinder. Therefore
on every stroke the position of the cylinders is monitored. Exact piston travel is controlled to allow
equal concrete.

2.7 CHEMICAL PUMP

2.7.1 CHEMICAL PUMP OPERATION
The accelerator dosing pump is a hydraulic driven hose pump, which is activated by a
solenoid valve. There are two electrical switches to activate this solenoid valve. One is
located on the rear control panel, the other is located on the cordless remote control. The
switch on the rear control panel is a two position switch. The two positions are MANUAL
and PUMP. The switch is placed in the MANUAL to calibrate the dosing system without
the necessity to have the concrete pump stroking. Once the system has been calibrated,
then the switch can be turned to the PUMP position. In this PUMP position the dosing unit
will now only operate when the concrete pump is stroking.
2.7.2 Calibrating the dosing system
To calibrate the dosing system, the engine must be running and there must be
pressure on the accumulator pressure gauge.
On the rear control panel, switch the dosing unit control switch to MANUAL.
There is a flow control valve located on driver’s cabin side, beside display flow meter. The
hydraulic motor that drives the dosing pump has a valve that may be adjusted to increase
or decrease the output of the dosing pump.

Located beside the flow control valve is a flow-rate totaliser unit. This will give a digital
display of output in litres per minute and also the total usage per job. This used in
conjunction with the above flow control valve, allows for accurate adjustment of the
dosing pump output.
Once the desired litres per minute output of accelerator has been reached, the electric
control switch on the rear panel will then switched to OFF position, the dosing system will
now only operate from remote control.
2.7.3 CALCULATING THE DOSE RATE
1) Decide the dose rate
i.e.: SA 160 @ %5 by weight of the cement content of a cubic meter shotcrete
2) Determine the cement content per cubic meter of shotcrete
i.e.: 450 kg/cubic meter
3) Calculate the amount of accelerator required per cubic meter
450 kg x %5 = 22.5 kg
22.5 kg/ divided by 1.4 (SG of SA160) = 16.07…… Say 16 litres per cubic meter.
NOTE: To calculate the flow rate of the accelerator, the output of the pump in cubic
meters per hour must be determined. The output can be calculated by either
of the following methods:
Method 1
Time how long it takes to pump 1 cubic meter of shotcrete and then relate that to
cubic meters per hour.
Method 2
Calculate the volume of one concrete cylinder and count the number of strokes per
minute the pump is set at.
(Using the equation Π x r² x length)
I.e.: One cylinder =Π x 75mm radius² x 1145mm long = volume of approx. 21 litres.
If the pump is cycling at 12 strokes per minute, then the output is 252 litres per minute
which equals 15.1 cubic meters per hour.

NOTE: The above calculations are theoretical and are based on the concrete
cylinders filling to full capacity on each stroke. In practice, all calculations
should be based on 80% of theoretical volume. The following example can
now be used to calculate the Flow Rate of the Accelerator.
Example
To calculate the flow rate of Accelerator per minute based on the above calculations.
Required dose rate of accelerator is 5%. Bwc
Cement content per cubic meter is 450 kg
Accelerator required is 16 litres per cubic meter
Pump output: 15.1 cubic meters less 20% = 12.08 cubic meters per hour (Say 12) which
equals 192 litres of accelerator per hour or 3.20 litres per minute.
2.8 ELECTROMAGNETIC FLOWMETER
Includes: 15mm bore electromagnetic flow meter with remote LCD display head reader
indicating Dual Litres/min to 1 dec.pl. + resettable total in litres. Wired with
1.5m cord for connection to 11-40VDC power source. Wired via 2metres
special signal cable to 15mm flanged sensor. Sensor fitted with opposing
15mm galvanized BSP(f) flanges, earth straps attached. Sensor also is
equipped with internal grounding probe.

Special durable remote wand magnet via 20cm S/S cable attached to reader.
Features: Wand resets totaliser total marked “reset”.
The flow meter is pre-programmed, customized and calibration checked.
No re-calibration is necessary
No on going maintenance required
Sensor does not block, no filters required.
Options: The function that changes display readings to forward/reverse/grand total,

velocity etc can be permanently disabled on request.
The MFS MagMaster is designed to be a highly accurate yet simple to use flow
meter and flow totaliser. The MagMaster requires no program setting and is ready
to use from delivery. The flow totaliser can be read and operated from the display
on the drivers side of the unit using the supplied magnetic button. The main reset
button is used to reset the flow total. This button is the main control of the unit.
The other button is used to change the display. This button cycles through the
options and then goes back to the beginning.
NOTE: DUE TO THE NATURE OF THE CHEMICAL PUMP, THE FLOW RATE
TOTALISER WILL TAKE 30 SECONDS TO GIVE A TRUE READING.
For further information on the Electromagnetic Flowmeter, please refer to ABB’s

operation manuals.

3 CONCRETE PUMP SPECIFICATIONS

Model: S20
Type: Swinger tube model with dual reciprocating pistons
Pump: 125mm hardchromed concrete cylinders with 910mm stroke.
Power unit: Diesel Engine.
Hydraulic pressure Max.: 210 BAR.
Variable Rated output: 0 to 25 m3/hr.
Line pressure max. 47 Bar.
Vertical reach: 40 metres.
Horizontal reach: 120 metres.
Aggregate size: * Up to 20mm that falls within the accepted grading curve for
pump mix.
Note: * Performance may vary due to material mix or line set up.
Features:
• Dual circuit hydraulic system for smooth positive swinger tube action.
• Electric over hydraulic pilot system with manual over-ride.
• Fully automatic stroke adjustment.
• 71cc Variable Displacement Piston Pump.
• Pressure filtration.
• Heavy duty suspension axle.
• Radio Remote & Manual Remote .
3.1 MIX DESIGN

3.1.1 Effects of Mix Design on Pumping
The correct mix design is most important in achieving maximum pump ability. Pump ability is affected
by, among other factors, the type and gradation of the aggregates used. In general, nearly all readily
workable concrete mixes can be pumped. Natural type aggregates make a more workable mix and pump
more readily than crushed aggregates. A blend of natural and crushed aggregates will produce a workable
mix. The type and gradation of an aggregate is equally important for workability as the size and
percentage of course aggregates in the mix.
Concrete mixes with a consistency as dry as 25 mm slump and as wet as 250mm slump have been
pumped, but to get maximum efficiency from the pump, slumps in the range 75mm to 125mm will
produce more pumpable mixes.
However, a slump rating should be used with discretion. It is not always a true indication of the pump
ability of the mix. The concrete may be workable in that it will readily flow into place, but the same mix
may not respond to pressure. Overly wet mixes tend to segregate. In addition to effecting the strength and
integrity of the concrete, segregation can not be tolerated in the transport lines. Overly dry mixes are
similarly unsatisfactory if the lack plasticity and are crumbly. To be properly pumped, the mix must be
able to continuously coat the inside of the line with a lubricating slurry of mortar.

The principle of concrete pumping is based on self-lubrication of the transport lines. As it moves through
the line the concrete takes the shape of a plastic cylinder. It is forced along the pipeline on a film of
mortar that is self-trowelled to the surface of the pipe around its full periphery by the slug of concrete.
There are three ways in which the lubricating slurry can be lost:
1) By pumping excessively wet mixes which do not have enough cohesion to hold together.
2) By pumping harsh, under-sanded concrete with poorly graded aggregates, which can jam together
when the pressure becomes too great for the insufficient amount of sand to hold the aggregates
apart.
3) Through excessive bleeding. If the mix is low in fines, but the sand is otherwise fairly well graded,
bleeding will not normally cause any problems as long as the pump continues operation.
But, if the pump is shut down, bleeding can cause a loss of lubricating slurry and blocked lines can occur
when pressure is re-applied to the concrete.
These are bad concrete practices anyway, regardless of how the mix is to be placed. But these points do
show that special mixes are not always needed, within limits, for pumping concrete. Good aggregate
gradation is most important to pump concrete the maximum distance.
The use of admixtures can have a beneficial effect on pump ability. Most of the dispersing agents will
reduce bleeding and improve the workability of the mix. Thus the concrete can be pumped longer
distances. Air entraining agents will reduce bleeding. Super plasticisers will improve workability and
reduce the amount of water required, thus also improving the ultimate strength.
However, admixtures can not be used as a substitute for good aggregate gradation.
3.2 PRIMING THE PUMP

Mix a thick slurry of cement and water and tip it into the hopper. A sufficient amount must be mixed to
ensure that there is enough to coat the inside of the transport line.
NOTE:- In most shotcreting situations, the transport line consists of one rubber line, a reducer and a
couple of elbows. In this situation, a bucket full of thick slurry introduced into the reducer and then pused
along by the concrete is quite adequate.
Introduce some concrete from the delivery vehicle into the hopper.
DO NOT add any water to the hopper prior to or during the addition of the first amount of concrete. This
water could cause the concrete to segregate and could also dilute the priming slurry sufficiently to cause
an immediate blockage.
PUMPING
• Increase the RPM of the motor to its pre-set maximum.
• The pressure reading on the accumulator valve should now be between 75 and 95 bar (1100 and
1400 PSI)

• Make sure the forward/ reverse switch is in the “forward” position.
• Operate the start switch.
• The pump should start to stroke.
NOTE:- By removing the cover from the pump lubricating box, the movement of the hydraulic pistons
can be observed.
The concrete should now be slowly moving along the transport line. If a shotcreting nozzle is attached to
the hose, make sure that the air is turned on to the nozzle as failure to do so will cause concrete to be
forced into the air holes in the nozzle and block it. Should this happen, immediately dismantle the nozzle
and thoroughly clean it.
Once the concrete is being discharged, the flow control knob can be rotated clockwise, should a greater
rate of discharge be desired.
3.3 REMOVING A BLOCKAGE

When a blockage occurs in the delivery system, the pumping pressure gauge will reach the
maximum of 170 bar (2500 psi). The needle will remain at this point and high-pressure oil can be
heard being dumped through the pressure relief valve. The stroking of the pump will cease.
IMMEDIATELY SHUT THE PUMP OFF.
Change the forward/ reverse switch to reverse. Cycle the pump for three strokes. Change to forward and
cycle the pump. If normal pumping resumes, then the blockage has been dislodged. If the hydraulic
system “pressures out” again, indicating that the blockage has not been displaced, immediately reverse
the pump until no concrete rises in the hopper. This reversing should release the pressure from the
blockage back to the pump.
CAUTION: IT IS POSSIBLE FOR PRESSURE TO STILL BE CONTAINED WITHIN THE

DELIVERY SYSTEN. EXTREME CARE MUST BE TAKEN WHEN REMOVING
CLAMPS. WARN ALL PERSONS IN THE AREA AND REMOVE CLAMPS
SLOWLY.
CAUSES OF BLOCKAGES
There are many contributing factors to a blockage occurring in the delivery system. The following are a
few of them.
• A non – pumpable mix design. Sand too coarse, a high percentage of large rock and poor gradation of
the components in the mix design.
• Foreign matter in the mix (cans, sticks, etc.)
• If steel or polypropylene fibres are being used, poor mixing practices can caused balling of the fibres.
Because only small aggregates are being used, care must be taken when introducing fibres to the mix,
as the smaller aggregates do not create the same mechanical action as the larger aggregates. This
mechanical action is needed to properly disperse the fibres and eliminate balling.

• Bleeding of water and paste from the mix.

During long standing times between cycles of the concrete pump, this situation can occur, especially
if the mix has a slight deficiency in fines. To combat this, reverse the pump one or two strokes then
change to forward. This will keep the concrete moving which will slow down the rate of bleeding.
• Kinking of the delivery hose.
• Sudden reduction of the concrete through a reducer. Always use the longest possible reducer
available, this will allow the concrete to gradually reduce through the system. When pumping with a
reducer, start the pump at a lower volume than normal, then increase the volume gradually until a
desired flow is achieved.
• Restrictions within the delivery system. Lines not properly cleaned after the last operation. Hoses
which are worn out and are suffering delamination of the inside layers.
3.4 HINTS ON SHOTCRETING WITH THE ROBOSHOT PRONTO

The following will, hopefully, give ideas on how to shotcrete with the PRONTO in safe and efficient
manner.
• No concrete should be ordered before the area where shotcrete work will take place is checked.
Check for “low points” along the route ie. Vents bags, air and water pipes, or cables. Also check
the actual height of the tunnel, to assist have a stick cut to length of the minimum height necessary
for both PRONTO and the concrete transporter. (Remember to check the width also). If the
concrete is delivered by a concrete truck find a place where is can easily turn around and relay the
information onto the batch plant.
• Check location of water and air valves and that the couplings are the same type and size as the one
the shotcrete crew is equipped with. Make sure that there is sufficient air and water pressure in the
lines. Having adaptors with the most common type of couplings should be part of the standard
equipment for the shotcrete crew.
• The area should be well ventilated both for health reasons and to clear the dust and fumes away
from the working area. This is critical as the operator should always be able to observe what is
happening when the shotcrete jet hits the wall. This ensures he can carry out the necessary
adjustments with accelerator, nozzle distance and angle all determining the quality of the applied
shotcrete accelerator consumption and percentage rebound. If for some reason the ventilation
cannot be improved, suggestion is to reduce the loads and allow longer intervals between loads.
This will assist in clearing the air between loads.
Note: No-one can expect good quality shotcrete, low rebound and low accelerator
consumption if the operator is not able to see exactly what is happening “on the wall”.
• Backs and roof should also be checked. The main reason is your safety, but remember when
scaling down, always work from a safe area. Do not attempt to scale down without the right
equipment and training. If in doubt as to safety, report immediately to a responsible person. If no
action is taken, make a note on the shift report. If the area is later checked for bond (“the hammer
test”) for drummy sound, it is not necessarily the bond between shotcrete and rock that has failed,

but is in fact the loose rock that gives the drummy sound. If in doubt request a qualified person to
check any dubious areas.
• The Pronto must be kept well maintained at all times. All repairs must be carried out as soon as
practicable. Doing a “walk around check” before any concrete is ordered should always be part of
your routine checks. Ensure all lights are OK and that the glass is clean. Remember, good
visibility is a must.
• Check diesel, hydraulic oil, engine oil, accelerator and water box oil, fill up if necessary.
• Start up the PRONTO and check that the remote control and pump are functioning.
• To make up a list of what kind of tools, spare parts, hoses etc, the list should be almost endless.
The minimum you should have on the PRONTO or on the list is; spare nozzle tip, spare concrete
hose clamps-all dimensions. One hydraulic hose, all dimensions, long enough to fit every hose on
the PRONTO. Tools and material to repair air hoses and water hoses, sufficient water and air
hoses to extend to air and water valves, tools, slump test equipment, 20 its Rheobuild super
plasticiser and bucket of cement for slurry.
• Where possible the Batch Plant should be told well in advance the planned time for starting the
shotcrete work so they can schedule it in with the other delivery they might have.
• Other information when ordering concrete should be total volume planned to be sprayed. Volume
per load, time the truck should be at the shotcrete rig or at the reloading point. Intervals between
loads, any change in mix-design, and, the precise route to the PRONTO or the reloading point.
• When the PRONTO is in position at the front end of the area for shotcrete, prepare for washing
down of the surface. Connect air hose to air manifold and air valve, the joints should be secured
with a “whip check cord”. Connect the water hose via clean out head to the concrete steel pipe at
the nozzle.
• Start washing from the highest point of the area to be shotcreted, observe that the surface is clean
ie. that the water flowing away from the area is clean. Also make sure that there is no loose
material laying on “shelves” on the wall.
• The air/water jet can wash away the “glue” that hold some rocks in place, so for safety reasons
washing shall always start at one end of the area and be carried out in a manner so no-one will be
in a newly washed area.
• When washing is completed, connect the concrete hose to the steel pipe at the nozzle and move
the PRONTO back to the starting point. Spray the whole PRONTO with form oil or other suitable
material.
• When the first load of shotcrete arrives, mix a “fat” slurry of water and cement and fill it into the
shotcrete hose at pump end. The slurry will “travel” in front of the shotcrete and lubricate the
walls inside the concrete hose, failure to do this will most likely result in a blockage in the
concrete hose. Connect the concrete hose to steel reducer pipe again and you are ready to spray.
• Check delivery note against ordered mix-design. Fill the hopper and visually check the slump and
that there is fibre in the mix (if fibre is a part of the mix design). If there is any doubt about the

slump, or the operator does not have the experience to visually determine if the slump is within
the given limits, request the concrete supplier to confirm slump.
• Fill the hopper with concrete and pump a few strokes before opening air pressure to nozzle. If the
air pressure is opened to the nozzle before any concrete is pumped into the line, the air will blow
the slurry back into the hopper. So when pumping starts there will be no slurry to “travel” in front
of the concrete and most likely a blockage will occur.
• Open air to the nozzle with nozzle pointed away from the area to be shotcreted. Start accelerator
pump and adjust so a find mist of accelerator is coming from the nozzle, observe the behaviour of
the concrete when it hits the surface. The shotcrete should still be “alive” when it hits the surface,
but not so wet that the impact from the jet creates “waves”. To control this, the operator can
change the distance between nozzle and surface, adjust volume of accelerator, adjust air pressure,
or maybe all of the above.
• Shotcrete must always start at the lowest part of the area to be sprayed. Remember always to
avoid spraying over rebound that is trapped of “shelves” of the wall. Use the boom extension to
travel the nozzle parallel to the tunnel surface while the nozzle is manipulated with the tilt and the
left/right movements of the robot to follow the contours of the surface. Use the right/left and
up/down movements of boom to help if necessary and to control the distance from surface.
• The joysticks on the remote control should be opened smoothly. All movements on the Mk3 are
fully proportional so how the nozzle and boom is moving will be a “direct mirror image of how
the operator handles the joysticks”.
• The handling of the joystick is good measure of how experienced the operators actually are. An
operator who is able to operate the boom and nozzle smoothly, shows that he knows his rig and is
able to plan his work so no rapid movements are necessary.
• To estimate how thick you can apply a layer, it is possible to build upon different types of surfaces
to see how the shotcrete will perform. An operator needs a lot of experience, even for a fully
experienced operator it is still a difficult task.
• Normally, there is no problem with vertical surfaces. It is spraying over head that is the problem.
This is why there usually is more shotcrete on the side of the tunnel than on the back or roof
where it is most needed.
• If “drop-outs” do occur from the shotcreted area during spraying, the operator should immediately
start applying the shotcrete in thinner layers. Building up to full thickness with several thin layers.
If the layer is too thick, shotcrete can also just “slip” from the surface, destroying the bond
between shotcrete and rock, and where there is no bond there is no “gluing” effect locking the
rock surface together. That is why it is so important to take care when spraying that no thicker
layer is building up than the bond between surface and concrete can support. Both to save costly
shotcrete being wasted and to achieve good bond.
• The way to achieve this is to first spray a thin layer, starting at the bottom of on wall. Spray a thin
layer up that wall and into the centre of the roof. Spray the other wall and continue with the roof
into centre line. Start build up to full thickness on the first wall and continue with another thin
layer on the roof into centre line.

• Start at the bottom of the second wall and build up to full thickness. When reaching the roof,
continue with a thin layer into centre line. Start again with the first half of the roof and build up to
full thickness. Complete the spraying with build up to full thickness of second half of the roof.
The idea is to build up the thickness in the rood with several thin layers, which is allowed to “set”
while spraying the walls. If the thickness is more than 75mm, it can be necessary to use more
layers, or to move the PRONTO into the next section and complete the roof in the first section
after sufficient “set” time. But remember the first section should still be “green” when it is
completed to avoid “cold joints”.
Also remember never to work under fresh applied shotcrete.
• When a “drop-out” does occur, the operator should never try to respray that section immediately.
The surrounding area should have time to “set” so that the bond between the rock and the
shotcrete can hold-up the extra weight from shotcrete that will build up on the “edges” around the
“drop-out” during respraying. Trying to respray a “drop-out” at once will, in most cases result in
more shotcrete on the floor.
The reasons for “drop-outs” are in most cases:
1. “Drop-out” from a rock bolt steel plate (bond between steel and concrete are close to zero).
2. “Drop-out” from an area normally close to a rock bolt, where there is oil “spill” from drilling
the rock bolts holes.
3. “Drop-out” from an area with (locally) lower bond capacity than the surrounding areas.
4. “Drop-out” from an area where the weight of the shotcrete overrides the bond capacity of the
surface eg. Shotcrete too thick.
5. “Drop-out” from an area where (locally) the rock is so cracked and fractured that a piece of the
rock surface itself will loosen due to the extra weight of the shotcrete.
• If larger sections of the sprayed area are falling out, the reason could be a too thick layer applied.
If there are pieces of rock falling down together with the shotcrete, the rock surface itself may be
so cracked and fractured that it cannot support the weight of the shotcrete. The solution – thinner
layers.
• If shotcrete work is carried out in areas with extremely poor bond or extremely poor rock
conditions, a thin layer with increased dosage of accelerator should be applied as first layer, then
given time to “set” before full thickness is built up. This thinner first layer will “glue” the rock
surface together and give good bond for the subsequent layers and always remember the next
layers should only be sprayed while the earlier layer is still “green”. This is to avoid “cold”
joints.
• But, the most common reasons for “drop-out” are poor preparation and workmanship during the
wash down process.

3.5 CLEANING THE PUMP

It is very important that the operator knows and follows the correct procedure for cleaning the pump. The
operator must use caution when cleaning the pump. The operator shall never place his hands in the
hopper when it is necessary to clean a blockage out of the hopper. The operator must be sure the power
to the pump is completely shut down with the engine turned off and that only a tool is used to clean out
the blockage, not the hands. The operator shall also warn everyone that may assist him in cleaning the
pump, that they must never place their hands in the hopper.
• Pump the remaining material out of the hopper until it is nearly empty, then turn the pump
switch off. Open the discharge door in the bottom of hopper and wash the entire hopper clean
with water.
3.6 CLEANING THE PIPELINE

Water is safer to use than compressed air when cleaning out the pipeline. Whenever possible it is always
recommended to use water rather than compressed air. When cleaning the pipeline, the following
precautions should be observed:
• All personnel involved in the clean-out procedure must wear protective clothing and
equipment as necessary, i.e. goggles, helmet, safety shoes and glasses.
• All components of the pipeline being cleaned must be secured against movement during
purging.
• No person should be in line with the direction of the discharge from the pipeline.
• The person in charge of the clean-out procedure must have visual or audible interference-free
communication with a responsible assistant positioned to monitor the discharge end of the
pipeline during the clean-out.
• No part of the pipeline shall be disconnected nor shall the pipeline be left unattended unless it
has been established that the pipeline is free of internal pressure.
• The clean out personnel shall ensure that all waste be disposed of in a manner so as not to
contaminate the environment.
3.7 CLEANING THE PIPELINE WITH WATER

Using the Concrete Pump
• Close the hopper and completely fill hopper with water.
• Start the pump cycling at ½ the full volume. Water will force all the concrete in the pipeline to
discharge. Water will flush lines clean.
• Disconnect delivery line from back of hopper outlet and open hopper door to discharge all
water.
Using a Water Pump

• Put clean-out ball into the pipeline.
• Attach the clean-out head to the pipeline.
• Apply the water pressure. This will push the ball and concrete out of the line.
Refer Reference Material – Slide No. 14
3.8 CLEANING THE PIPELINE WITH COMPRESSED AIR

• Put clean-out ball into the pipeline.
• Attach the clean-out head to the pipeline.

Refer Reference Material – Slide No. 14
• Apply the air gradually (for safety reasons as well as not to make too much mess at the
pipeline discharge point).
• Repeat the same process but use two balls with a slug of water between them will ensure the
pipeline is thoroughly clean.
CAUTION: NEVER DISCONNECT ANY PART OF THE PIPELINE UNLESS IT HAS BEEN
ABSOLUTELY ESTABLISHED THAT ALL PRESSURE HAS BEEN RELEASED.
3.9 CLEAN-UP
Cleaning up at the end of the job is as important as any other part of the job.
By following the steps set out below, the cleaning operation can not only be effective, but also not take
too much time.
Step 1. Remove the shotcrete nozzle if one is being used and immediately wash it thoroughly, paying
particular attention to the inside of the nozzle and the air holes, connecting a water hose to the air inlet is
a good way of flushing out the air holes. Should any holes be blocked, the nozzle should be dismantled
immediately. Do not leave it till later as the concrete will be a lot harder and the nozzle could be damaged
when trying to remove hardened concrete.
Step 2. Remove the bends and reducer. Insert the clean out sponge in the clean out assembly and
connect it to the line. Very carefully apply a small amount of air pressure to the system and force the
sponge through the line. The discharge end of the line should be secured to stop it from whipping around
when the pressure is applied. This process should be repeated a minimum of three times, adding some
water to the line each time before reconnecting the clean out assembly.
DO NOT apply full air pressure to the clean-out assembly, as severe injury could be caused.
Step 3. Open the clean-out door under the concrete hopper and thoroughly wash all concrete from the
hopper, paying particular attention to all corners. If the pumping campaign was over several hours, some
of the built up concrete may be set. Use a small bar to remove this build up.

Step 4. With the pump operating in reverse and the hopper clean-out door open, put a water hose into
the outlet of the pump. This will clean out the swing tube and the concrete cylinders. Keep on with this
operation until the water runs clean. It is necessary from time to time to check for build-up inside of the
swing tube. To do this, follow the safety procedures outlined under section 1.3 to ensure that all stored
pressures are released. A ¾” rod, bent into a slight arc and with a half circle scraper welded to it is a
sufficient tool.
NEVER INSPECT BY INSERTING A HAND INTO THE OUTLET.

4 MAINTENANCE
4.1 GENERAL INFORMATION
The Pronto is designed for long, trouble free performance. Nevertheless, breakdown is
possible if proper maintenance is not performed as specified intervals.
Maintenance and lubrication procedures detailed in this section are of the utmost
importance and avoid costly breakdowns and loss of valuable production time.
4.2 ESSENTIAL PART LIST
ITEM DESCRIPTION PART NUMBER QTY

ENGINE PARTS
24V Alternator CAT C4.4 JSE-NAB300-24 1
Starter Motor JSE-BX368085 1
Oil Filter JSD-7W-2326 1
Fuel Filter Water Separator Cartridge JSD-308-7298 1
Fuel Filter JSD- 299-8229 1
Radiator Coolant JSO-RADGUARD 505
Vee Belt JSFS-2614B855-197 1
Filter Element As - Air (Primary) JSFS-P532966 1
Filter Element As - Air (Secondary) JSFS-P533781 1
Filter Element As - Air JSFS-110-2556 1
Battery JSE-MFM70-900 2
CONCRETE PUMP
Piston cups PM-1251070-031 2
Piston cups O ring JSSE-BS425-90 2
Concrete Piston PM-1251070-029 2
Couplings PM-1251070-043 2
Wear Plate SH-5000-059 1
Wear Ring SH-5000-060 1
Wear Ring Adjustment Seal SH-5000-061 1
Flange Bearing SH-5000-041A 1
Bell Crank SH-5000-033 1
Chromed Sleeve SH-5000-034A 1
Outlet Seal SH-5000-044 1
Outlet Seal Housing SH-5000-043 1
Outlet O-ring JSSE-BS258-90 1
Outlet Flange. SH-5000-045 1
Gland Packing Seal JSSE 2
Hopper Safety proxy JSE-E2E-X5E1-M1 1
Gland Packing Seal JSSE
Change-over Proxy JSE-X82F-D422-GCO-AZ 1
Hopper Safety Sensor

CHEMICAL PUMP
Chemical pump Hose SP15 JSP-015020 1
Chemical Pump SP15 Lubricant JSP-SP15 LUBE 2 litres
SHOTCRETE BOOM
Boom Cover (1 Set) MJ-6400-165 1
Boom Sliding Pads (1 Set) JSB-SLIDE BLOCK-0400 1
1st & 2nd Extension Cylinder JSB-09.2.502-A 2
3rd Extension Cylinder JSB-09.2.503-A 1
Nozzle tip OH-6300-025 1
Nozzle insert OH-6300-027F 1
Nozzle body OH-6300-026E 1
4” H/Duty Snap Coupling AOS-0012 4
3” H/Duty Snap Coupling AOS-0011 4
Concrete Delivery hose 2.5" X 10mDE AOC-0080-10-DE-SP 1
1/4" hoses X 2.0m MJ-6400-W8 6
Chemical hose x 1,5m MJ-6400-W10 2
HYDRAULIC PARTS
Relief Valve Main Ram JSA-R4V06L00310A1 1
Relief Valve Swing Ram JSA-R4V06L00310A1 1
KK16-2/EMDV-16-N-C2-MI-
ON/OFF Valve
24D-GK4 1
Single Solenoid valves JSA-B66095 (VB-214) 1
3 Position Double solenoid valve ABT Connect 5
Return Filter Element 1
Pressure Filter Element 1
Accummulator 4L JSA-99610 1
Accummulator 2L JSA-99620 1
Pressure gauges 250 Bar JSA-SPG063-250-1-RBU 3
Pressure gauges 400 Bar JSA-SPG063-16BP-RB 1
Level gauge 127 JSA-13663 1
Level Gauge 254 JSA-SNA-254B-S-12 1
Hydraulic oil 68 JSO-HYD-68 200
Oil Cooler fan 24V
KK8-3/EMDV-8-N-3L-S2B-
Catridge Solenoid Valves 24V 24D-GK4 2
TRANSMISSION
Park Brake caliper pads JSDL-02-530-628 1
Front Tail Shaft 1
Rear Tail Shaft 1
Gear Shifting Cylinder Assembly 1
LIGHTINGS
Front Driving Light JSE-9X-1439 2
Front Driving Light JSE-9X-7170 2
Boom HID lights JSE-62-9720F 2
Rear Operating Light JSE-9X-1439 2
Brake Lights JSE-RES-278 2
Warning Lights JSE-1657 2
Interior Light JSE-4M-3601(3E-7301) 2

Amber Strobe JSE-1657 1
ELECTRICAL COMPONENTS
Mini Relay 24VDC – 40 A JSE-57-47393 10
24V Red Warning Light ( 2 PIN) JSE-RES-127 4
Green Warning Light 24V JSE- RES-128 2
Temperature Murphy Gauge JSE—09EGS21T250 1
30 AMP Overload Switch JSE-60-19349 1
Reversing Buzzer JSE-6044 1
Isolator Switch JSE-61075 1
Hydraulic Temperature Sender JSE-RES=125 1
2 Position Switch JSE-ZB2-BD2 5
NO Contact Block JSE-ZB2-BE101 10
NC Contact Block JSE-ZB2-BE102 5
Emergency Stop JSE-ZB2-BS54 2
120 OHM (0.5W) Resistor JSE-933-9884 1
510 OHM (0.5W) Resistor JSE-934-0670 1
3 Position Switch JSE-ZB2-BD3 2
3 Position Switch Spring Center JSE-ZB2-BD5 2
Black Push Button JSE-ZB2-BP2 2
Red Push Button JSE-ZB2-BP4 1
Stop Button Push Pull JSE-ZB2-BT4 1
Push Button JSE-ZB2-BA2 1
Green Push Button Metal Body JSE-ZB2-BA3 1
2 Position Key Switch JSE-ZB2-BG2 1
NO Contact Block & Base JSE-ZB2-BZ101 10
NC Contact Bloc & Base JSE-ZB2-BZ102 2
OTHERS
Hopper Vibrator 24DC
Stabilizer Valve
Water Pump
Hydraulic Jack Leg

4.3 LUBRICATION CHART

Lubrication Type & Description Quantity
GP Hydraulic Oil
Hydraulic Oil
For temperatures above 10’C ISO 68
(General Purpose)
P/N: JSO-HYD-68 400 litres approx.
For temperatures below 10’C ISO 46
P/N: JSO-HYD-46
SAE 20W-40 Grade Engine Oil Approximately:
Engine Oil (API CF Diesel or equivalent) 16L without Filter
P/N: JSO-RM-400-20 17.5L with Filter
Engine Coolant
Greases Valvoline LB-2, BP-LS2 or equivalent Pump until full
LS90 Graded (per differential)

(API GL4 or equivalent with additives for
Axle Differential Oil 9 litres approx.
oil-bath brakes)
P/N: JSO-LS90-20
LS90 Graded (per hub)

(API GL4 or equivalent with additives for
Axle Planetary Hubs Oil 0.5 litre approx
oil-bath brakes)
P/N: JSO-LS90-20
“Food” Graded Lubricant and Coolant mix

Ingredients (>50% of Glycerine, <50%
Chemical Pump 0.5 litre
Propylene glycol)
P/N: JSP-SP15 LUBE (1/2 litre)
Standard Hydraulic Oil is Recommended

Fill until it
(same Hydraulic Oil Grade as used on
reaches the
Pumping Module machine)
bottom of the
Waterbox Lubrication *On an emergency situation when hydraulic cylinder
lubrication is required, Water is also shaft.
applicable.
Cable Reel Gearbox EP90 Graded 2.8 litres approx.

Air Compressor – Fully Synthetic Oil

24 litres approx.
Cooling Oil P/N: JSO-9.5409.00010
Air Compressor -
ESSO UNIREX N3 N-A
Grease
Air Conditioning Refrigerant R134A N-A
4.4 HYDRAULIC CIRCUIT
1. Locations:
Appendices in this Manual

Jacon Manual CD as a soft copy.
2. Hydraulic components:
ITEM
DESCRIPTION PART No QTY
No
1 GAUGE - SIGHT LEVEL+THERMOMETER JSA-13663 1
2 BREATHER FILTER 3/4" JSA-22920 1
3 PB300SGS JSA-PB300SGS 1
4 FILTER-TANK MTD.685L/M+VIS.IND JSA-19465 1
5 COUPLING-MINIMESS 16-20 JSA-74015 1
6 FLOW CONTROL AND CHECK VALVE JSA-FCG-03-125-03 1
7 VALVE-BRAKING-DUAL JSA-VB249SGS 1
ACCUM-DIAPHRAGM-2.0 LITRE-250 BAR-
JSA-99620 1
8 M22x1.5
10 CART.SOL.DIR. JSA-B7560,L 1
11 MOTOR-PISTON-FIXED+FLUSHING JSA-20065 1
12 STEERING UNIT-ORBITAL JSA-67951 1
13 STEERING WHEEL JSA-OP0257 1
14 COLUMN-STEERING UNIT ORBITAL JSA-OP0255 1
15 SHUTTLE 1/4" BSP JSA-69344 4
16 8HSR-LS BOOM CONTROL MANIFOLD JSA-MA582SGS 1
17 ACTUATOR-ROTARY JSA-69621 1
18 4HRS AUX MANIFOLD JSA-MA620SGS 1
19 ACCUM-BLADDER-3.8 LITRE-345 BAR 1-1/4"BSP JSA-99610 1
20 DOUBLE SOLENOID VALVE 24V TWO POS. JSA-66127 1
21 FLOW CONTROL+ BPC.1/2" BSP JSA-69505 1

22 VALV-MONOBLOCK-DIR.45L.2 SPOOL (JJC) JSA-VB257SGS 2

23 VALV-CHECK-DUAL P/OP 1/4"BSPP JSA-69056 4
24 MOTOR-ORBITAL-25.4mm SHAFT JSA-67457 1
25 MOTOR-ORBITAL-25.4mm SHAFT JSA-67140 1
26 CART.12-2 SOL.POP.NO.24V JSA-VB221SGS 1
27 CART.SOL.DIR.2/2 JSA-B7705,H 1
28 FLOW CONTROL+BPC.1/2"BSP JSA-69505 1
29 24V SINGLE SOLENOID VALVE JSA-B66203 1
30 SWITCH-PRESSURE-LINE- MOUNTED JSA-61480 1
31 CART-DIR-24VDIN-BODY JSA-VB171SGS 1
32 MOTOR-PISTON-FIXED JSA-30034 1
33 CART.8-2 SOL.POP.NC. JSA-VB261SGS 1
34 VALVE-RELIEF-CARTRIDGE RRI JSA-VB262SGS 1
35 VALVE-RELIEF-CARTRIDGE JSA-B11360,C 1
36 VALVE RELIEFT JSA-B69804,J 1
37 RELIEF VALVE-S26-75439-0 JSA-R4V06L00311A1 1
DOUBLE SOLENOID VALVE 24V TWO POS.
JSA-66203 1
38 DETENT
39 COUTERBLANCE VALVE JSA-VA.1.033 1
40 TAILEND MANIFOLD JSA-TEM-V-001 1
41 MAIN MANIFOLD 30 JSA-M5000-001 1
42 VALVE 040 ROTATION JSA-VA.1.017 1
43 EXT SEQUENTIAL VALVE JSA-VA.1.030 4
44 DKH DN10-63-8 JSA-500-1125 1

4.5 ELECTRICAL CIRCUITS

3. Locations:
Appendices in this Manual

Jacon Manual CD as a soft copy.
4.5.1 ASH BOARD CONTROL BOX.
ITEM
PART NUMBER DESCRIPTION QTY NOTES
NO.
1 JSE-RES-127 RED WARNING LIGHT LED 24V 4
2 JSE-RES-128 GREEN WARNING LIGHT LED 24V 1
3 WHITE WARNING LIGHT LED 24V 3
4 JSE-09EGS21T250 TEMPERATURE GUAGE MURPHY 12V 1
5 JSE-85093 HOUR METER (HOBBS) ROUND TYPE 1
6 JSE-ZB2-BT4 STOP BUTTON PUSH PULL 1
7 JSE-ZB2-BG4 2 POSITION KEY SWITCH 1
8 JSE-ZB2-BD2 2 POSITION SWITCH 4
9 JSE-ZB2-BA2 PUSH BUTTON 1

4.5.2 MAIN ELECTRICAL BOX
ITEM
NO.
ENCLOSURE TMX3 MAIN
1 JSE-7877854 1
BOX 400X310X111MM
2 JSE-57-22332 MINI RELAY 24VDC 40 AMP 21
RELAY SOCKETS - RELAYS,
3 JSE-57-47000 21
FLASHER

4.5.3 BATTERY BOX
ITEM
NO.
1 JSE-61075 ISOLATION SWITCH 1
2 JSE-419-0178 BATTERY BOX 1
3 JSE-57230 BOOST PLUG 1
4 JSE-1493594 CAT FUSE 1
5 JSE-6012580 80 AMP OVERLOAD SWITCH 2
6 JSE-57-47393 MINI RELAY 24VDC 40 AMP 1
RELAY SOCKETS - RELAYS,
7 JSE-57-47000 1
FLASHER
8 JSE-JAC128F IGNITION RELAY 2
9 JSE-60-19349 30 AMP OVERLOAD SWITCH 1
1 2 3
9
5
8
4.5.4 REAR PUMP CONTROL BOX
ITEM
NO.
LIGHT 4" ROUND LED WITH F9-
1 JSE-RES-278 1
32V STOP TAIL RED
LIGHT 4" ROUND LED WITH F9-
2 JSE-V15-2AML4PB 1
32V STOP TAIL RED
3 JSE-ZB2-BP2 BLACK PUSH BUTTON 1
1 2
4 5

4.5.5 EMERGENCY BOX:
ITEM
NO.
LIGHT 4" ROUND LED WITH
1 JSE-RES-278 1
F9-32V STOP TAIL RED
LIGHT 4" ROUND LED WITH
2 JSE-RES-278 1
F9-32V STOP TAIL RED
3 JSE-ZB2-BZ102 NC CONTACT BLOCK & BASE 1
1 2

4.5.6 REMOTE CONTROL RECEIVER.
ITEM
NO.
ANGLE ENTRY
1 JSE-B101140 1
HOOD70.350.2435.0

4.6 SWINGTUBE ADJUSTMENT AND REPLACEMENT OF PARTS

CAUTION : ANY WORK ON THE SWINGTUBE OR HOPPER AREA REQUIRES
ABSOLUTE DISCHARGE OF ACCUMULATOR SWINGTUBE CIRCUIT
WITH ENGINE STOPPED. DISCONNECT THE HYDRAULIC LINES TO
THE SWINGTUBE THROW CYLINDER AND REMIXER MOTOR AND
CAP TO PROTECT FROM CONTAMINATION.
The clearance between the wear plate and ring should be no greater than 1-2mm. Excess will cause
loss of concrete paste and fines which will create blockage problems in the swingtube or delivery
line system.
SETTING THE CLEARANCE
Loosen the clamping bolt of the bell crank, tighten the 1 1/2” nyloc hex nut on the back end of the
swingtube pivot shaft. A piece of paper placed on the wear ring and plate should easily be pulled
through. The wear ring should be able to turn freely. If the ring is too tight against the wear plate heat
build-up will result in poor snap action of the swingtube throw. This will cause incomplete throw and
jamming problems.
REPLACEMENT OF WEAR PLATE (RING AND PLATE)
Loosen the clamping bolt of the bell crank, loosen the 1 1/2” nyloc hex nut on the swing pivot shaft. This
will allow the swingtube assembly to move backward toward the hopper outlet. Remove the 4 nuts on the
pump outlet flange and remove the flange. Carefully pry the swingtube pivot arm backward sufficiently
to gain clearance to remove the wear plate first. Two bolts hold the plate to the hopper cylinders. Remove
the screws and nuts and lift plate out. Now the ring can be slipped forward off the end of the swingtube.
The wear plate and ring are made from Hi-resistance wear material.
CAUTION: SHOULD BE EXERCISED WHEN INSTALLING THE NEW WEAR PLATE. THE
MATING SURFACE OF THE WEAR PLATE AND HOPPER FLANGE MUST BE
ABSOLUTELY CLEAN. NO SEALING MATERIAL IS REQUIRED. REMOVE ALL
CONCRETE BUILD - UP FROM THIS AREA. FAILURE TO KEEP CLEAN ON
INSTALLATION WILL RESULT IN A BROKEN WEAR PLATE IMMEDIATELY.
While replacing wear ring and plate it is good practice to replace anti-chip rings that are clamped between
the wear plate and each concrete cylinder. Coat each chip ring with light grease and clean surfaces so that
ring can seat easily.
Proper installation is to install wear ring on swingtube. Insert chip rings and place wear plate in place with
screws and tighten. Then set the clearance of the wear ring and plate.
The outlet flange (5” heavy duty) houses a seal ring which seals the swing tube outlet which rotates
against the housing flange. The outlet seal is a wearing item although it has a long life expectancy. Its
replacement requires removing the housing outlet. There is also a thin O-ring which should be replaced.
When installing new parts, coat parts with grease to ensure easy alignment. The swing tube has a
replaceable chromed outlet piece which is flange bolted. In time the inside will wear reducing the wall
thickness. Replacement is required when the wall thickness is 3mm or less

• Using two modified pins (refer sketch below) and working from the hopper end screw these into the
piston diagonally opposed.
• Apply grease to outside edge of the piston cup and push over the pins until it starts to go into the
cylinder. (Ensure the flat face of piston cup is facing the water box)
• Using a suitable piece of timber tap the piston cup into the cylinder until it rests firmly up against the
piston body. Check to ensure it has located onto the spigot of the piston body.
• Refit two standard bolts to the piston assembly and do up tight, then remove the two modified pins
and replace with remaining two standard bolts.
• Prepare the second piston body with O-Ring and fit to its mating piston rod with the coupling. This is
done at the water box.
• Start the engine and reverse the cylinders so the second one is now at the hopper end.
(NOTE: YOU WILL HAVE TO MANUALLY PUSH THE SWINGER TUBE ASSEMBLY ACROSS TO
OPPOSITE SIDE TO GAIN ACCESS INTO CYLINDER)
• Repeat the above procedure to install the second piston cup.
• Replace the swinger ram hydraulic hoses and fill the water box with oil.
• Start the engine and charge the accumulator circuit with the dump valve. (Note, the swinger tube
assembly could move during charging, so keep well clear of the hopper)
• The unit is now ready to operate.
NOTE: IT IS RECOMMENDED TO INSPECT THE INSIDE DIAMETER OF THE CYLINDERS FOR

ANY SCORING WHEN REPLACING THE PISTON CUPS.

4.7 REPLACEMENT OF THE WEAR PLATE

Caution Notes:
1) Discharge all hydraulic pressure, using safety dump valve confirm with pressure gauges for swing
tube. Should read zero pressure.
2) Isolate electrics. Lock out and tag.
3) Obey all site safety procedures including barricading wheel chocks etc.
Loosen bell-crank clamp bolt, remove 1 ½” nyloc nut and recessed washer from the swing tube pivot
shaft.
Remove the 4 bolts from the flanged outlet and remove outlet and o-ring. Remove seal housing and seal
by striking the housing outer face from the inside of the hopper area. Once it has moved initially it is
generally a simple task to complete removal of the housing from the outside of the hopper using a suitable
pinch bar or lever.
Clean accumulated shotcrete from around the 6 nuts and bolts that secure the chromed outlet to the swing
tube and remove these bolts using a socket with an extension. Access using the extension is simple going
through the outlet port of the hopper. Remove chromed outlet.
Depending on condition of the above bolts and nuts it maybe simpler to cut using oxy acetylene and then
later fitting new bolts and nuts.
This will allow the swing tube assembly to move backwards towards to hopper outlet and by prying /
easing the swing tube outlet through the hopper outlet, The shaft will withdraw through the bell-crank and
through in to the hopper, Taking care not to damage the shaft seal.
Remove the shaft across to a front corner of the hopper and lift, the swing tube will just clear allowing it
to be removed using the hopper outlet port before lifting using tube clear of the hopper shaft and first.
Take care not to damage the threaded section of the shaft, once removed refit 1 ½” nyloc nut by a few
turns (3 – 6 turns is sufficient, this will protect the thread) wear ring can be removed depending on
whether it is grouted to the swing tube or is free.
NOTE:
This is the ideal time to remove any build up of shotcrete in the swing tube.
Remove the two ¾” bolts that hold the wear plate to the hopper, the wear plate will invariably be grouted
in place and as the Jacon wear plate is made from high resistance wear material it is not advisable to
strike with a hammer as the plate well chip and may cause personal injury.
Try to remove plate by wedging away from mount face, once it moves it should come away quite freely.
The anti chip rings are not so easy to remove unless newly installed, the quickest method is to carefully
run a bead of weld around the inner surface of chip ring being careful not to weld the inner surface of the
concrete cylinder, this method results in the ring expanding and then contracting leaving it relatively
loose and easy to remove. These rings can not be reused once welded as described.
Thoroughly clean out the recess for the anti-chip ring and check installation of new anti chip-ring.

It will be a loose fit and the shoulder will not protrude beyond the mount face ONLY the spigot
will protrude.
Very thoroughly clean hopper flange face and check with a straight edge or new wear plate and ensure
ALL AND ANY high spots are removed prior to installing the wear plate.(Wire buffer is ideal for
removing high spots).
REMEMBER both of these parts are surface ground when new so to prevent immediate damage to wear
plate this condition must be maintained at ALL TIMES at fit up.
Check the installation of the wear plate with the anti-chip rings in place as well to ensure spigots align
correctly with wear plate prior to final assembly.
FINAL ASSEMBLY:
Once satisfied that the final assembly and go ahead anti-chip rings can be fitted after a bead of silicon is
laid in the recess (This helps the seal plus holds them in place). A second bead of silicon can be laid
around each spigots before fitting wear plate lay a bead of silicon around the edge of each cylinder
opening plus the a bead some 20 mm. inside the outer edge of the plate. Fit the wear plate in position
ensuring anti chip-rings are correctly located with the spigots engaging the wear plate.
Install two mounting bolts tightening evenly to allow silicon to spread a this point the wear plate should
be hard against the hopper face with no visible gap. If a gap is apparent remove and refit the wear plate,
do not continue to tighten bolts as the wear plate will most likely be destroyed thus requiring a new wear
plate immediately. Tighten to final torque of 80-100 ft/Lb.
The access silicon can be wiped in to the corners of the wear plate or cleaned off to suit.
The use of silicon as described is optional.

4.8 REPLACING THE SWING TUBE

This is a reversal of the steps to remove.
Once the swing tube is in the hopper guide the shaft trough the shaft seal taking care when the square
section meets with the seal, Carefully ease the seal over the square shoulders using a smaller screwdriver
by feeding the seal in a circular motion at the same time offering the shaft through the seal and into the
bearing.
Once the seal is seated correctly feed the shaft further inwards until the seal meets the hard sleeve. Again
use the screwdriver or a similar blunt tool. Easing the seal over the hard sleeve whilst feeding the shaft
through the bearing housing.
When the seal is correctly seated on the hard sleeve install the sewing tube into the bearing housing been
careful to maintain alignment especially as the hard sleeve first enters the bearing housing. Prior to fully
installing the swing tube the wear-ring can be fitted on to the locater and then the completed assembly can
be pushed in to meet the wear plate.
Depending on whether the bell-crank was disconnected from the cylinder the reassembly off the thrust
washer and the bell-crank can be done simultaneously with the using tube installation or it can be fitted
separately.
Reassemble chromed outlet again with a bead of silicon, if reinstalling old chromed outlet ensure flange
faces are clean of any grout and that the hard chromed surface is not pitted or warn and the wall thickness
is more than 3 mm.
With seal housing cleaned of all traces of grout, pit to hopper by sliding over and a long chromed outlet,
with surfaces lightly greased. Fit new outlet seal until it is located in housing, this will locate swing tube
in its final position.
With flanged outlet cleaned of all traces of grout and the O-ring held in place with a coating grease install
ensuring the 4 pointed seal locators are in place. Tighten the 4 bolts evenly but leave loose.
The wear-ring gap should now be adjusted by tightening 1 ½” nyloc nut until the wear-ring is just
beginning to make contact with the wear plate, but is still able to be turned by hand Maximum clearance
is 3 mm.
Once clearance is set tighten clamping bolt to a torque of 364 ft/lbs or 372 Nm.
THIS IS VERY IMPORTANT AS IT PREVENTS PREMATURE WEAR ON BOTH PARTS.
Complete tightening bolts for cast outlet checking that there is clearance between the end of the chromed
outlet and the outlet housing (Minimum 1 mm.).
A gap of 5-8 mm. is acceptable especially if old parts are fitted.
Before returning unit to surface greased swing tube shaft bearings and cylinder clevises making sure
grease is visible at the shaft/seal lip inside the hopper and also around the thrust washer.
Check for equal throw of swing tube and adjust as required by altering length of swing tube cylinder
shaft.
Once the throw is equal tighten lock nut 1 ½” AF size spanner will fit. Check also for excess wear in
clevis pins, clevis yokes and bushes, replace as necessary.
Finally ensure swing tube accumulator is pre-charged to 50 Bar and swing tube pressure is 100 Bar
Maximum (43 Bar / 85 Bar PRONTO). Hopper grate safety dump valve operation should also be
confirmed.

4.9 SETTING THE PROXIMITY SWITCH
FACE ( B) FACE ( A)
X1
Y1
H1
X Y H
5 8.3 904
ROD END PROXI SETTING PISTON END PROXI SETTING
1. Extend/Retract the Hydraulic Piston to ward End Cap.

2. Measure the distance from the face (A) or face (B) of End Cap to the Hydraulic Piston.
3. The mark up the distance from the end of the Proximity indicate how far the Proximity with go
into the End Cap housing.
4. Slightly turn the Proximity until it touches the Hydraulic Piston as per sketch.
5. Connect the Proximity cable on the Proximity switch.
6. The yellow light is now “ON”. When the proximity touches the Hydraulic Piston. Turn the
ignition switch on but “DO NOT START THE ENGINE”. “TURN THE PUMP TO ON
POSITION”.
• Unwind the Proximity until the yellow light on Proximity is on off.
• Then turn the Proximity clock wise direction at Proximity 1/2 circle turn until the yellow is
on.
• Then slightly tie up the lock nut.
Note: on the Proximity cable adaptor there are 2 signal lights:
Green: light is on indicates power to the Proximity cable adaptor.
Yellow: light is in indicates signal of the Proximity.

4.10 ASSEMBLY AND DISASSEMBLY NOZZLE ORBITAL HEAD
This section provides you with steps on how to assembly and disassembly the Orbital
Head Assembly to/from the Shotcreting Boom for maintenance purposes.
1) Install Manual extension (No.18) to the RA80/360 Mounting Head (No. 12) with 2 by
3/4" x 5 1/4" UNF hex Hd Bolt (No. 19) and 3/4" UNF Nyloc nut (No. 20) Torque: 258
Nm.
REV # DATE DESCRIPTION

- -

2) 2 by M10x25 hex hd.bolt and nyloc nut used with flat washer for connection of
Bulkhead plate air (No.15) and Bulkhead plate 8 holes (No. 17). Torque: 44 Nm.
3) Install Rotary Actuator 80/360 (No. 11) to the RA80/360 Mounting head (No. 12) with
6 by M12X55 Hex head Bolt (No. 9) and 6 by M12 Nyloc nut (No. 3) Torque: 77 Nm
4) Actuator Mounting RA80 (No. 8) install to the Rotary Actuator RA80/360 (No. 11) with
1 by M12x45 hex Hd Bolt (No. 2) Torque: 77 Nm

5) Rotary Actuator 80/180 (No. 10) install to the Actuator Mounting (No. 8) with 6 by
M12x55 hex head bolt (No. 9) and 6 by M12 nyloc nut (No. 3) Torque: 77 Nm
6) Oscillating Assembly (No. 1) install to the Rotary Actuator RA80/180 (No. 10) with 1
by M12x45 Hex Hd Bolt (No. 2) Torque: 77 Nm

7) Nozzle Mounting Assembly (No. 7) install to the Oscillating Assembly (No. 1) with 2
by M12x45 hex Hd Bolt (No. 2) and nyloc nut (No. 3) Torque: 77 Nm
1
ITEM 002-N 1REQ'D
8) 2 1/2" Nozzle Assy. 2006 (No. 6) goes in to Nozzle Mounting Assembly (No. 7) with
4" gasket (No. 4) and 4" H/Duty snap coupling (No. 5)


5 TROUBLE SHOOTING
5.1 ENGINE AND DRIVE UNIT
• Engine difficult to start:
A) Loose or damaged V-Belt.
B) Emergency stop buttons all reset.
C) Throttle in start position.
D) Electric connections to battery and starter tight.
E) Air in fuel system.
F) Low fuel.
G) Fuel Solenoid lost connection.
• Engine starts but runs unevenly:
A) Leaking injection line.
B) Loose or damaged V-Belt.
C) Incorrect valve clearance.
D) Defective injector.
E) Fuel filter dirty or loose.
F) Incorrect fuel quality.
• Engine overheats check:
A) Oil level incorrect.
B) Dirty air cleaner.
C) Coolant pump defective.
D) Charge air line leaking.
E) Radiator dirty.
F) Cooling air temperature rise/hot air recirculation.
G) Coolant level too low.
H) Broken fan belt.
I) Missing radiator cap.
• Unit will not drive check:
A) Correct setting of all switches on main panel.
B) Reset button depressed.
• Unit drives sluggish check:
A) Park brake released.
B) Oil level in tank.
C) Maximum pressure setting on system.
D) Oil temperature is not excessive.
E) Transmission pump flow test.

5.2 CONCRETE PUMP
Concrete pump will not cycle – NO PRESSURE on main gauge check:
Engine running. Standby pressure 25 bar (375psi).
Pump switch “forward”.
Remote control pump switch “ON”. Possible electrical problem.
Stop engine.
Discharge all pressures in Hydraulic system.
Check pump ON/OFF solenoid valve.
Concrete pump will not cycle – HIGH PRESSURE on pump gauge check:
Check pump direction switch is in forward position.
Pressure in swing ram pressure gauge is 83 bar (1245psi). If not, refer to pressure adjustments.
Place pump switch in off position. Switch pump in reverse – turn pump switch on again and cycle a few
strokes. If no cycling and the hydraulic pistons are on the end of their stroke (one of the piston connector
blocks will be in water box opening) the pump has lost stroking. Possible no signal for change over due to
Signal to change over problem.
On the Master Hydraulic cylinder each end of the cylinder there is a Proximity switch mounted at the
Gland Cap. Each Proximity Switch always has a Green Light when turn the Pump to ON position. If no
Green light then check for a loose electric connection to that switch.
If the Green light of the Proximity switch is ON then check:
Location of the Master hydraulic Piston and check Proximity Switch at that location.
Then clearance of the face of the Proximity switch to the hydraulic piston is 1.0mm to 1.5mm. (Make sure
the engine is SHUT-DOWN and Ignition switch is ON position). Remove the Lock NUT on the
Proximity Switch then turn the Proximity Switch 1 or 2 turns to see if the YELLOW is ON. If the Yellow
light on the Proximity switch is not switch ON probable the Proximity need to replace. If the YELLOW
light is ON then UNDO the Proximity switch until the YELOOW light went off and Turn the Proximity
Switch 1 turn and tie up the lock nut.
Front Proximity
Rear Proximity
Switch
Switch
Check Change over Solenoid Valve function: This Change Over Solenoid Valve (Double Solenoid
Valve) mounted on the SWING RAM MANIFOLD.
Change Over
Swing Ram Solenoid
Manifold
At the end of the Solenoid valve, use 3mm steel bar push the centre pin in to see if the Swing Ram
is change over. (Make sure the engine is running, Swing Ram pressure gauge indicates the
pressure approx. 100 Bar). If it changes over possible causes loose electric connection from the
Proximity switches to the solenoid valve.
5.3 SWING RAM MOVING SLOWLY:

• Check pressure on the Swing Ram Pressure Gauge (100 Bar setting). If lower then need to
adjust (see pressure setting).
• Check the LOCK NUT on the Swing Tube make sure it is not over tied, means the Wear
Ring & Wear Plate is jammed hard. Loose the LOCK NUT few turns and turn the Pump to
ON for few stroke to ensure the Wear Ring & Wear Plate gap is approx. 0.5-1.0mm.
• If the Swing Ram Pressure loose pressure after 1 or 2 strokes and the swing ram change
over “lazy”, possible the Swing Ram Accumulator Bladder got damaged. Replace new
Bladder and Re-charge Nitrogen.

5.4 SHOTCRETE BOOM AND ROBOT (NOZZLE)
• NO FUNCTIONS OPERATE. CHECK:

A) Power switch on remote is on.
B) Main control switching is in the correct sequence.
C) The remote control lead is properly secured.
D) The remote control lead has not been damaged.
• Functions operate slowly. Check :
A) Maximum pressure setting on Boom Manifold block (250Bar).
B) Check Standby Pressure setting from Hydraulic pump.
C) Adjust Boom function speed control.
D) Hydraulic oil level.
• One function not working. Check:
A) The remote control lead is properly and securely connected.
B) The electrical connection on directional control valve.
C) The hydraulic lines have not been broken.

6 PRESSURE SETTINGS
6.1 CONCRETE PUMP
• Main Ram Relief Pressure set at: 200 Bar.
Location: Main Hydraulic Manifold – Driver side box compartment.
Pumping Relief Valve set at 200

Bar.
P/N: JSA-R4V06L00310A1
• Screw in to increase
pressure setting.
• Screw out to decrease
pressure setting
Main Hydraulic
Concrete Pump
Manifold
• Swing Ram Relief Valve Pressure set at: 120Bar.

Location: Swing Ram Hydraulic Manifold – Driver side box compartment, behind the Oil
Cooler.
Swing Ram Relief Valve set at 120

Bar.
P/N: JSA-R4V06L00310A1
• Screw in to increase
pressure setting.
• Screw out to decrease
pressure setting
Swing Ram
Hydraulic Concrete
Pump Manifold

6.2 SHOTCRETE BOOM
• Boom Relief Valve set at: 250 Bar.
Location: Front passenger side.
Boom Control Relief Valve set at 250 Bar.

• Screw in to increase pressure setting.
• Screw out to decrease pressure setting
6.3 STEERING PRESSURE SET AT 200 BAR (PRE-SET).
Steering Pressure set

at 200 Bar. Pre-set.

6.4 SERVICE BRAKE PRESSURE SET AT 40 BAR.

• Service Brake Accumulator Pressure Setting: 50 Bar.
Source: from 22cc gear pump
Location: outside, front of Driver Cab.
Accumulator Service
Brake, Pressure set at
50 Bar.
Front Accumulator
Service Brake:
2 litres Accumulator
Pressure set at 50 Min. –
100 Bar Max.
Nitrogen charge at 40
Bar.
Rear Accumulator Service

Brake:
2 litres Accumulator
Pressure set at 50 Min. –
100 Bar Max.
Nitrogen (N2) charge at
40 Bar.
• Pedal Service Brake Pressure, set at 40 Bar.

Pedal Service Brake

Pressure, set at 40.
6.5 PARK BRAKE PRESSURE SET AT 100 BAR.

Source: from Boost pump of Transmission Pump.
Pressure Pre-set at: 100 Bar.
Park Brake
Pressure gauge
set at 100 Bar.

6.6 HYDRAULIC COMPONENTS & FUNCTIONS
PUMP GROUP:
ITEM QTY DESCRIPTION PART No

1 A4VG90+A10VO71+A10VO45+ PG3BS19BR JSA-PB334SAS
Hydraulic
Piston Pump
A4VG90for
Transmission,
Compressor
Hydraulic
Piston Pump
A10VO71 for
Steering, Boom
control, Swing
ram,
water pump
Hydraulic
Piston Pump
A10VO45 for
concrete pump,
Landing legs,
chemical pump,
oscilation, remixer.
Gear Pump 19cc

for Bake
6.7 TRANSMISSION PUMP (A4VG90)

Transmission Pump (A4VG90): 90cc closed loop pump supplies oil to the hydraulic motor
A2FM90/6xW. This hydraulic motor is connected to the Split 2-speed Gear box, which provides
the turning torque to the two output flange. One connects to the Front Axle and one connects the
rear axles via the tailshafts.
Pressure set at Port A&B = 400 Bar.
Boost Pressure set at = 30 Bar.

Note: The boost pump also supplies oil to:
* Park Brake via the solenoid valve.

Axial Piston
Fixed Motor
A2FM90/6xW
Transmission
Gear box

6.8 LOAD SENSING PISTON PUMP A10VO71

Load sensing Piston Pump A10VO71 : pressure set at 250 Bar @ 2200 RPM
This Pump provides the hydraulic oil to the following functions:
• Steering System: Supplies oil to steering hydraulic motor via a solenoid valve for selecting
DRIVE/REMOTE.
• Boom Functions and concrete Pump: when selecting REMOTE in Driver Cabin, this will
stop the oil flows through the steering wheel. All the oil will partially supply for Boom
functions, Concrete Pump and Water Pump.
Pump speed is controled by Pressure Compensated Flow Control Valve.
Pressure Compensated Flow

Control Valve
- Counterclockwise rotate to
increase speed of concrete pump.
- Clockwise rotate to decrease
speed of concrete pump.
Boom Valve Bank – Oil Supplies

from A10VO71

6.9 PISTON PUMP A10VO45 NO.3

Piston Pump No.3: 45cc @ 2200 RPM, Pressure set at 250 Bar. This pump supplies oil to
charge up the 4 Litres Accumulator for the Swing Ram of the Concrete Pump and other
functions such as: Front & Rear Stabiliser Legs, Oscillator (Spray Head).
Swing Ram Accumulator

4 Litres. Nitrogen Charge
at 35 Bar
Hopper Solenoid Dump

Valve – Dump all
Accumulator pressure
to tank when Hopper
Grate is lift up

Rotational Speed Chemical

Adjustment Pump Solenoid
Valve
Oscilator Solenoid
Valve
Chemical
Flowmeter
Chemical Flow
Control
Chemical
Totaliser
Chemical
Pump

WATER PUMP
Hydraulic
Motor
Water Pump
6.10 PUMP NO.4

Gear Pump 19cc @ 2200 RPM. This Pump is to charge up the accumulators for Service
Brakes FRONT & REAR and goes back tank through the oil cooler for cooling purpose.
Hydraulic
Oil Cooler.

7 GLOSSARY OF TERMS & THE FUNCTION OF

DIFFERENT PARTS
Pilot signal
Is a volume of pressurised oil that forces the swing valve four-way spool to rise
or lower, thus changing direction of the swing valve from right to left.
Four-way spools
Are hardened lengths of metal with three grooves machined around their
circumferences, the width of these grooves are equal to two grooves of a total
of five groove machined in the control block to give a pumping action, for
example when the spools are in the bottom position pressure goes to Port B,
tank pressure goes to Port A, and when lifted, to Top position, pressure goes to
port A, tank pressure goes to Port B. This causes the main rams to go
backwards and forwards for a pumping action, the swinger tube to go left and
right.
Oil Cooler
This optional extra is sometimes fitted to pumps when they are to be operated
in high temperature areas or when heavy hard pumping or long high output
pours to be carried out with not a lot of time between trucks.
When fitted oil coolers must be used from the first truck load to last, an oil
cooler can not be expected to cool a tank full of hot oil after some hours work
are carried out. The oil cooler, takes off the small amount of H.P. put into the oil
as heat to inefficiency and restrictions found in all hydraulic systems, it is can
not capable of getting rid of excess temperature already put into a tank full of
hot oil after hours of pumping as well as cool off oil being used during pumping.
Swing valve hydraulic ram
The purpose of this ram is to move the swing tube from left to right, it gets its oil
volume supply from the accumulator powered (swing valve) four-way valve oil
circuit.
Oil pump main ram pressure gauge -

Which relates to main rams pressure gives the operator an insight as to “load”
required to pump different materials and also to “monitor” the pump
performance. Gauges should always be in good working order and tested at
regular intervals. They allow vital information in case of break downs.

Relief valve -
Bypass valve - is fitted to control block and is used as a safety medium to

protect the pump hydraulic system in cases where overload, or blockage
occur, and when pump signal circuit malfunctions, returning oil to tank, when
a relief valve is by passing heat is generated because oil is going through a
restricted passage at high pressure.
Solenoid dump valve -
Fitted to control block and is connected internally to the relief valve balance
vent line, when the solenoid is de-energised, the relief valve is stopped from
venting or by-passing (at zero pressure) to tank, causing pressure to be
applied to main rams, it acts as a clutch to give an ON/OFF action.
Accumulator
Is a means of “ storage of energy” the bottle is fitted with a rubber bladder
which has a “pre-charge” of “dry nitrogen gas”, when a volume of oil under
pressure is applied from rear section of oil pump through an internal “check
valve” the oil compresses the rubber bladder to allow a volume of oil to be
stored in the bottle, the “check valve” stop the oil from returning to the pump.
The accumulator bottle gives the “swing valve” a snappy action, when the
pre-charge is lost, the swing valve will be sluggish or lazy.
Poppet
Relief valve, unloader and safety dump valves - are located under the relief
valve, unloader and safety dump valve cartridge heads. These valve are
“hydraulic balanced” type valves, a small “JET” is fitted to Poppets and allows
oil from each circuit to pass through to balance the Poppets so they are
hydraulically held on their seats to ensure “pressured oil” (without bypass).
Should a foreign object block the ”jet”, the poppet will lift off its seat causing oil
pressure to drop to zero and by pass to tank.

Swing ram pressure gauge -.
Gives the operator same details as the main oil pump gauge but for the swing
tube oil circuit. The same care and attention should be given to the swing ram
pressure gauge as describe above.
Swing Tube -
Is the Concrete valve, this swings from side to side in time with the main rams
to pump or suck concrete up in pipeline, it should be cleaned carefully after all
jobs to ensure no build up of concrete occurs inside.
DANGER : never adjust or touch the swing tube when engine is running
as serious personal injury could result.
Piston cups
Are fitted to the ends of the main hydraulic ram shafts and give a seal so
suction and pressure can be applied to the concrete. Clean piston faces fater
every jobs by hosing from the hopper.
Control block -
Is a module of steel machined and milled to contain and organise a
combination of functions allowing “automatic” cycling of the pump. Most of the
hydraulic circuit system is internal in the control block. All testing should be
carried out by factory representatives or dealer.
Oil Filters -
The pump is fitted with several filters, for hydraulic oil, fuel. They should be
replaced regularly.
Make-up needle valve -

This needle valve fitted to the front gland block on the master cylinder is used
to manually over-ride the “automatic” closed loop system, to ensure rapid quick
change over. As pumps age internal leakage occurs and some adjustment is
called for. Long hard pushes also require attention of the needle valve.
Wear plate & Wear ring
These items are used to ensure ease of maintenance as the pumping swing
tube ages. The gap between the ring and plates should be checked at regular
intervals excess wear or gap causes blockages and loss of slurry and fines.

Hopper grease seal
This seal ensures that slurries do not penetrate the swing tube bearings,
regular grease filling protects this seal.
Clevis pin
Connects a hydraulic ram to the swing tube sub-assembly grease or anti-seize

type lubricants should be applied at regular intervals.
Slave ram
The slave ram is so called because it has no function in the “ automatic” pilot
circuit. The slave ram, however, dose control the “long” and “short” stroke
adjustments.
Master ram
It controls the automatic cycling of the pump by striking the front and rear
impulse valves.
Reversing solenoids -
Located on the control block these valves allow instant reversal of the main
ram.
Accumulator dump valve
This valve allows “dumping” of all pressurised oil in the accumulator circuit to tank.
This is a safety valve. Check regularly for its safe and correct operation.

8 SPARE PARTS

8.1 SHOTCRETE BOOM
8.1.1 Assembly No.: JSB-040-NL-A – Non LANCING BOOM ASSEMBLY
ITEM NO. PART NUMBER DESCRIPTION QTY NOTES
1 JSB-040-3L-VB SHOTCRETE BOOM 040 1 1.3

2 JSB-040-SUPPORT JSB-040 SUPPORT HOSE KIT 1
3 JSFA-MWF10-N M10 FLAT WASHER 20
4 JSFA-MNNN10N08 M10 NYLOC NUT 16
5 JSFA-MBHD10-025N08 M10X25MM LG HEX HD BOLT 16
6 JSB-VA.1.030 VALVE EXT SEQUENCE 1
7 JSB-VA.1.033 COUNTERBALANCE VALVE 1
8 JSFA-MBCS08-035N08 M8X35MM LG S/H CAPSCREW 4
9 JSF-714101100/100 CLAMP 2
10 JSB-VA.1.017 VALVE 040 ROTATION 1
12 JSB-040-3L-PP JSB-040 PIPE LINE KIT 1
13 GS-0093A BULKHEAD PLATE 3 HOLE BC 1
14 JSFA-MNNN20N08 M20 NYLOC NUT 2
15 JSFA-MNHD20-130N08 M20X130MM LG HEX HD BOLT 2
16 JSB-040-NL-A-HOSES NON LANCING BOOM HOSES ASSY 1 1.2
17 GS-0048 BULKHEAD PLATE 8 HOLE 1

12 16
1 3
14
15
5
2
13
4
3
6
17
11
7
8
10
1
ITEM JSB-040-NL-A
1REQ'D
NOTES:
BREAK ALL SHARP CORNERS
DO NOT SCALE - IF IN DOUBT ASK
NT 27/10/2011 NTS CS JSB-040-NL-A

8.1.2 Assembly No.: JSB-040-NL-A-HOSES – SHOTCRETE BOOM NON LANCING ASSY
ITEM
NO.
1 JSB-040-3L-VB SHOTCRETE BOOM 040 1.3

2 MJ-6400-W1 BOOM HYD. HOSES STAGE 1 TO 4 24
3 MJ-6400-W12 BOOM AIR HOSES STAGE 1 TO 4 4
4 MJ-6400-W14 BOOM & BULKHEAD CHEMICAL HOSES 5
5 JSB-040-SUPPORT SUPPORT HOSES ASSY.
6 MJ-6400-W11 AIR HOSE BOOM TO BULKHEAD 1
7 MJ-6400-W0 ORBITAL NOZZLE FORWARD/BACK 2
8 MJ-6400-W13 CHEMICAL TO NOZZLE 1
9 MJ-6400-W10 AIR HOSE TO NOZZLE 1
10 MJ-6400-W15 HOSES TO NOZZLE 2
11 MJ-6400-W2 ORBITAL NOZZLE OSCILATOR 2
12 MJ-6400-W8 HYD. HOSES BOOM TO BULKHEAD 6
13 MJ-6400-W3 ORBITAL NOZZLE RIGHT 1
14 MJ-6400-W5 ORBITAL NOZZLE LEFT 1

86
MAXIJET PRONTO
- Please understand the Operation Instructions before operating. -

1
5
3
4
2
14
Operator’s Manual
1
ITEM 1REQ'D
JSB-040-HOSES ASSY
BOOM AND EXTENSIONS
NOTES:
DO NOT SCALE - IF IN DOUBT ASK. NT 08/01/2010 NTS VT JSB-040-HOSES ASSY.
8.1.3 Assembly No.: JSB-040-3L-Vb – LANCING SHOTCRETE BOOM 040
1 JSB-040-3L-CV BOM COVER COMPLETE 1 1.7

2 JSB-040-3L-BB BASE ASSEMBLY 1 1.4
3 JSB-040-3L-BC-A COLUMN ASSEMBLY 1 1.5
4 JSB-040-3L-BE-A BOOM & EXTENSIONS ASSEMBLY 1 1.6

1
ITEM JSB-040-3L-VB1REQ'D
NT 24/10/2011 NTS CS JSB-040-3L-VB -

8.1.4 Assembly No.: JSB-040-3L-BB – Boom Base Assembly
1 JSB-09.1.009TP BOOM RING 1

2 JSB-BR.0.017 BUSHING (175X160X60) 1
3 JSB-09.1.001 BOOM BASE WELDMENT 1
4 JSB-DA.1.023 LOCK NUT 4
5 JSB-09.1.011 STOP 2
6 JSB-09.1.008TP RACK 596MM 2
7 JSG-0034-5901 SPTING PIN M8X45MM LG 4
8 JSB-09.1.007 LINER 460MM 4
9 JSFA-MWF14-N M14 SPRING WASHER 16
10 JSFA-MBCS14-050N08 M14X50 SOCKET HD CAP SCREWS 16
11 JSSE-4602800 PISTON SEAL HALLITE 601 (80X100X13) 4
12 JSSE-8581010 WEAR RING HALLITE 506 13X3 4
13 JSB-PT.0.014 PISTON 4
14 JSB-0427-0409 1/8” GREASE NIPPLE(~JSG-096-BSPP) 4
15 JSB-BR.0.016 BUSHING(145X130X60) 1
16 JSB-BR.0.01 BOTTOM BUSH 1
17 JSB-09.1.012 ADJUSTER ASSEMBLY 1
18 JSB-09.1.010 SLIDING BLOCK HOLDER 2
19 JSB-PA.2.003TP SLIDING BLOCK 2
20 JSB-09.1.017 SET SCREW GRUB 1

REVISION HISTORY
REV DATE DESCRIPTION BY APP'D
1
ITEM JSB-040-3L-BB 1REQ'D
Operator’s Manual

NOTES:
DO NOT SCALE - IF IN DOUBT ASK NT 10/04/2008 NTS HK JSB-040-3L-BB
MAXIJET PRONTO
90
8.1.5 Assembly No.: JSB-040-3L-BC-A – Boom Column Assembly
1 JSBP-D1400-0400 CIRCLIP D1400-0400 4

2 JSB-PE.1.013 BOOM COLUMN BOTTOM PIN 1
3 JSB-09.1.004 BOOM COLUMN WELDMENT 1
4 MG-5000-196 BOOM COLUMN TOP PIN 1
5 JSB-09.2.501S CYLINDER ASSEMBLY 1 1.8
6 JSB-09.2.025 ELECTRIC WIRE BRACKET 1
7 JSFA-M8 FLAT WASHER M8 FLAT WASHER 4
8 JSFA-M8X20 HEX HD BOLT M8X20MM LG HEX HD BOLT 4

1
ITEMJSB-040-3L-BC-A1REQ'D
NOTES:
NT 11/04/2008 NTS HK JSB-040-3L-BC-A -

8.1.6 Assembly No.: JSB-040-3L-BE-A– Boom Extension Arm Assembly
1 JSB-09.2.004V ARM ASSEMBLY 1 1.9

RD
2 JSB-09.2.503A 3 EXTENSION CYLINDER 040 BOOM 1 1.10
3 JSG-2/1/2IN-P-CLAMP 2 1/2” P-CLAMP 1
5 JSFA-MNNN08N08 M8 HEX NUT 1
6 JSB-PE.6.001 BOOM PIN 1
8 JSFA-MWF20-N M20 FLAT WASHER 1
9 JSG-0153-7200 COTTER PIN M5X40MM LG 1
RD
10 JSB-09.2.008V 3 EXTENSION ASSEMBLY 1 1.12
ND
13 JSFA-MWS08-N M8 SPRING WASHER 2
ST
15 JSB-PE.3.008 PIN 2
ST ND
16 JSB-09.2.502 1 &2 EXTENSION CYLINDER 2 1.11
17 JSB-09.2.026 GUIDE 1
18 JSB-07.2.014 KEPPER PLATE 1
20 JSBP-D1400-0400 CIRCLIP D1400-0400 2
21 JSB-PE.1.013 BOOM COLUMN BOTTOM PIN 1

5 4 6 3 2 1
REVISION HISTORY
D D
Operator’s Manual
16
17 16
18
13
19 15
C C
21 14
20 1
13
12
11
B B
2 10
4
5
8
7
6

A 9 A
NOTES:
BREAK ALL SHARP CORNERS 1 1
NT 24/10/2011 NTS CS JSB-040-3L-BE-A DO NOT SCALE - IF IN DOUBT ASK ITEM MATERIAL QTY
5 4 6 3 2 1
MAXIJET PRONTO
94
8.1.7 Assembly No.: JSB-040-3L-CV – BOOM COVER COMPLETE
ITEM
NUMBER
1 JSB-040-3L-CV-005 BOOM COVER 1 1


Operator’s Manual
1 BOOM COVER COMPLETE

ITEM 1 REQ'D

165
JSB-0400 BOOM COVER
NOTES:
DO NOT SCALE - IF IN DOUBT ASK NT 27/09/2008 DB JSB-0400-3L-CV
MAXIJET PRONTO
96
8.1.8 Assembly No.: JSB-09.2.501S – Lifting Cyl. 040 Boom
1 JSFA-MNHD42N08 M42x2 HEX HD NUT 1

2 JSSE-0083612 PISTON SEAL HALLITE 53 1
3 JSB-PT.0.013S PISTON 1
4 JSSE-BS-223 O’RING BS223-90 1
5 JSSE-BS-341 O’RING BS341-90 1
6 JSSE-BS-341 B/UP BACK UP RING BS341 1
7 JSB-TS.0.010S GLAND CAP 1
8 JSSE-4363200 HALLITE SEAL TYPE 601 1
9 JSSE-2234500 HALLITE SEAL TYPE 33 1
10 JSB-09.2.010S PISTON ROD WELDMENT 1
11 JSBP-PAP4030P10 PERMAGLIDE BUSH 4
12 JSG-0427-0409 1/8” GREASE NIPPLE 2
13 JSB-09.2.009S CYLINDER WELDMENT 1

REV # DATE DESCRIPTION BY APP'D
- - - - -
Operator’s Manual
JSSE-09.2.501S
1
ITEM 501S
1REQ'D

NOTES:
NT 16/05/2007 nts ML JSB-09.2.501S
MAXIJET PRONTO
98
8.1.9 Assembly No.: JSB-09.2.004V – Arm Assembly
ITEM
NO.
1 JSFA-M8X12MM LG HEX BOLT M8X12MM LG HEX BOLT 2

3 JSB-PA.1.007 MAIN OUTLET 2
4 JSB-05.2.026 RING NUT 2
5 JSB-06.2.029 BOOM SECTION PLATE 1
6 JSFA-M6X10 COUNTERSUNK
M6X10MM LG COUNTERSUNK SCREW 2
SCREW
7 JSB-09.2.004 ARM BODY WELDMENT 1
8 M8X8 S/H CAPSCREW M8X8MM LG S/H CAPSCREW 2
9 JSB-09.2.027 CYLINDER SLIDE RAIL 1

REVISION HISTORY
- - - - -
Operator’s Manual
1
ITEM JSB-09.2.004V1REQ'D 4
ARM ASSEMBLY

NOTES:
NT 16/01/2009 NTS HK JSB-09.2.004V DO NOT SCALE - IF IN DOUBT ASK ITEM
MAXIJET PRONTO
100
8.1.10 Assembly No.: JSB-09.2.503A – 3rd Extension Cylinder 040 Boom
ITEM
NUMBER
1 JSB-09.2.016 CYL. BARREL WELDMENT 1

2 JSSE-BS-224-90 ORING BS-224 1
2 JSSE-BS-224B/UP B/UP WASHER 1
RD
3 JSB-TS.0.009 GLAND HOUSING 3 EXT CYL 1
4 JSSE-4610200 ROD SEAL TYPE 605 1
5 JSSE-FQ0025DO WIPER SEAL 30X38X6.5 1
6 JSFA-M16X1.5 NYLOC NUT M16X1.5 NYLOC NUT 1
7 JSSE-0209912 DOUBLE ACT PIST. SEAL TYPE 53 1
8 JSB-PT.0.009 HYDRAULIC PISTON 1
9 JSSE-BS-114-90 PISTON ORING BS-114 1
10 JSB-09.2.017 MAIN SHAFT 1
11 JSSE-09.2.503-A SEAL KIT 1

REV # DATE DESCRIPTION BY APP'O
B 14/12/2005 CHANGE DIMENSIONS & SEALS TQ -
Operator’s Manual
1
ITEM 503-AExpVer1REQ'D

NOTES:
BREAK ALL SHARP CONNERS
DO NOT SCALE - IF IN DOUBT ASK. NT 14/12/2005 NTS TQ JSB-09.2.503-AExpVer
MAXIJET PRONTO
102
8.1.11 Assembly No.: JSB-09.2.502– 1st & 2nd Extension Cylinder Assembly
ITEM
NUMBER
1 JSB-09.2.011 CYL. BARREL WELDMENT 1

2 JSB-09.2.012/1 MAIN SHAFT 1
3 JSB-09.2.014/1 ROD INNER TUBE 1
4 JSSE-0209912 DOUBLE ACT PIST. SEAL TYPE 53 1
5 JSSE-BS-114-90 PISTON ORING BS-114 1
6 JSB-09.2.012/2 HYDRAULIC PISTON 1
7 JSSE-BS-224-90 ORING BS-224 1
7 JSSE-BS-224B/UP B/UP WASHER 1
8 JSSE-4402800 ROD SEAL TYPE 605 1
9 JSSE-FQ0031DO WIPER SEAL 35X43X6.5 1
10 JSB-TS.0.013 GLAND HOUSING 1
11 JSB-09.2.014/2 CLEVIS END 1
12 JSB-RO.7.024 SEALING WASHER 1
13 JSSE-09.2.502 SEAL KIT 1


8.1.12 Assembly No.: JSB-09.2.008V – 3rd Extension Assembly
ITEM
NO.
1 JSB-09.2.008 3RD EXTENSION BODY WELDMENT 1

2 JSFA-M8X12 HEX HEAD BOLT M8X12 HEX HEAD BOLT 2
4 JSB-PA.1.004 OUTER 3 RD
EXTENSION 2
REVISION HISTORY
- - - - -
5 1
ITEMJSB-09.2.008V 1REQ'D
4
NOTES:
DO NOT SCALE - IF IN DOUBT ASK NT 07/05/2009 NTS HK JSB-09.2.008V

8.1.13 Assembly No.: JSB-09.2.006V – 2nd Extension Assembly
ITEM
NO.

3 JSB-PA.1.005 OUTER 2 ND
EXTENSION SLIDING PLATE 2
5 JSB-09.2.006 2 ND
EXTENSION BODY WELDMENT 1
6 JSFA-M6X10 COUNTERSUNK
M6X10MM LG COUNTERSUNK SCREW 2
SCREW
7 JSB-PA.1.004 OUTER 3RD EXTENSION 2

REVISION HISTORY
- - - - -
Operator’s Manual
3 5
6 4
2
7
1
1 1
ITEM JSB-09.2.006V1REQ'D

NOTES:
NT 16/01/2009 NTS HK JSB-09.2.006V DO NOT SCALE - IF IN DOUBT ASK
MAXIJET PRONTO
107
8.1.14 Assembly No.: JSB-09.2.005V – 1st Extension Assembly
ITEM
NO.

3 JSB-PA.1.011 1 ST
EXTENSION SLIDING PLATE 2
5 JSB-09.2.005 ST
1 EXTENSION BODY WELDMENT 1
6 JSFA-M6X10 COUNTERSUNK SCREW M6X10MM LG COUNTERSUNK SCREW 2
8 JSB-PA.1.005 OUTER 2ND EXTENSION 2
BY APP'D
- -
2
7
1
REVISION HISTORY
DESCRIPTION
-
6
5
REV DATE
- -

NOTES:
ITEMJSB-09.2.005V 1REQ'D
JSB-09.2.005V
1
HK
NTS
24/06/2009
1
2
3
NT
4

8.2 NOZZLE ORBITAL HEAD
8.2.1 Assembly No.: OH-6300-002-N – 2.5” 2006 C/W ½ Scale No Tilt

ITEM
NO.
1 OH-6300-002 OSCILLATING ASSEMBLY 1 15.1.1

2 JSFA-M12 X 45 HEX HD BOLT M12 X 45 HEX HD BOLT 4
3 JSFA-M12 NYLOC NUT M12 NYLOC NUT 14
4 AOC-0051 4” GASKET 1
5 AOS-0012 4” H/DUTY SNAP COUPLING 1
6 OH-6300-040C 2 ½” NOZZLE ASSY 2006 1 15.1.2
7 OH-6300-028K NOZZLE MOUNTING ASSEMBLY 1 15.1.3
8 OH-6300-019-A ACTUATOR MOUNTING RA80 1
10 JSA-69617 ROTARY ACTUATOR RA80/180 1 15.1.4
11 JSA-69621 ROTARY ACTUATOR 80/360 1 15.1.4
12 OH-6300-045 RA80/360 MOUNTING HEAD 1
15 GS-0093A BULK HEAD PLATE AIR 1
16 JSFA-M10X25 HEX HD BOLT M10 X 25 HEX HD BOLT 4
17 GS-0048 BULKHEAD PLATES 8 HOLES 1
18 JSB-09.2.514 MANUAL EXTENSION 040 BOOM 1
19 JSFA-¾”X5 ¼”UNF HEX HD BOLT ¾” X 5 ¼” UNF HEX H D BOLT 2
20 JSFA-¾” UNF NYLOC NUT ¾” UNF NYLOC NUT 2


- - - - -
1
ITEM 002-N 1REQ'D
NOTES:
NT 15/03/2007 NTS TQ OH-6300-002-N

8.3 Oscillating Assembly
8.3.1 Assembly No.: OH-6300-002– Oscillating Assembly
ITEM
NO.
1 OH-6300-006-A INNER FRAME RA80 1

2 JSFA-M12x45 HEX HD BOLT M12 X 45 HEX HD BOLT 2
3 OH-6300-012 CAM BLOCK WELDMENT 1
5 JSA-67140 MOTOR ORBITAL – 25.4MM SHAFT 1
7 JSFA- M8 SOCKET SET SCREW M8 SOCKET SET SCREW 1
9 JSG-UNI-JOINT UNIVERSAL JOINT 1
12 OH-6300-014 BEARING PLATE 1
13 JSBP-D1300-0620APP ROBOT HEAD BEARING CIRCLIP 1
14 JSBP-2206ETN9 ROBOT HEAD BEARING 1
15 OH-6300-013 BEARING HOUSING 1
16 OH-6300-032 CUSHION PLATE 1
17 OH-6300-033 SEAL RETAINER 1
18 OH-6300-010 OUTER FRAME 1

6 5 4 3 2 1
REVISION HISTORY
REV# DATE DESCRIPTION BY APPROVED
- - - -
7 8 9
D D
C C
B B
A ITEM 1REQ'D A
NOTES :
DO NOT SCALE - IF IN DOUBT ASK NT 12/03/2007 NTS TQ OH-6300-002
6 5 4 3 2 1

8.4 2.5” Nozzle Assembly
8.4.1 Assembly No.: OH-6300-040C – 2.5” Nozzle Assembly 2006
ITEM
NO.
1 OH-6300-025 2.5” NOZZLE TIP (RED) 1

1A OH-6300-025D 2.5” NOZZLE FRAZ (YELLOW) 1 ALT
2 JSG-SHC-130 122MM-130MM SUPA CLAMP 1
3 OH-6300-026E 2.5” NOZZLE BODY 2006 1
4 OH-6300-027F 2.5” NOZZLE INSERT 2006 1

- - - - -
1
ITEM 040C 1REQ'D
NOTES:
NT 19/02/2007 NTS TQ OH-6300-040C

8.5 2.5” Nozzle Mounting Assembly
8.5.1 Assembly No.: OH-6300-028K – Nozzle Mounting Assembly
ITEM
NO.
1 OH-6300-028K-1 NOZZLE MOUNT WELDMENT 1

2 GS-0060 SPRAY NOZZLE ASSY 1
GS-0189/1 500MM DEPT GAUGE 1 OPT
3 GS-0189/2 750MM DEPT GAUGE 1
GS-0189/3 1000MM DEPT GAUGE 1 OPT
4 OH-6300-063 “T” AIR HOSE SUPPORT 1
5 JSFA-M10 HEX HD NUT M10 HEX HD NUT 2
JSF-1/4”MEG0004 HYDROSCALER NOZZLE TIP 0004 1
7 JSF-1/4”MEG0006 HYDROSCALER NOZZLE TIP 0006 1 OPT
JSF-1/4”MEG0008 HYDROSCALER NOZZLE TIP 0008 1 OPT
6 5 4 3 2 1
REVISION HISTORY
REV # DATE DESCRIPTION BY APPROVED
- - - -
D D
C C
B 7 B
1
ITEM 028K 1REQ'D
A A
NOTES:
DO NOT SCALE - IF IN DOUBT ASK. NT 15/03/2007 NTS TQ OH-6300-028K -
6 5 4 3 2 1


8.6 Rotary Actuator RA80/180
8.6.1 Assembly No.: JSA-69617 – Rotary Actuator RA80/180
ITEM
NO.
JSSE-RA80 Seal Kit SEAL KIT (RA80/180 AND RA80/360) 1 *
* Note: If the repair needed is any part other than the seals, you will need to replace the
whole unit.

8.7 PUMPING MODULE & HOPPER ASSEMBLY
8.7.1 Assembly No.: PM-1251070-002A – Pumping Module Assembly
ITEM
No.
1 PM-1251070-012 DIA.125 HOPPER ADAPTOR 2

2 JSFA-M10x40 LG Hex Head M10X40 LG HEX HEAD BOLT 8
3 PM-1251070-031 DIA.125 CONCRETE CUP 2
4 PM-1251070-029 DIA.125 CONCRETE PISTON 2
5 PM-1251070-043 COUPLING 2
6 PM-1251070-013 DIA.125 CONCRETE CYLINDER 2
7 PM-1251070-036 MASTER PISTON ROD 1
8 PM-1251070-011 DIA. WATER BOX ADAPTOR 2
9 JSSE-385020 VEE PACK HALLITE 07 2
10 PM-1251070-023 GLAND HOUSING 2
11 PM-1251070-024 BRONZE BUSH 2
12 PM-1251070-018 GLAND HOUSING MASTER 1
13 PM-1251070-016 MASTER HYD. CYL. TIE ROD 4
14 PM-1251070-037 IMPULSE COLLAR 1
15 PM-1251070-035 HYDRAULIC PISTON MASTER 1
16 PM-1251070-014A MASTER HYDRAULIC 1
17 PM-1251070-019M AND CAP MASTER CYLINDER 1
18 JSFA-M16 Hex Head Nut M16 HEX HEAD NUT 16
19 PM-1251070-021 AND CAP SLAVE CYLINDER 1
20 JSSE-BS-236-90 O’RING BS 236-90 4
21 PM-1251070-014B SLAVE HYDRAULIC CYLINDER 1
22 JSSE-7261510 PISTON RING TYPE 714/2 ¾’’ 2
23 PM-1251070-025 HYDRAULIC PISTON SLAVE 1
24 JSSE-BS-215-90 O’RING BS-215 1
25 PM-1251070-026 SLAVE PISTON ROD 1
26 PM-1251070-017 SLAVE HYD. CYLINDER TIE 4
27 PM-1251070-020 GLAND HOUSING SLAVE 1
28 JSFA – M20 Hex Head Nut M20 HEX HEAD NUT 6
29 JSSE-BS-147-90 O’RING BS-147-90 2
30 PM-1251070-005 WATER BOX WELDMENT 1
31 JSSE-6950140 WIPER SEAL HALLITE 860 2
32 PM-1251070-022 PLATE GRAND RET 2
33 PM-1251070-010A TOP PLATE WATER BOX 1
34 PM-1251070-015 CONCRETE CYL. TIE ROD 6
35 PM-1251070-044 COUPLING FIT 8
36 JSSE-BS-425-90 O’RING BS-425-90 2
37 PM-1251070-032 DIA.125 CONCRETE PLATE 2
38 JSSE-BS-433-90 ORING BS-433-90 2
39 JSA-M5000-001 MAIN MANIFOLD 1 Not use

-
APP'O
PM-1251070-002A
-
BY
-
DS
DESCRIPTION
05/12/2009 NTS
-
NT
DATE
-
REV #
-
1REQ'D
002A
1
ITEM

8.7.2 Assembly No.: SH-5000-001 – SH-5000 HOPPER ASSEMBLY
ITEM
NUMBER

2 SH-5000-045 CAST OUTLET 1
3 JSFA-M14 X 40LG HEX HD BOLT M14 X 40LG HEX HD BOLT 4
4 JSSE-BS - 258 ORING OUTLET BS-258 1
5 SH-5000-044 OUTLET SEAL 1
6 SH-5000-043 OUTLET SEAL HOUSING 1
7 GS-0034 HOPPER GRATE STOPPER 1
8 SH-5000-048 HINGE BAR 1
9 SH-5000-047 GRATE WELDMENT STANDARD 1
FRONT SPLASH GRUAD
10
SH-5000-049 WELDMENT 1
11 JSFA-M8 X 20 LG HEX HD BOLT M8 X 20 LG HEX HD BOLT 9
JSFA-M6 X 60MM LG CAP
13
SCREW M6 X 60MM LG CAP SCREW 4
14 GS - 0051 INTERLOCK HANDLE 1
15 JSA-3KHG1/4"-1125L DUMP VALVE ACTUATOR 1
17 SH-5000-030 HOPPER WELDMENT 1
18 SH-5000-040A FLANGE BEARING ASSEMBLY 1 See Section
19 SH-5000-086 SWING RAM CYLINDER PINS 2
20 SH-5000-087 2,5" SWING RAM CYLINDER 1 See Section
21 JSG-0153-7501 DIA. 5 X 50 LG COTTER PIN 2
23 JSFA-M10 X 40 CAP SCREW M10 X 40 CAP SCREW 2
24 JSSE-BS-444 ORING HOPPER DOOR 1
25 SH-6000-147 HOPPER DOOR WELDMENT 1
JSFA-M20 X 50 LG HEX HD
26
BOLT M20 X 50 LG HEX HD BOLT 1
27 SH-5000-033 SWING LEVER WELDMENT 1
28 SH-5000-042 THRUST WASHER 1
29 JSFA-1 ½” UNF NYLOC NUT 1 ½” UNF NYLOC NUT 1
30 SH-5000-059 WEAR PLATE 1
JSFA-M16 X 50 LG HEX HD
31
BOLT M16 X 50 LG HEX HD BOLT 2
32 SH-5000-060 WEAR RING 1
33 SH-5000-061 WEAR RING SEAL 1
34 SH-5000-025 SWING TUBE WELDMENT 1

23
1
ITEM 001 1REQ'D
NOTES:
DO NOT SCALE - IF IN DOUBT ASK. NT 16/04/2007 NTS TQ SH-5000-001 -

8.7.3 Assembly No.: SH-5000-040A – Flange Bearing Assembly
ITEM
NUMBER
1 SH-5000-034 CHROME SLEEVE 1

2 JSSE-BS-229 ORING BS-229 1
3 SH-5000-064 THRUST WASHER - PLAIN 1
5 JSFA-M10x50mmLG CAPSCREW M10x50mmLG CAPSCREW 2
7 SH-5000-039 FLANGE BEARING OTHER POSITION 1
9 JSBP-PAP7050P10 PERMAGLIDE BUSH 1
10 JSSE-FU0857FO USEAL 70x85x13 1
11 SH-5000-088 FLANGE BEARING WASHER 1
12 JSBP-D1300-0850 BEARING CIRCLIP 1

REV # DATE DESCRIPTION BY APP'O
A 16/12/2005 ADD WASHER TQ -
Operator’s Manual
2
1
ITEM 040A-ExpVer1REQ'D

NOTES:
DO NOT SCALE - IF IN DOUBT ASK. NT 26/10/2008 NTS CD SH-5000-040A-ExpVer
-
MAXIJET PRONTO
122
8.7.4 Assembly No.:SH-5000-078– D35 Swinger Ram Cyl Assembly
ITEM
NUMBER
1 JSBP-PAP2525P10 PERMAGLIDE BUSHES 4

2 SH-5000-081 CYLINDER BARREL WELDMENT 1
3 JSSE-GZ1292V0 WEAR RING TYPE RYT 2
4 SH-5000-083 SWING RAM PISTON 1
5 JSSE-7261510 PISTON SEAL 1
6 SH-5000-082 RAM SHAFT 1
7 JSSE-BS-230 ORING & B/UP WASHER 1
8 SH-5000-084 GLAND HOUSING 1
9 JSSE-CU0424K0 USEAL 35X45X10 1
10 JSSE-FQ0031D0 WIPER SEAL 35X43X5X6.5 1
11 JSFA-M24 HEX NUT M24 HEX NUT 1
12 SH-5000-085 RAM CLEVIS 1

REVISION HISTORY
REW # DATE DESCRIPTION BY APPROVED
- - - - -
Operator’s Manual
10
11
12
1
ITEM 078
1REQ'D

NOTES:
DO NOT SCALE - IF IN DOUBT ASK. ITEM MATERIAL NT 16/05/2007 NTS TQ SH-5000-078 -
MAXIJET PRONTO
124
8.8 CONCRETE DISCHARGE ASSEMBLY

SPARE PARTS LIST AOS-1024-E
8.8.1 pronto mk2 DISCHARGE ASSembly
ITEM
NUMBER
3 MXPR-MK2-232 PRONTO OUTLET BEND 1
4 MXPR-MK2-231 4” X 3” X 1000MM LG REDUCER 1
7
MXPR-MK2-233 3” DISCHARGE PIPE BEND 1
8 MXPR-MK2-230 PRONTO MK2 DISCHARGE PIPE 1

(STRAIGHT 3095MM LG. )
9 MXE2-321A 3" X 2 1/2'' X 385MM LG REDUCER 1
11 AOC-0080-10-DE-SP 2.5” HOSE X 10M DE + SPRING 1
12 AOC-0078B 2 ½” SPRING 2
13 AOS-0001-A 2 ½” BLOWOUT CAP 3” VIC 1
14 MXE2-307 PIPE LINE LOCK 1
15 JSDP-08.44900 SPRING LOCK BOLT 3
16 MX-0400-255 REAR PIPE LINE LOCK 2

1,2 3 4 5,6 7
8 9

8.9 CHEMICAL PUMP
8.9.1 Assembly No.: JSP-SP15-250-C1 – Chemical Pump

ITEM
NO.
1 JSP-SP15 CHEMICAL PUMP 1 20.1.2

2 JSA-67457 CHEMICAL PUMP MOTOR 1
3 JSA-UCDC28M22 COUPLING (CHEMICAL PUMP) 1
4 JSA-UCDC28S SPLINED SLEEVE 1
5 JSA-UCDC28B08K COUPLING (MOTOR) 1
6 JSE-FEP FET 321 ELECTROMAGNETIC FLOWMETER 1
7 JSA-DV12-1.1/0-V 1/2" NEEDLE VALVE - DV12V 1
8 JSG-0415-8000 22 mm. WORM CLAMPS 2
9 GS-0106 COVER - CHEMICAL PUMP 1
10 JSFA-M8x20 Hex Hd Bolt M8x20 HEX HEAD BOLT 8
11 JSFA-M8 Flat Washer M8 Flat Washer 8
12 JSFA-M8 Nyloc Nut M8 Nyloc Nut 4
17 GS-0139 MOUNTING BRACKET FLOW METER 1
18 JSG-0132-0363 MULTI-CUSHION MOUNT M10-504555 3
19 JSFA-M10x16 HEX HEAD BOLT M10 x 16 HEX HEAD BOLT H/T 3
20 JSFA-M10x20 Hex HD BOLT M10 x 20 HEX HEAD BOLT 3
JSFS-SP15-32BUTT CHEM PUMP SUCTION SCREEN ASSY 1 20.1.1
JSA-69505 FLOW CONTROL+BPC.1/2”BSP 1
JSP-SP15 LUBE (1/2 LITRE) CHEM PUMP LUBE 901143 1/2L 1

1 3,4,5,9
2 8
7 6 17

8.10 Chemical Suction Screen
Assembly No.: JSFS-SP15-32BUTT – Chem Pump Suction Screen Assy

ITEM
NO.
1 JSG-BWCR0410080050 80 X 50 REDUCER STAINLESS 2

2 AOS-0132 3” WELD ON – SHRINK RINGS 2
3 JSS-20037 6.3MM X 2.0 WOVEN MESH S/S 0.002
4 JSG-BSPSO040 40 NB BPS SOCKET STAINLESS 2
REVISION HISTORY
REV # DATE DESCRIPTION BY APPROVED
- - - -
1
ITEM 1REQ'D
JSFS-SP15-32BUTT
NOTES:
DO NOT SCALE - IF IN DOUBT ASK. NT 12/06/2007 NTS HK JSFS-SP15-32BUTT

8.11 Chemical Pump
Assembly No.: JSP-SP15-001 – Chemical Pump Assembly

ITEM
NO.
101 JSP-015101 PUMP HOUSING 1

102 JSP-015102 PUMP COVER 1
103 JSP-015103 ROTOR PUMP 1
104 JSP-015104 CHEMICAL PUMP SHAFT 1
106R JSP-015106R MOUNTING SUPPORT RIGHT 1
106L JSP-015106L MOUNTING SUPPORT LEFT 1
108A JSFA-F419001 PIN SCREW 2
111 JSP-015111 SP15 BEARING 1 1
112 JSP-015112 SP15 BEARING 2 1
113 JSP-015113 SP15 JOINT RING 1
114 JSP-015114 SP15 OIL SEAL 1
116 JSP-F436055 SP15 DRIVE KEY 1
117 JSP-F436076 SP15 ROTOR KEY 1
118 JSP-015118 CHEM PUMP 015 SNAP RING 1
119 JSP-015119 RUBBER BUSHING 2
120 JSP-015120 HOSE CLIP 2
121 JSP-015121 HOSE CLIP 2
123 JSP-015123 SP15 PUMP COVER O-RING 1
130 JSFA-M6x16 Hex Hd Bolt M6 X 16 HEX HD BOLT 8
131 JSFA-M6 Spring Washer M6 SPRING WASHER 8
132 JSFA-M8x20mm Hex Hd Bolt M8 X 20 HEX HD BOLT H/T 4
134 JSFA-M6x20 Hex Hd Bolt M6 X 20 HEX HD BOLT H/T 8
143 JSP-SP15 LUBE (1/2 litre) CHEM. PUMP LUBE 901143 1/2L 1
144 EP-S-29082235 SP15 CAUTION STICKER 1
151 JSP-29040223 SP15 BREATHER CAP 1
184 JSP-015184 INSERT RETAINING FLANGE 2
186 JSP-015186 INSERT STAINLESS STEEL SP15 1
191 JSDP-F543017 SP15 CIRCLIP 2
192 JSDP-F344052 SP15 CIRCLIP 1


8.12 AXLE ASSEMBLY

PARK BRAKE / TRANSMISSION ASSEMBLY
ITEM
NUMB PART NUMBER DESCRIPTION QTY NOTES
ER
1 JSDL-2260-9041A REAR TAIL SHAFT 1
2 JSDL-K1025504 TRANSMISSION GEAR BOX 1
DRIVE HYDRAULIC MOTOR
3 JSA-20065 1
A2FM90/6xW-VAB027
4 JSDL-02-530-628 DISC BRAKE CALIPER 2
5 GS-0261 PRONTO BRAKE DISC 12” 1
6 JSDL-2260-9053A FRONT TAIL SHAFT 1
7 JSDL-220-00044A STEERING AXLE 2
8 JSFA-M20x220 HEX HD M20 x 220 HEX HD BOLT H/T 8
JSFA-M20 BELLVILLE
9 M20 BELLVILLE WASHER 8
WASHER
10 JSFA-M20 HEX NUT M20 HEX NUT 16
11 MX-0400-003-A/2 212 AXLE MOUNT PLATE 2
12 JSDL-300-15-8-278 PRONTO WHEEL ASSEMBLY 4
13 MX-0406PRT-103 PIVOT PIN 1
14 MX-0406PRT-101 PIVOT MOUNT ROLLER 1
15 JSDL-RFW265D DETROIT ENGINE MOUNT 4
JSO-LS90-20 LS90 TRANSMISSION OIL 1

3 15
1 2
5 4

10
7
8 9
11
12

13
14
13
14

SPARE PARTS LIST 8.13 Front Axle

JSDL-220-00044A
ITEM No PART NUMBER DESCRIPTION QTY NOTES
1 JSDL-171-07-053-01 O-Ring 2
2 JSDL-171-01-003-18 Cover, Intermediate 1
3 JSDL-171-01-003-02 O-Ring 2
4 JSDL-278-01-002-01 Housing 1
5 JSDL-278-01-003-01 Bushing, Thrust 2
6 JSDL-171-01-015-04 Plug 1
7 JSDL-002-02-0088 Circlip 1
8 JSDL-819-01-610-01 Plug, Magnet 3
9 JSDL-171-01-002-18 Cover, Intermediate 1
10 JSDL-006-01-1556 Nut 32
11 JSDL-278-06-011-01 Stud 4
12 JSDL-016-14-1138 Plug 1
13 JSDL-278-06-012-01 Stud 28
14 JSDL-702-01-003-01 Vent 1
16 JSDL-808-01-017-01 Plug 2

SPARE PARTS LIST 8.14 Front Axle (2)

JSDL-016-01-1180
ITEM
No
1 JSDL-016-01-1180 Bolt, Hex 2
2 JSDL-171-04-020-01 Plate, Locking 2
3 JSDL-016-28-3312 Bolt 12
5 JSDL-171-04-001-07 Carrier, Differential 1
6 JSDL-171-04-501-14 Set, Bevel gear 1
7 JSDL-171-04-007-02 Pin 1
8 JSDL-171-04-004-01 Pinion Differential 4
9 JSDL-171-04-012-01 Washer, Friction 4
10 JSDL-014-03-2841 Dowel 3
11 JSDL-171-04-008-02 Pin 2
12 JSDL-171-04-005-05 Gear, Differential Side 2
13 JSDL-171-04-011-01 Washer, Friction 2
14 JSDL-171-04-013-02 Cover 1
15 JSDL-005-09-0496 Bearing, Taper roller 2
16 JSDL-171-04-015-02 Nut, Ring 2
17 JSDL-016-01-1161 Bolt, Hex 8
18 JSDL-005-09-2938 Bearing 2
19 JSDL-171-04-016-02 Spacer 1
JSDL-013-01-1369
JSDL-013-01-1371
20 SHIM 1 each
JSDL-013-01-3067
JSDL-013-01-3279
JSDL-013-01-1549
21 JSDL-013-01-1550 SHIM 1 each
JSDL-013-01-1551
22 JSDL-171-04-018-01 Spacer 1
23 JSDL-001-03-0730 Seal 1
24 JSDL-542-22-004-06 Flange 1
25 JSDL-001-05-0041 O-ring 1
26 JSDL-746-04-008-01 Nut 1
27 JSDL-953-01-025-01 Plate, Cover 1
28 JSDL-171-04-006-02 Retainer, Shaft 1


SPARE PARTS LIST 8.15 Transmission

JSDL-K1025504
ITEM
NUMBER
1 JSDL-016-01-1002 Bolt 2
2 JSDL-357-14-022-01 Velt 1
3 JSDL-011-04-1318 Washer, Spring 12
4 JSDL-011-07-2763 Washer 1
5 JSDL-005-01-0121 Bearing, ball 1
6 JSDL-808-01-017-01 Plug 1
7 JSDL-357-14-101-14 Cover 1
8 JSDL-357-14-125-01 Cover 1
9 JSDL-005-01-0119 Bearing, Ball 1
10 JSDL-016-10-2629 Bolt 1
11 JSDL-014-02-2988 Dowel 2
12 JSDL-357-14-100-15 Housing 1
13 JSDL-016-01-0376 Bolt, Hex 12
14 JSDL-016-01-0378 Bolt, Hex 4
15 JSDL-357-14-102-03 Cover 1
16 JSDL-001-01-0018 Seal 1
17 JSDL-357-14-102-03 Spacer 2
18 JSDL-016-01-0369 Bolt, Hex 2
19 JSDL-011-01-022 Washer, spring 2
20 JSDL-357-14-133-01 Sheet 1
21 JSDL-005-13-2906 Bearing, needle 4
22 JSDL-357-14-124-01 Shaft, Output 1
23 JSDL-355-14-101-02 Selector, Change 1
24 JSDL-016-08-1406 Bolt 1
25 JSDL-357-14-132-01 Sheet 1
26 JSDL-819-01-610-01 Plug, Magnet 1
28 JSDL-011-07-1478 Washer, Seal 1
29 JSDL-717-14-047-01 Spacer 1
30 JSDL-932-03-019-01 Plug 1
31 JSDL-717-14-052-01 Bolt 1
32 JSDL-819-03-042-01 Spring 1
33 JSDL-932-08-033-01 Pusher 1
34 JSDL-001-05-2918 O-Ring 1
35 JSDL-013-01-0311 SHIM 1

35-1 JSDL-013-01-0311 SHIM 1

35-2 JSDL-013-01-0313 SHIM 1
35-3 JSDL-013-01-0314 SHIM 1
35-4 JSDL-013-01-1241 SHIM 1
35-5 JSDL-013-01-3177 SHIM 1
36 JSDL-005-01-0118 Bearing, Ball 2
37 JSDL-001-03-0621 Seal 2
38 JSDL-357-14-103-03 Cover 1
39 JSDL-357-14-141-03 Flange 2
40 JSDL-001-05-0044 O-Ring 2
41 JSDL-357-14-139-01 Nut 2
42 JSDL-355-14-056-01 Pin, Sliding 2
43 JSDL-357-14-115-01 Fork, Selector 1
44 JSDL-001-09-3070 Seal 1
45 JSDL-357-14-118-02 Plate, cover 1
46 JSDL-357-14-116-03 Shaft, Selector 1
50 JSDL-357-14-705-17 Shaft, Input 1
51 JSDL-357-14-109-05 Gear 1
52 JSDL-357-14-107-01 Gear 1


SPARE PARTS 8.16 Front axle (3)

LIST
ITEM
NUMBER
1 JSDL-278-06-008-05 Case, Axle 2

2 JSDL-006-03-0196 Nut 2
3 JSDL-016-13-1267 Bolt, Grub 2
4 JSDL-008-01-0213 Fitting, Grease 4
5 JSDL-016-01-0758 Bolt, Hex 16
6 JSDL-011-04-0758 Washer, Spring 16
7 JSDL-278-06-003-01 Pin, Pivot 4
8 JSDL-278-06-010-01 SHIM 2
8-1 JSDL-278-06-010-02 SHIM 2
8-2 JSDL-278-06-010-03 SHIM 2
9 JSDL-278-06-009-01 Seal 4
10 JSDL-005-09-1553 Bearing 4
11 JSDL-002-01-0074 Circlip 2
12 JSDL-002-02-1211 Ring, Synchroniser 2
13 JSDL-005-01-0116 Bearing 2
14 JSDL-278-06-004-01 Bushing, Reduction 2
15 JSDL-001-05-1239 O-Ring 2
16 JSDL-275-06-007-01 Seal 4
17 JSDL-002-06-1552 Ring 2
18 JSDL-005-23-2599 Bearing, Needle 4
19 JSDL-006-05-0202 Nut 4
23 JSDL-278-06-032-01 Seal 2
24 JSDL-819-06-006-02 Stud, Wheel 12
25 JSDL-001-05-1350 Ring 2
26 JSDL-005-10-1380 Bearing 4
27 JSDL-002-06-1362 Ring 2
28 JSDL-171-06-004-01 Supporting gear 2
29 JSDL-171-06-005-02 Gear,Rring 2
30 JSDL-171-06-015-01 Plate Locking 2
31 JSDL-002-02-1363 Ring 2
32 JSDL-171-06-011-02 Spacer 6
33 JSDL-171-06-007-01 Gear, Planet 6
34 JSDL-005-13-1365 Bearing, Needle 12
35 JSDL-016-06-2055 Bolt, Cylinder 6

36 JSDL-112-01-610-01 Plug 2
37 JSDL-011-07-0704 Washer, Seal 2
38 JSDL-001-05-1152 O-Ring 6
39 JSDL-171-06-009-01 Pin 6
40 JSDL-171-06-003-05 Carrier, Planet Gear 2
41 JSDL-016-02-1374 Bolt, Hex 8
42 JSDL-014-02-0913 Dowel 8
43 JSDL-006-11-1319 Wheel Nut 12
44 JSDL-271-06-002-02 Hub, Wheel 2
45 JSDL-278-06-611-03 Joint 2


SPARE PARTS LIST 8.17 Front axle (4)
ITEM
NUMBER
1 JSDL-171-07-003-02 Piston 6
2 JSDL-738-07-009-01 O-Ring 6
3 JSDL-378-07-010-01 Ring, Back up 6
4 JSDL-171-07-009-02 Bolt, Adjusting 6
5 JSDL-171-07-010-01 Spring 6
6 JSDL-001-05-1357 O-Ring 6
7 JSDL-006-02-0193 Nut 6
8 JSDL-171-07-002-03 Disc, Intermediate brake 8
9 JSDL-734-07-015-01 Plug 2
10 JSDL-734-07-014-01 Bolt, Bleeding 2
11 JSDL-171-07-011-01 Spacer 2
12 JSDL-171-01-610-05 Disc, Brake 8
13 JSDL-171-07004-01 Disc, Brake (Left) 1
14 JSDL-171-07-004-02 Disc, Brake (Rright) 1

SPARE PARTS LIST 8.18 Front axle (5)
ITEM
NUMB PART NUMBER DESCRIPTION QTY NOTES
ER
1 JSDL-278-24-621-07 Rod, Articulated 2

2 JSDL-278-24-620-01 Cylinder 1
2A JSDL-278-24-450-01 Seal Kit, Steering Cyl. 1
3 JSDL-016-04-0729 Bolt, Cylinder 5
4 JSDL-001-05-1548 Ring 1
8 JSDL-278-06-001-04 Case, Steering (Left) 1
9 JSDL-278-06-002-04 Case, Steering (Right) 1
10 JSDL-278-06-013-04 Bolt, Adjustment 4

Operator’s Manual MAXIJET
PRONTO

147

Jacon Shotcrete Operation Manual-Mxprt-109

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Jacon Shotcrete Operation Manual-Mxprt-109

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Operator’s Manual MAXIJET PRONTO

MACHINE MODEL: MAXIJET PRONTO

Jacon Technologies Pty. Ltd.

- Please understand the Operation Instructions before operating. - 1

- Please understand the Operation Instructions before operating. - 2

6.4 SERVICE BRAKE PRESSURE SET AT 40 BAR. ...................................................70

- Please understand the Operation Instructions before operating. - 3

SHOTCRETE PUMP Jacon S125

- Please understand the Operation Instructions before operating. - 4

TYPE: Triple extension 8.6 metres reach parallel slewing boom

LOW VOLTAGE ELECTRICAL SYSTEM

EXHAUST: Catalytic converter on exhaust system

CABINS: One cabin.

We guarantee each new machine sold by us to be free from defects in

This warranty does not obligate us to bear the cost of labour or

We make no warranty in respect of trade accessories, such being subject to

We shall, in no event, be liable for consequential damages or contingent

No express, implied or statutory warranty other than herein set forth is

- Please understand the Operation Instructions before operating. - 6

1.2 GENERAL DIMENSIONS:

1579 2700 852

- Please understand the Operation Instructions before operating. - 7

- Please understand the Operation Instructions before operating. - 8

MAXIJET PRONTO IDENTIFICATION

Model: Serial No.: Date of Manufacture:

Carrier model: Maxijet Carrier Serial No.:MXPR-001

Diesel engine: CAT C4.4 (24V) Engine No: 44412768

Front axle: Spicer Dana 278/209 Serial No.: N-HUN-119389

Rear axle: Spicer Dana 278/209 Serial No.: N-HUN-134127

Rim: RIM ASSEMBLY (8.0-15) Serial No.: JSDL-300-15-RIM

Wheel: WHEEL (300-15) Serial No.: JSDL-300-8-278-2

Hydraulic pump group Assembly ASSY No.: JSA-PB393SAS

Hydraulic pump unit 1: A4VG90DA2D2/32R Part No.: JSA-RNO190

Hydraulic pump unit 2: A10VO71DFR1/31R Part No.: JSA-B3067

Hydraulic pump unit 3: A10VO45DFR1/31R Part No.: JSA-B30111,F

Hydraulic pump unit 4: PG3BS19BR Part No.: JSA-79515

Transmision gear box: JSDL-K1025504 Serial No.: N-ITA-710083

Main drive Hydraulic motor: A2FM90/6xW-VAB027 Serial No.: JSA-20065

Concrete pump model: PM-1251070 ASSY No.: PM-1251070-002A

Hopper model: SH-5000 ASSY No.: SH-5000-001B

Shotcrete boom model: JSB-040-NL-A Serial No.: SVB-0711073

Orbital head : OH-6300-002-N ASSY No.: OH-6300-002-N

Chemical pump: CHEM.SP15 COMP. ASSY No.: JSP-SP15-250-C-1

Water pump : D52F002250 ASSY No.: JSP-D52F002250-A

- Please understand the Operation Instructions before operating. - 9

- Please understand the Operation Instructions before operating. - 10

At appropriate stages consideration should be given to the following points:

• Management plan and risk assessment.

• Personal protective equipment.

- Please understand the Operation Instructions before operating. - 11

1.5 SAFETY PRECAUTIONS

• Avoid steep slopes that may cause the unit to overturn.

• Reduce speed when turning so there is no danger of overturning.

• Never operate the unit in any site without adequate ventilation.

• Do not smoke when handling fuel. Avoid spilling fuel.

• Never walk underneath the boom whilst in operation.

- Please understand the Operation Instructions before operating. - 12

- Please understand the Operation Instructions before operating. - 13

2 DRIVING AND OPERATING INSTRUCTIONS

2.1 DRIVING INSTRUCTIONS:

2.1.2 START UP PROCEDURES

CAUTION: OBSERVE YOUR SURROUNDINGS FOR HAZARDS AND NEARBY

- Please understand the Operation Instructions before operating. - 14