INSTRUCTION

MANUAL
ELITE 40

1733 90th Street

Sturtevant, WI 53177
800-553-3414
610-398-0451
Fax: 262-884-3070
 WARNING

DO NOT ATTEMPT TO OPERATE

THIS EQUIPMENT WITHOUT A
THOROUGH UNDERSTANDING OF THE
OPERATING, MAINTENANCE AND SAFETY
CONSIDERATIONS CONTAINED IN
THIS TECHNICAL MANUAL

TO PREVENT DAMAGE TO
EQUIPMENT AND/OR INJURY TO YOURSELF
OR OTHER PERSONNEL, THESE
INSTRUCTIONS MUST BE
FOLLOWED CAREFULLY.

A COPY OF THIS MANUAL SHALL ACCOMPANY THE UNIT AT ALL TIMES.

 FOR PARTS AND SERVICE PLEASE
CALL OUR TOLL FREE NUMBER

PARTS & SERVICE: 800-553-3414

To help us assist you, please have equipment Model

and Serial Number available at time of inquiry.

The Model and Serial Number are available on the

equipment Data Tag attached to the frame of the equipment.

Record the following information on this

equipment below:

Model No. ________________________

Serial No. ________________________

Date Purchased ___________________

TABLE OF CONTENTS - ELITE
PAGE
INTRODUCTION ………………………………………………………………………….. iii
WARRANTY ………………………………………………………………………………… iv
SECTION I- EQUIPMENT DESCRIPTION
SPECIFICATIONS …………………………………………………………………………………. 1-1
SECTION I- EQUIPMENT DESCRIPTION
SAFE OPERATION ……………………………………………………………………………….. 2-1
TOWING THE TRAILER ………………………………………………………………………….. 2-4
OPERATOR QUALIFICATIONS …………………………………………………………………. 2-5
RESPONSIBILITY OF OWNERS AND EMPLOYEES ……………………………………….. 2-6
PRINCIPAL OF OPERATION …………………………………………………………………….. 2-7
The Material Pump ……………………………………………………………………………. 2-7
The Hydraulic System ………………………………………………………………………… 2-8
HYDRAULIC SYSTEM- DESCRIPTION OF PRINCIPAL COMPONENTS …………………. 2-9
CONTROLS IDENTIFICATION w/ POTENTIOMETER ……………………………………………… 2-11
CONTROLS IDENTIFICATION w/ DISPLAY CONTROLS…………………………………….. 2-14
HYDRAULIC TANK OIL GUAGE / OIL LEVEL …………………………………………………. 2-17
INTERLOCK SAFETY SYSTEM ………………………………………………………………….. 2-18
DAILY SAFETY CHECK OF EQUIPMENT …………………………………………………….. 2-19
SET UP OF EQUIPMENT ………………………………………………………………………… 2-19
OPERATION OF EQUIPMENT ………………………………………………………………….. 2-21
Start up of equipment …………………………………………………………………………. 2-21
Functional Check Out ………………………………………………………………………… 2-22
Lubricating the Material Delivery Line ………………………………………………………. 2-23
Precautions and Trouble shooting during operation ………………………………………. 2-23
Clearing material plugs ………………………………………………………………………. 2-25
Clean-up at end of pour ………………………………………………………………………. 2-26
OPERATOR CONTROLS - GRAPHICAL TERMINAL…………………………………………… 2-28
SECTION III- MAINTENANCE
MAINTENACE INTERVALS ……………………………………………………………………… 3-1
MATERIAL PUMP- WEAR PARTS ……………………………………………………………. 3-2
Swing Tube Adjustment ……………………………………………………………………… 3-3
Outer seal, Wear ring, and Wear Plate 3-3
Flange Adapters ………………………………………………………………………………. 3-3
Replace Piston Cups …………………………………………………………………………. 3-3
MIXER AND RE-MIXER SEAL REPLACEMENT ………………………………………………. 3-6
SENSOR SWITCH ADJUSTMENT ……………………………………………………………… 3-7
RECOMMENED LUBRICANTS …………………………………………………………………. 3-8
Washbox, Hydraulic tank, Mixer ……………………………………………………………. 3-8
TROUBLE SHOOTING …………………………………………………………………………… 3-9
SECTION IV - PARTS MANUAL
MATERIAL PUMP ……………………………………………………………………………….. 4-1
HYDRAULIC SYSTEM ……………………………………………………………………………. 4-5
RE-MIXER, STANDARD ………………………………………………………………………….. 4-7
VIBRATOR GRATE ASM ………………………………………………………………………… 4-8
OPERATORS CONTROLSW/ DISPLAY ……………………………………………………….. 4-9
OPERATORS CONTROLSW/ POTENTIOMETER ……………………………………………. 4-11
MICROPROCESSOR …………………………………………………………………………….. 4-13
MISCELLANEOUS COMPONENTS ……………………………………………………………. 4-14
SAFETY DECALS ………………………………………………………………………………… 4-15
ELECTRICAL SCHEMATICS
COMPONENT MANUALS
INTRODUCTION

The Allentown Powercreter pump is a high-pressure hydraulically powered piston

pump for the mixing, pumping or spraying of concrete, grout, mortar or
refractories. This manual describes the operation, maintenance, and safety
considerations, which must be followed. Close attention to these details by the
operator and maintenance personnel is necessary to assure a minimum of
problems while striving for maximum productivity and safety.

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

Pumpability can be defined as that combination of physical properties of both
material and pump, which determine if the material will flow into the inlet chamber
of the pump and can be discharged. Physical properties of the material which in
various degree determine it’s pumpability are water content, size of aggregates
and gradation, slump, viscosity, density, presence of reinforcing fibers, and
presence of additives to improve pumpabilty or influence set time. The
ALLENTOWN EQUIPMENT Div. Sales department will provide application
assistance to establish the Powercreter is suitable for your application.
Call 1-800-553-3414.

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

iii
 New Equipment Warranty
Seller expressly warrants that its new equipment will be fit and sufficient for the purpose(s)
intended, and free from defects in material and workmanship. This warranty shall remain in effect
for a period of six months from date on which the equipment is first put to intended use, with first
date of use not being later than three months from date of shipment. This warranty shall apply
only to equipment in normal use and service, and shall not apply to equipment which has been
subjected to misuse, negligence or accident, or otherwise not used in accordance with Seller’s
recommendations or specifications regarding operation and/or maintenance.

All items found defective as to material, workmanship or manufacture, in the sole judgement of
Allentown Equipment Div., will be replaced or repaired free of charge, F.O.B. Allentown,
Pennsylvania. This warranty does not cover the cost of labor in replacement or transportation.

Certain parts of the equipment in contact with mortar, concrete or refractory mixture, such as
rotors, wear plates, seals, hoses, nozzles, tips, etc., are subject to normal wear associated with
abrasive materials. Such normal wear is not covered by this warranty, and Allentown Equipment
Div. shall not be liable for consequential damages, expenses, losses, or delays of any kind
incidental to any failure of equipment. Under no circumstances shall Seller’s liability exceed the
price for the equipment or parts for which liability is claimed.

Seller makes no warranty of its outside purchased components such as engines, air motors,
hydraulic pumps, wheels, tires, etc., as the same are subject to the warranties of their respective
manufacturers.

There is no implied warranty of marketability or fitness for particular performances.

Any attempt to remedy a claimed defect by persons or entities not expressly authorized to perform
such work by Seller shall void this warranty.

421 Schantz Road

Allentown, PA 18104
800-553-3414
610-398-0451
Fax 610-398-1934

iv
SPECIFICATIONS:

The specifications for this unit with all applicable data are provided on the unit
“DATA TAG”, usually located inside the processor controls box.

1-1
SAFE OPERATION
Any person assigned to operate, troubleshoot, maintain, or repair the Allentown
Pump must first be thoroughly familiar with the instruction manual. Your safety and the
safety of others are at all times very important. To work safely you must understand the
job you do. If in doubt, use extreme caution, obtain assistance from trained personnel.

The Allentown Pump is constructed with safety features for operating personnel.
However construction features alone cannot ensure complete safety. Safe work practice
observance of O.S.H.A. regulations, specific work methods and procedures, timely
maintenance and an alert, well trained operator are all factors in safe operation. In order
to highlight situations, which historically have been the cause of accidents, the material in
this manual, which addresses safety is preceded with a graphic symbol which identifies
the principal hazard. Within the frame of the graphic symbol the following signal words
indicate the likelihood of occurrence and the degree of potential injury or damage. If in
doubt about this classification assume the worst case, some hazards, which are minor at
the time of occurrence can develop into hazards with a severe degree of potential injury
or damage.

Signal Word Information about dangers which can lead:

DANGER - to life threatening bodily injuries

WARNING - to medium serious bodily injury.

- to considerable personal property damage

CAUTION - to slight bodily injury

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

Never remove the hopper grate cover when the pump is in

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

2-1
Never put hands in the lubricating wash box when the pump is
operating. Oscillating linkage can amputate fingers or hand. Severe
injury can result. Never work on any part of the pump that is in motion
while the engine is running. Take time to stop the engine power system
for your protection.

The hydraulic system of the Allentown Pump operates under high

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

The hydraulic system of the Allentown Pump operates under high

pressure. Fluid at high pressure will discharge at a high velocity if the
hydraulic system is opened to atmosphere by venting, loosening of
flange bolts, removing fittings, etc., when the power source is operating.
Until discharged, the accumulator has stored a charge of oil under
pressure, which operates the swing tube cylinder. Stop the engine of the
material pump, and allow sufficient time for the accumulator to discharge.
Confirm by looking at the pressure gauge, which should read zero PSI.
When removing fittings, or removing any hydraulic component wear
safety goggles and cover the joint from which hydraulic fluid will
discharge with a large cloth to absorb and discharge of fluid. If hydraulic
fluid gets in eyes, flush with a generous amount of clean water. Consult
a physician.

In case of blockage of the delivery line never open any coupling of the
material delivery line system without reversing the pump and pumping
backward to remove pressure in the system. Discharge can propel
particles at high velocity capable of eye damage. If eye protection is not
worn serious eye injury can result.

2-2
Reliable operation of this equipment is dependent on proper
operation, scheduled cleaning, and maintenance. Failure to follow
instructions can result in accelerated wear or equipment failure.
During operation, repair or troubleshooting, problems may arise that
seem singular but may be due to several causes. The information in
this manual should be used to assist in the safest and best manner to
operate the material pump. Use caution and safe methods in the
repair and operation of the equipment.

The mechanical linkage located on the side of the mixer opposite the
dump control valve, positions the mixer grate when the mixer is
dumped. The relative motion of this link, the mixer drum and the
hopper produces a scissors movement which can pinch anything in
it’s path. Confirm this area is clear of all personnel when operating
the mixer. Severe bodily injury can occur to any body member
pinched.

The rapid release of a blocked hose can cause a material hose to

whip or move abruptly with potential injury to personnel. Do not
attempt to dislodge blockage with increased or continued pumping
pressure. Dislodge the blockage as instructed by “Clearing Material
Plugs”. Only trained personnel should be permitted to handle the
material hose.

2-3
TOWING THE TRAILER

The Allentown Pump is designed to be towed by a truck at a maximum speed of 55

MPH, conditions permitting. Towing Vehicle must be equipped and rated to tow a
trailer in accordance with the specifications for your model. See
“SPECIFICATIONS” and refer to Federal Motor Code, Part 393, Title 49, Sub
Paragraph F for towing regulations.

Prior to towing the Allentown Pump, the following safety precautions must be
observed.

1. Secure hitch and safety chains to the towing truck.

2. Raise all jack-stands to their fully retracted position.

3. Check tail and stoplights for correct functions.

4. Do not tow the unit with material in the hopper.

5. Remove all material delivery line components from the outlet of the material pump.

6. Check tire pressure and the function of the brake system.

NOTE: For maintenance of the brake system, refer to the manufacture’s manual or
consult the factory.

2-4
OPERATOR QUALIFICATIONS

Before operation, the operator must be thoroughly familiar with the

equipment and it’s operation so that he can operate it in a SAFE manner. His
eligibility to operate the equipment shall be based on the following qualifications:

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

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

2-5
RESPONSIBILTY OF EMPLOYERS AND OWNERS

As an owner or employer using this equipment, it is your responsibility to

ensure that the operator is qualified, has read this manual, and has received
training in the safe operation of the Powercreter pump, and the safe work
practices for the job to be accomplished. It is also your responsibility to provide
for regularly scheduled preventative maintenance and repair of the Powercreter by
trained repair personnel using only parts supplied by Allentown Equipment
Divison. Modification of any part of this Powercreter can create a new safety
hazard. If the Powercreter is modified or rebuilt it must be done under the
direction of Allentown Equipment Div. Factory. No field modification of the
Powercreter is permitted, unless authorized in writing by Allentown Equipment
Div.
It is a further responsibility of the owner or employer to train the operating
personnel in all the specific requirements, government regulations, safety
regulations, safety regulation of the product liability insurance company,
precaution, and work hazards which exist in a work situation and ensure that all
involved take the necessary precaution and safety measures. Only a trained and
qualified operator who abides by safe work practices can avoid accidents.

2-6
PRINCIPLE OF OPERATION

FIG. 2-1 MATERIAL PUMP

THE MATERIAL PUMP

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

2-7
 THE HYDRAULIC SYSTEM – ELITE W/CPR

INTRODUCTION
The ELITE has a four pump hydraulic system. The first pump, which is the first main
pump off the engine flywheel, is a variable displacement piston pump, with horsepower
limit control. This pump powers the hydraulic pumping cylinders. These cylinders are
controlled through a proportional directional control valve, which is operated from the
micro controller. The micro controller receives signals from the electronic limit switches,
which are located in the pumps wash-box. Each retracted stroke of the hydraulic
pumping cylinder will signal the micro controller to switch direction. Speed of theses
cylinders are also operated through the micro controller (see 2-25). The next two pumps
are piggy backed off the Main pump. This is a double gear pump. The First gear pump
operates the Accumulator (Swing-tube) circuit. This pump provides a continuous flow of
oil for this manifold. (See page 2-10 for a full operation description). The third pump,
which is part of the double gear pump, performs multi-functions. The first function it
serves is powering the re-mixer hopper motor. A manual directional control valve located
near the operator control, will control this. The next function after the re-mixer is it powers
are the hydraulic outriggers (Pump option). A 2-spool valve located off the pump valve
body controls the outriggers, one operator side and one far side. The last pump, which is
located off the side drive of the engine, powers the motor for the pressure washer. This is
an optional feature for the pump. To run the pressure washer a selector valve is to be
activated which is located aside of the pressure washer.
For the hydraulic component P/N’s, refer to the Hydraulic Schematic pg.4-5 in this manual.

Double gear pump for Main pump for Gear pump for Accel Pump or
Accum. And Re-mixer Pumping Cylinders Pressure Washer (Optional)

2-8
HYDRAULIC SYSTEM COMPONENTS

Hydraulic Oil Optional hydraulic

Cooler w/ operated Accelerator
Theromostat pump.

Hydraulic Swing-tube cylinders.

Operated by Accumulator circuit

Hydraulic Outrigger with Re-mixer paddle control valve

Control Valve. (Pump option)

2-9
THE HYDRAULIC SYSTEM

PUMPING CYLINDERS

The two hydraulic pumping cylinders are linked by means of a cross over loop system.
The cross over loop is located on the rod side of the cylinders. As one cylinder is
pumping, powered from the piston side, the oil on the rod side is being forced out over to
the other cylinders rod side, forcing the other cylinder to retract. See Fig. 1. When the
cylinder that is being retracted meets the electronic limit switch, which is sensed off the
piston adapter, the system will switch, and run the opposite way. To insure that there is
equal and full travel of both cylinders, there are (4) check valves located external of the
cylinders, to add oil to the side which is being pushed back to make sure it makes a full
retraction. These are put in the circuit to prevent ‘Short Stroking’.

ACCUMULATOR (SWING TUBE) CIRCUIT

The hydraulic cylinder switching the swing tube is powered through an accumulator-
assisted circuit. When the machine is first turned on, the operator will energize the
accumulator circuit by toggling the ‘Pump’ switch on and off. This will signal the manifold
‘On/Off’ valve to open and charge the accumulator to a preset pressure. Once this
pressure is met, which is determined by a pre-set pressure switch, the system will hold
the pressure by means of a check valve in the manifold. The ‘On/Off’ valve will switch,
sending the oil back to tank. At this point the system will hold and wait for the first
response from the processor to switch. After switching, the system will recharge, hold,
and wait for the next response. When the machine is turned off, there is a ‘Dump’ valve
in the manifold, which will slowly discharge the pressure from the accumulator back to
tank. You should see no pressure reading on the gauge.

Note: While the charged accumulator circuit is holding for it’s response, and that
response is a period of a long time, it is common for the system to turn on and off to re-
charge the accumulator to the pre-set pressure. The pressure switch has a differential
pressure setting of 100-200 PSI.

2-10
ENGINE / OPERATOR CONTROLS IDENTIFICATION

1 2 3 4 5 6

9 10 11 12 13 14 15

2-11
CONTROLS IDENTIFICATION

1. Display Screen – Main terminal display and function input device. Please see
‘Operator Controls – Graphic Terminal’ for complete use of this device.

2. Water Temperature Gauge – This gauge monitors the engine coolant

temperature.

3. Oil Pressure Gauge – This gauge displays the internal operating pressure of the
engine oil system.

4. Vibrator Toggle Switch (Optional) – This will operate the optional electric
vibrator on the re-mixer grate. Turn on the vibrator only when there is material on
the grate. CAUTION: Leaving the vibrator on when there is no material on the
grate can cause damage to the grate.

5. ‘ ALT’ Indicator light - This light is only on, when the alternator output is
inadequate to keep the battery charged. Service may be required when the light
is lit. Contact the service department.

6. Engine Tachometer/Hour meter – This gauge indicates the RPM of the engine. It
also logs the hours of engine operation.

7. Manual lube switch ( Optional) – This will operate the optional automatic
lubrication device. By pressing the button this will activate the lube cycle. The
automatic lube device has a preset lube cycle. The manual button is to be used at
the end of the day, after the equipment has been cleaned, and the auto-lube is
between the automatic cycle.

8. Ignition Switch – Turn the ignition key clockwise against spring return to start the
engine. The magnetic switch ( Item.14) , needs to be held in at the same time the
ignition key is key is turned to start the engine. Turn counter-clockwise to stop
engine.

9. Accumulator Pressure Gauge – This indicates the pressure for the Swing tube
manifold assembly.

10. ‘FAULT’ Indicator light – This light will come on if the re-mixer grate is up, and
the safety locking pin is pulled up. This will prevent the material pump from being
operated. Close the grate and push the locking pin in, and the light should go out,
and the pump can now be ready for operation.

11. Pumping Pressure Gauge – This will display the hydraulic pressure to pump the
material. The resulting material pressure is a function of the piston diameters of
both the hydraulic and material cylinders. See Figure 2-6 and the data tag of your
pump to determine material pressure versus hydraulic pressure.

2-12
12. Remote Pendent socket – The optional remote control pendent when used is
plugged into this connector. See ‘Operator Controls – Graphical Terminal’ for
switching the pump from ‘Local’ to the ‘Remote’ mode. To connect the Remote
Pendent, remove the E-stop jumper Connector * and insert the Remote Pendant
mating connector. When removing the Remote Pendant, make sure to reinstall the
E-stop connector.
* - The installation of the E-Stop jumper Connector is required to run the
equipment when the remote is not used.

13. Throttle control – The vernier throttle cable adjusts the engine speed. Push in
the red button and pull the throttle all the way out to run the pump. Release the
red button, and turn the black knob counterclockwise to make sure the throttle is
fully open. Push the red button in and push to reduce the engine speed.

14. Magnetic ( Tattletale) Switch – Provides a closed-loop circuit to monitor low

engine oil pressure, high engine coolant temperature, and alternator failure. It
allows the system to be sensitive to open circuits, broken wires, false grounds,
corrosion, and loss of power. This switch is to be depressed and held in while
turning the ignition key to get the engine running. Continue to hold to switch
closed for a few seconds while the engine is running, then you can release the
button. The button should be held in by the switch while the engine is running.

15. Emergency Stop Switch – Pushing on this palm knob shuts down the engine
and consequently all power to the pump. The switch must be reset to restart the
engine. Turn the knob clockwise to reset the switch.

2-13
ENGINE / OPERATOR CONTROL w/POTENTIOMETER

1 2 3 4 5 6 7 8 9 10

11

12

13 14 15 16 17 18 19 20 21

2-14
ENGINE / OPERATOR CONTROL w/POTENTIOMETER
1. Start/Stop/Remote Switch – will “Start” and “Stop” the pump at the Control Panel or
when in the remote position, the pump can be Started and Stopped with the Remote
control pendent. In an emergency the remote control can be overridden by placing the
switch in the center "Stop” position.
2. Pressure Test/Pumping Switch – must be in “Pumping” position for normal
operation. In “Pressure Test” position, the pump will make one stroke; stop and the
pump will high-pressure test.
3. Forward/Reverse Switch – is used for “Forward” or “Reverse” pumping.

4. Potentiometer ( Flow Control Dial) – This is to control the output of the material
pump. To adjust the output, slowly turn the dial clockwise to increase the output and
counterclockwise to decrease the output.
5. Manual Cycling Switch – This switch provides manual override of the automatic
cycle of the pumping cylinders. Each time the switch is toggled to position “A” or “B”
the material pump goes through alternate strokes of the material cylinders. In the
event of failure of the automatic cycle control circuit during pumping, the switch
permits manually controlled pumping.

6. Water Temperature Gauge – This gauge monitors the engine coolant temperature.

7. Oil Pressure Gauge – This gauge displays the internal operating pressure of the
engine oil system.

8. Vibrator Toggle Switch (Optional) – This will operate the optional electric vibrator
on the re-mixer grate. Turn on the vibrator only when there is material on the grate.
CAUTION: Leaving the vibrator on when there is no material on the grate can cause
damage to the grate.

9. ‘ ALT’ Indicator light - This light is only on, when the alternator output is inadequate
to keep the battery charged. Service may be required when the light is lit. Contact
the service department.

10. Engine Tachometer/Hour meter – This gauge indicates the RPM of the engine. It
also logs the hours of engine operation.

11. Manual lube switch ( Optional) – This will operate the optional automatic lubrication
device. By pressing the button this will activate the lube cycle. The automatic lube
device has a preset lube cycle. The manual button is to be used at the end of the day,
after the equipment has been cleaned, and the auto-lube is between the automatic
cycle.

2-15
12. Ignition Switch – Turn the ignition key clockwise against spring return to start the
engine. The magnetic switch ( Item.14) , needs to be held in at the same time the
ignition key is key is turned to start the engine. Turn counter-clockwise to stop engine.

13. Stoke Counter – Displays the total strokes the left and right pumping cylinders cycle.

14. Accumulator Pressure Gauge – This indicates the pressure for the Swing tube
manifold assembly.

15. ‘FAULT’ Indicator light – This light will come on if the re-mixer grate is up, and the
safety locking pin is pulled up. This will prevent the material pump from being
operated. Close the grate and push the locking pin in, and the light should go out, and
the pump can now be ready for operation.

16. Pumping Pressure Gauge – This will display the hydraulic pressure to pump the
material. The resulting material pressure is a function of the piston diameters of both
the hydraulic and material cylinders. See Figure 2-6 and the data tag of your pump to
determine material pressure versus hydraulic pressure.

17. Remote Pendent socket – The optional remote control pendent when used is
plugged into this connector. See ‘Operator Controls – Graphical Terminal’ for
switching the pump from ‘Local’ to the ‘Remote’ mode. To connect the Remote
Pendent, remove the E-stop jumper Connector * and insert the Remote Pendant
mating connector. When removing the Remote Pendant, make sure to reinstall the E-
stop connector.
* - The installation of the E-Stop jumper Connector is required to run the
equipment when the remote is not used.

18. Throttle control – The vernier throttle cable adjusts the engine speed. Push in the
red button and pull the throttle all the way out to run the pump. Release the red
button, and turn the black knob counterclockwise to make sure the throttle is fully
open. Push the red button in and push to reduce the engine speed.

19. Magnetic ( Tattletale) Switch – Provides a closed-loop circuit to monitor low engine
oil pressure, high engine coolant temperature, and alternator failure. It allows the
system to be sensitive to open circuits, broken wires, false grounds, corrosion, and
loss of power. This switch is to be depressed and held in while turning the ignition key
to get the engine running. Continue to hold to switch closed for a few seconds while
the engine is running, then you can release the button. The button should be held in
by the switch while the engine is running.

20. Pre-Heat Button – ( Deutz BF4L2011 Engines) – Used in cold conditions. Press
and hold for 20 Seconds if pre-heat is required.

21. Emergency Stop Switch – Pushing on this palm knob shuts down the engine and
consequently all power to the pump. The switch must be reset to restart the engine.
Turn the knob clockwise to reset the switch.

2-16
HYDRAULIC TANK – Oil Level / Temperature gauge

Oil level gauge

Temperature
Gauge

Hydraulic Reservoir Oil level Gauge – Never operate the pump when the oil level is
not visible in the sight tube. Inspection of the oil level periodically during operation and at
shutdown is considered good operator awareness. This will protect against accidental
loss of oil. With the pump running the oil level should be visible at the sight glass mid
point.

Hydraulic Oil Temperature Gauge – Normal range of oil temperature is 100-160 deg. F
Oil temperature of less then 50 deg. F is in the cautionary range. The material pump
should not be operated at full output until oil is above 50 deg.F. Hydraulic pump damage
may occur. Oil that is below 10 deg. F should be preheated to above 50 deg. F by
running the engine at idle with the material pump “OFF”.

2-17
PAPAN MIXER PAN MIXER GRATE INTERLOCK
INTERLOCK SAFETY SYSTEM

INTRODUCTION

The purpose of the interlock system is to prevent operation of the re-mixer and
swing tube operation if the re-mixer grate is opened.
The interlock is achieved with a two position; normally open limit switch which is
activated by a roller/plunger. In the normal run position this switch is held in the closed
position by the safety pin (See picture below). When the grate is closed, and the pin is
pushed in and locked, normal operation of the pump can take place. Opening of the re-
mixer grate will open the limit switch and shut the re-mixer paddles off, and shut down
the pump operations. After closing the grate, push in the lock pin, and the pump will be
ready for production in a few seconds, once the accumulator system in charged and
ready.

LOCKING PIN LIMIT SWITCH

RE-MIXER CONTROL VALVE

WARNING - the rotating moving parts in the mixer can cause severe
bodily injury. Do not operate machine without the safety shutdown
system.

Prior to starting the engine visually inspect the re-mixer drum for foreign objects.
With the engine operating at idle speed, turn the re-mixer on and verify the correct
operation of the limit switch before adding material for mixing.
DO NOT operate the mixer if this switch is not functional; repair or replace immediately.
DO NOT attempt repairs with the engine running.

2-18
DAILY SAFETY CHECK OF EQUIPMENT
1. Equipment must not be operated at any new site, or at the start of a new shift until a
safety check is made of the condition of the equipment.
2. Equipment must have a sign-off sheet attached to the vehicle where an operator can
report any damage, defects, problems, or accidents to the next shift operators and
work supervisor.
3. Confirm the unit has received scheduled lubrication. See “Maintenance Intervals” in
this section. Inspect the wash box to ensure it contains a lubricant.
4. Walk around the unit and inspect for damaged or missing parts. All safety devices
and provision against accidents such as warning labels, decals, information signs,
safety covers, etc. must be in place. Do not remove or alter these and replace any
which are missing or defective. “Safety Decals” will be replaced free of charge. See
“Parts Catalog”. Visually inspect air and hydraulic hoses for indication of leaks, or
damage. Confirm no foreign objects are in the hopper or lubricating wash box that
would interfere with operation.

SET UP OF EQUIPMENT - Locating the Equipment on the Job

1. Locate material pump on as level ground as possible.
2. Prior to supporting the unit with the jack stand, check the condition of the soil. Keep
sufficient distance from excavations or slopes.
3. Places chocks behind the wheels on trailer pumps.
4. To level the material pump, lower rear leveling stands. Raise the front leveling stand
until the material pump is level.

SET-UP OF MATERIAL DELIVERY LINE

1. It is the responsibility of each pump owner/operator to check the material delivery

system pressure capability with the manufacturer if it is not supplied by ALLENTOWN
EQUIPMENT. Failure to observe these rules can result in a serious personnel injury
and damage to equipment. ALLENTOWN EQUIPMENT recommends use of only
shouldered or Heavy Duty pipeline system, hose and clamping devises that are
specifically designed for material pumping applications. ALLENTOWN EQUIPMENT
has available connection packages for the material pump which contains Couplings,
Reducers, Material Hose, Air Hose, Nozzles, Tips, and clean out balls. Contact our
sales department for additional information.

2. The inside diameter of the material pumping pipeline, or ‘system’ must be at least
three times the size of the largest aggregate of the mix, and with some difficult mixes,
four time times the size. For example: A difficult mix must have a 3 inch line to pump

2-19
 ¾ inch aggregate material. The larger the line diameter the less pump pressure
needed at a given output rate, or a higher output rate can be achieved with a larger
line with the same pressure.

3. Ideally, the same size pipeline as the pumping cylinder will allow very low pressure
pumping long distances, Practically, the larger the line, the heavier and more difficult
to set up, place, and clean up. Utilize as little reduction as possible in the line. In
addition, long reducers use less pump output pressure than short reducers.

4. Set up the material delivery line using a minimum of rubber hose, since rubber hose
offers three times the resistance to the flow of the material compared to steel pipe.
One length of rubber hose at the discharge end of a delivery system provides flexibility
for changing discharge point and the capability for kinking for down hill pumping.

5. Use the most direct line from the material pump to the placement site.

6. Clamp type flanges should be clean and have seals that will retain the slurry in the
delivery line.

7. Horizontal pipelines must be adequately supported. Support the pipeline attached to

the pump outlet. If the material system crosses rebar, support the pipe so it does not
contact the rebar.

8. If your job site has a vertical material delivery system, the vertical pipeline should be
anchored to the building every 10 feet of height.

9. Place the hoses or pipe to reach the farthest delivery point. It is easier to remove than
to add sections after pumping has begun.

10. Material will flow with less back pressure through pipe than through hose. Bends in
hose or elbows in delivery line will also require more pressure. Take these facts into
consideration when laying out the system.

11. Vertical and down hill pumping are more difficult than horizontal pumping. Vertical
pumping requires higher pumping pressure while down hill pumping can cause
separation of the material, which may result in a blockage in the delivery line.
Accordingly, back pressure in the delivery line must be maintained when not pumping,
by kinking the hose at the discharge lend.

12. When laying pipeline utilize as few elbows or reducers as possible. If you are
pumping a marginal mix, the first way you will know it is with “plugging” in the reducer.

13. Replace any worn or damaged hoses, pipe line, or coupling immediately.

14. In hot and dry weather, pre-soak the hose in water to avoid absorption of moisture
from the pumped material.

2-20
 15. Spray a release agent (WD40, Form oil, vegetable oil) on all accessible parts which
will be in contact with the pumped material to ease clean up after operation. Do not
use Diesel fuel. This has a negative effect on the hopper seals and other
components.

OPERATION OF EQUIPMENT - Start Up procedure

Diesel Engine Models

1. Confirm the daily safety check has been performed.

2. On the operator control panel, position the ON/OFF/REMOTE switch to ‘OFF’
3. Position the throttle to idle speed. If there is no throttle cable, and there is a throttle
‘HI’ and ‘LO’ rocker switch, switch to ‘LO’
4. Position the mixer, and or Re-mixer “Mix” and “Dump” valves in the neutral position.
5. Make sure the hopper re-mixer grate and or mixer grate is lowered and in place, and
the Safety lockout pin is pushed in. (See ‘Interlock Safety System)

NOTE: Engine will not start if this device is not in place. On most models a
‘FAULT’ light on the control panel will be lit. If this occurs please see the
troubleshooting guide in this manual.

6. Confirm the “emergency stop” switch is reset by turning it clockwise.

7. Turn the Ignition Switch key to the ‘IGN’ position. Keep this key at this position for at
least 5 seconds. This will power up the operating system*. After 5 seconds
continue to start the engine, by continue turning the key clockwise against the spring
pressure, and then release as soon as the engine fires. Most models will have a
‘Tattletale’ switch installed in the control panel. This must be depressed and held
during ignition. Once engine is running, continue holding the switch closed for about
5 seconds, and then release. The switch will hold the button in during operation. If
the button fails to latch after releasing, there might be a failure within the engine
shutdown system. Refer to the engine manual, or call the service department.

CAUTION : Do not crank the engine for more then 20 seconds at a

time. If the engine does not catch, wait a minute then try
again. If engine fails to start after two attempts, refer to
the engine manual.

*NOTE: Once the engine is running, the Accumulator system will automatically
charge after about 10 seconds. Once charged, you should see the
Acc. Pressure gauge read the pre-set PSI charge. If this does not
happen, shut down engine and follow the start-up procedure again.

2-21
 8. In cold weather starts, let the pump run at idle until the hydraulic oil temperature
warms up to at least 50 degrees F. Once temperature reaches this temperature,
you can then continue to operating speed.

FUNCTIONAL CHECK

Once the engine is running, and ready to start production, a functional check out of the
Pump Equipment, and any optional accessories should be performed prior to adding any
material to the hopper.

1. Check to make sure the Accumulator is charged and holding the pre-set pressure.
This pressure setting is listed on the Data tag.

NOTE: It is common for the Accumulator system to re-charge periodically when

the pump is at idle. A slight internal hydraulic leakage in the system is
normal. Once the pressure deviates more then 100-200 PSI, the system
will recharge automatically.

2. Check the swing tube oscillation. Toggle the ‘FORWARD/REVERSE’ switch to

make sure the swing tube moves freely.

CAUTION : Make sure there are no objects in the hopper prior to

switching cylinder.

3. To check the pumping cylinders:

• Close the ‘FLOW CONTROL’ Valve, and open two full turns. If a
potentiometer type dial, turn the dial to the ‘2’ position.
• Turn the pump ON/OFF switch to ‘ON’ and observe for automatic
oscillation of the pumping cylinders.
• Toggle the ‘MANUAL PUMPING’ switch to confirm the manual override will
function each of the pumping cylinders.

4. Actuate the mixer and/or re-mixer valve. Observe for rotation of the mixer blades. If
the pump has a mixer, raise and lower the mixer drum with actuating the ‘DUMP’
valve.

5. If there is an optional Accelerator pump being used, make sure this a primed and
ready for operation. See the Accelerator pump manual for starting up.

2-22
LUBRICATING THE MATERIAL DELIVERY LINE

An important prerequisite of pumping is the proper lubrication of the pipeline or

hose system at the start of the pour. Failure to lubricate the material delivery line
will contribute to plugging of the line resulting in excessive downtime to clear
plugs.

The choice of lubricating agent is dependent upon the physical properties of the
material pumped. For pumping concrete, a rich, sloppy grout with a 1 to 1
sand/cement mix about the consistency of thick soup is recommended or contact
ALLENTOWN EQUIPMENT parts department for “Slick Line” materials.

First wet the hopper with lubricating agent, then slowly pump the lubricating agent into
the pipeline system. It provides a smooth coat in the pipeline system ahead of the
material to be pumped and prevents cracking or bleeding of the material. The amount
of lubricating required depends on the length of line, its diameter, and the pumpability
of the material being pumped. The minimum is 5-6 cubic feet for short runs of small
diameter line. It can be a cubic yard or more for several hundred feet of large
diameter line. Experience will indicate the proper amount, but it is always safe to have
too much rather than too little.

A small amount of lubricating agent should be kept in the hopper and blended with the
mix to provide a transition into the pumping operation. As the material is starting to
flow through the line monitor the hydraulic pressure gauge and flow from the material
line to ensure a plug or blockage is not forming. Only after pressure and flow are
stable should the pump speed be increased to the planned operating rate.

PRECAUTIONS DURING PUMP OPERATION

1. Operator and nozzle man must always wear eye protection and hard hats.

2. Never fill the fuel tank while the engine is running or hot. Avoid the possibility of
spilling fuel causing fire or explosion.

3. Do not operate the ALLENTOWN EQUIPMENT pump without the hopper grate
mounted firmly in place. Never stand on the hopper grate, and never place any parts
of the body into the hopper while the engine is running.

WARNING : Failure to follow these precautions can result in serious

personal injury or death.

2-23
4. In the event of downtime during material placement, it may be necessary to stop
pumping to wait for material, or have other job site problems. During these periods
the material should be moved every 10-15 minutes. One method is to reverse the
pump and convey backwards two or three strokes and turn the material off for 10-15
minutes and then pump forward two or three strokes. If the problem continues until
the material starts to set, it may become necessary to clean out the material delivery
system and the material pump. Experience with your application will determine how
long you can safely hold material in your system before it becomes necessary to
clean out the delivery system and the material pump. If shut down periods exceed 2
to 3 minutes, turn off the engine between moves, to prevent separation of the mix in
the hopper due to vibration. Separation of the mix in the hopper can cause a
blockage in the delivery line when pumping is resumed.

5. When pumping long distances or stiff mixes, you can expect less volume than with
shorter lines, and wetter mixes. Water leaking from hose coupling gaskets can cause
separation of the mix in the material line and subsequent blockage at that point.
Damaged hoses with internal restrictions can also cause blockages.

6. The maximum material pressure is a function of the maximum hydraulic pressure and
the areas of the hydraulic and the material cylinders. (See Fig. 2-6). Maximum
pressure is only obtained under no flow conditions, average pumping pressure will
normally be somewhat less than the maximum. Pressures are highest at the material
pump outlet and reduce uniformly to zero at the discharge end of the material pipeline
under normal pumping condition. Do not kink the material delivery hose. If the hose
is kinked during material placement or a dry pack or blockage does occur in the
material delivery system the flow of material will be stopped and pressure will build up
to maximum in the material delivery system to the point of blockage. If a plug has
formed, follow the instructions for “Cleaning Material Plugs”

2-24
7. Down hill pumping can be difficult on some jobs. When the pump is stopped the
material can flow slowly in the material line and permit the hose to collapse. A plug
can form at the point of hose collapse. To prevent this, the hose can be “kinked off”
at the discharge while the pump is stopped. This will prevent the gravity flow. The
use of stiffer mixes when pumping down hill will also avoid gravity flow

8. When pumping vertically up along the side of a building (above 40 ft.), installation of
steel pipe securely fastened at intervals of 10 feet to support the pipe column is
recommended. 90 degree long radius pipe sweeps should be installed at the top and
bottom of the steel line. Use a 25 ft. (or shorter) section of hose off the pump. For
the balance of the horizontal distance to the vertical line, utilize pipe. This type of
installation has been satisfactory on many jobs pumping material to heights in excess
of 100 feet.

9. When using snap coupling with gaskets to join hoses, wash and clean after each job.
Dip both coupling and gaskets into water prior to use for easier installation.

If the delivery system is blocked for any reason, or the line

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

10. A slight pulsation of the delivery hose near the pump will always be noticeable.
Excessive pulsation near the pump is normally due to higher than average line
pressure caused by stiff, harsh mixes or extremely long pumping distances. The use
of hoses with larger internal diameter than specified in “Set Up Of Equipment” will
reduce the line pressure.

11. In order to reduce the line pressure, slight amount of water may be added to the mix.
The use of admixture may also help. ( See ‘Admixture’ section in this manual.)

Clearing Material Plugs

The probable causes for material plugs are:

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

• Failure to clean up after prior pour. See “Clean Up at end of pour”
• Poor pipeline set up. See “Set Up of Material Line”

2-25
When a block occurs in the material delivery system, the pumping pressure gauge will
reach the maximum of the hydraulic system and the material will not flow from the
material line. To clear the plug:

• Immediately shut “OFF” the pump. Do not stop the engine.

• Switch the sing tube “FORWARD” to REVERSE”

• Switch the pump to “ON” and pump two strokes in reverse the pressure from the
plug from the plug back to the material pump.

• Switch the pump to “FORWARD” and observe if the plug is dislodged. If material
is flowing, slowly increase the volume to the desired output. If material is not flowing,
repeat this and the previous step a few times.

• If “REVERSE” pumping has not dislodged the plug, shut “OFF” the pump and walk
along the hose until you find the point of blockage. The hose will be soft immediately
past the blockage. Elevate the hose at that point with blockage hanging down.
Shake or hit the hose with a rubber mallet, until the blockage is broken up.

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

• If none of the above are effective in dislodging the plug, rotate the section of line
containing the plug end for end or replace the section with a new clean section of line.

Even after pumping in “REVERSE”, it is possible for sections

or all of the material in the delivery line to be under pressure.
Clear the immediate area of all personnel, and wear eye and
body protection prior to opening any flanges. Open any
clamps with caution to discharge any pressurized material
slowly. Start the pump up at a low volume rate until a steady
flow of material is being pumped.

Clean Up at End of Pour

Clean up at the end of a pour is essential to trouble free operation on the next pour.
Hardened material anywhere in the delivery system will increase the drag on material
being pumped, resulting in additional build up, higher pumping pressre, reduced flow,
and material blockage.

2-26
Clean the pump as follows:

1. At low engine speed and the volume control set low, pump the remaining material out
of the hopper until it is half empty, then turn the pump off.

2. Add enough water to the material hopper to make a thin slurry.

3. Place the FORWARD / REVERSE switch in the “REVERSE” pumping mode. Turn
the pump “ON”. The reverse pumping will cause the water to mix with the material to
form a thin slurry.

4. Switch the pump to “FORWARD” and pump the slurry through the line followed with a
mixer-load of water.

5. Remove the hopper clean out door.

6. With the pump turned “ON” and in “REVERSE” pumping mode, turn a water hose into
the discharge outlet. This will draw water into the material cylinders and push rock
and sand out through hopper door.
CAUTION: Do not insert hose nozzle or hands into outlet while engine is
running.

If material remains in the hopper, turn “OFF” the ignition switch

to shut down the engine. A solenoid operated dump valve built
into the accumulator circuit will automatically discharge the
circuit when the power is turned off. Check pressure gauge
that it reads ‘zero’ PSI. There are moving parts in the hopper
and lubricating wash box, the operator, and any assistant must
know and follow the correct procedure and use caution when
cleaning the pump. DO NOT puts hands or tools into hopper,
outlet, or lubricating box while power is “ON”. Use the clean
out tool supplied with the pump to clean the outlet and swing
tube area.

7. Repeat steps 2 thru 4 if material remains in the hopper.

8. If the machine will be left on a job site unattended, secure it from unauthorized use or
movement.
9. Life of the internal seals of the mixing paddle shaft, and re-mixer shaft is prolonged by
cleaning thoroughly. After cleaning at the end of the day, apply lubricant to surfaces
which material contacts to inhibit corrosion and act as a release agent to ease
removal of subsequent material build up.
10. Turn the pump back “ON”. Grease the Mixer, Re-mixer, and the Material Pump
seals. This is to be down while the paddles and swing tube is in operation. This is to
be done to work out grout that has worked its way by the seals during operation.

2-27
 OPERATOR CONTROLS – GRAPHICAL TERMINAL
ALLENTOWN EQUIPMENT has introduced an innovative way of operating our pumps.
The graphic terminal is a newly released product from Sauer Danfoss which offers
greater flexibility, and more options. This section will introduce you to the operator
controls, and the screens in which the operator will have to interact and input when
required.

MAIN TERMINAL
FUNCTION
INPUT
BUTTONS LIGHT SENSOR

(DISPLAY SCREEN)

ESCAPE ENTER MENU FUNCTION

FUNCTION FUNCTION NAVIGATION NAVIGATION
BUTTONS BUTTONS

2-28
INITIAL POWER-UP

When the pump is started, whether diesel or electric powered, the Graphical Terminal will
power-up. The Display screen will first show a welcome screen, and then an
ALLENTOWN EQUIPMENT information screen. Press the right Menu Navigation Button
to proceed to the ‘Main Operation Screen’

MAIN OPERATION SCREEN

This screen is the main screen in which most of your pump operation will be controlled.
Below is a diagram of that screen. Below that are the descriptions of each of the
functions, and pump information displayed in this screen.

FUNCTION 1 - By pressing this function, this will ‘START’ and ‘STOP’ the engine or
motor. Note the pump direction ‘FWD’ or ‘REV’ in function ‘5’, prior to
starting. In the event the ‘Remote’ function is ‘ON’, a Warning will
appear to inform you of the function.

2-29
FUNCTION 2 - By pressing this function, this will Increase (+) the volume of material
being pumped. The volume level of this function is displayed in the
center of the screen as ‘PUMP RATE %’. The value will be show from
0-100%.

FUNCTION 3 - By pressing this function, this will Decrease (-) the volume of material
being pumped.

FUNCTION 4 - By pressing this function, this will activate (REMOTE ON) or de-activate
(REMOTE OFF). When the REMOTE ON is indicated, the Remote is
off.

FUNCTION 5 - By pressing this function, this will change the direction of the material
being pumped. With the ‘FWD’ shown, pump will be pumping in the
forward direction. ‘REV’ shown will be pumping in the reverse
direction.

FUNCTION 6 - By pressing this function, this will send you to the Manual Cyling
screen. See ‘MANUAL CYCLING SCREEN’ in this manual.
FUNCTION 7 - By pressing this function, this will START or STOP the Accelerator
Pump, if this is an equipment option to your pump. See ‘ACCERATOR
PUMP OPERATION’ in this manual.

FUNCTION 8 - By pressing this function, this will send you to the Accel Menu screen.
See ‘ACCERATOR PUMP OPERATION’ in this manual.

INFORMATION IN CENTER OF SCREEN

PUMP RATE % - Percentage of output set by function ‘2’ and ‘3’.

Pump may not be able to run as low as 1%. Pump may stall. If
pump stalls, increase (+) volume till cylinders start to move, then re-
adjust volume to suit output.

DOSING PERCENT - Percentage of accelerator being used (Optional

Equipment). See ‘Accelerator Screen’ to change rate.

BATCH VOLUME DELIVERED – This is an accumulative value of material being

pumped. This is derived from the pump size and fillage rate inputted
into the ‘SETUP MENU’. The value will read in cubic yards. This value
will accumulate even after the machine is shut down for the day. To
reset this value, press the ‘ESC’ button and hold for 3 seconds.

2-30
MENU NAVIGATION BUTTONS

To go forward and back from screen to screen, use the ‘Menu Navigation Buttons’.
Use the right arrow to go forward and the left to go back. Some screen will have option
going back to the Main Menu by using a Function input button. Below is a list of screens
in order that they will appear.

1. Initial ALLENTOWN EQUIPMENT welcome screen.

2. Main operational menu screen.
3. Accelerator setup screen
4. Manual Toggling and Pressure Test screen.
5. Pump Diagnostic screen
6. End of day totals.
7. Engine Performance Screen (Diesel Units)
8. System setup screen (Password protected)

ACCELERATOR SETUP SCREEN

2-31
This screen will be used if you chose to use an accelerator in your material, and your
machine has the optional hydraulic driven accelerator pump.
To input the necessary information needed, the following steps are required. Once the
Values are entered for the specific accelerator chosen, the information will be stored and
saved.
1. Push the ‘ACCEL TYPE’ button. A list of four options will show for the right
side functions. If the type of Accelerator you desire is not shown, chose
‘OTHER’. Input the required information. The input information will turn
red. Use the + and – function buttons to change the values, and then push
the ‘OK’ button to save the value.
2. Push the ‘CEMENT CONTENT’ button to enter the cement to be used in the
material in pounds/cubic yards. The specific gravity will automatically
change as you enter the value.
3. Push the DOSING PERCENT + or – buttons to input the required dosing
percentage. A ‘Warning’ will appear if the value is exceeding the
recommended range of percentage. The function will still work even though
the Warning appears. See ‘Setup Menu’ for setting dosing range.
4. Press ‘OK’ to enter all values.
5. Press the back menu navigation button the go back to the Main Menu.

MANUAL TOGGLING / PRESSURE TEST SCREEN

2-32
This menu can be accessed through the Main Menu or through toggling through the
screen navigation buttons.

This screen is to be used in the case of sensor failure, or the need to test the pumping
cylinders pressure, or to correct a short stroke of one of the cylinders.

To manually operate the pump, press the ‘LEFT’ or ‘RIGHT’ buttons to move the material
pumping cylinders.

The ‘PUMP STOP’ function is also present on this screen.

Use the ‘RETURN MAIN MENU’ button to return to the Main Operating screen.

DIAGNOSTIC SCREEN

This screen is to be used for diagnostics. In the event of a pump failure you can use this
screen to check which solenoids, which operate the hydraulic control valves, are
energized. (See troubleshooting for complete description of these functions)
If needed, call the Service Dept., and they might have you access this screen.

2-33
END OF DAY TOTALS SCREEN

This screen will give you the accumulation of Concrete or Refractory material used in
cubic yards. In addition, it will show the amount of accelerator used in pounds along with
the material pumped. These values can be reset by pushing the ‘RESET’ button and
holding for 3 seconds. Values will be stored even though the pump is shut downed.

PASSWORD SCREEN

Enter the Password number ‘257’ to proceed to the ‘System Setup Screen’. This is to
prevent sensitive information being changed inadvertently in the Setup Screen.
This number can not be changed. Please contact the ALLENTOWN EQUIPMENT
service department if this number is lost. Allentown can custom set this value with any
three digits prior to equipment shipping.

2-34
SYSTEM SETUP SCREEN

These values are critical information the computer uses to determine pump output,
default dosing percentage, and pump performance.

1. Volume Per Stroke – depending on the material cylinder diameter and stroke
length, this is the value the computer uses to calculate output, and accelerator
dosing. The chart below will indicate which value to use.

OUTPUT IN
MATERIAL CYLINDER
CUBIC YARDS/STROKE*
3" DIA BORE X 16" STROKE 0.002
3" DIA BORE X 24" STROKE 0.003
4.5" DIA BORE X 30" STROKE 0.010
6" DIA BORE X 30" STROKE 0.018
6" DIA BORE X 39" STROKE 0.024

2-35
2. Dosing Calibration - A value in pounds per pulse. This value which the
computer uses to determine the amount of actual accelerator that is pumped. This
is metered through the flow meter or Flow Switch. Depending on the size of the
pump the values should be as follows:

ACCEL. PUMP SIZE LBS/PULSE

A10 0.0010
A20 0.0063

3. Percent Cylinder Fillage - This value is a educated guess, of the actual

percentage of material being filled in the material cylinder each stroke. This value
is usually between 80-90 percent. The operator needs to have some
understanding of the material being pumped to enter this value. The default set
from the factory is 85%. This value is used to calculate the material usage which
is displayed on the Main Menu screen, and End of Day Totals. This value is
important if a desired accuracy is needed by material pumped.

4. Dosing Percentage – The percentage valve required when using the optional
Accelerator dosing system. This value will be used a intermediate number when
selecting a dosing percentage. For example: If a 5% dosing percentage is
required, input 5% for this value. In the Accelerator run screen, the operator will
have the option of running accelerator at 5% +/- 25% of this value. If the value is
exceeded, a warning will appear on the screen. This will prevent the operator of
over or under dosing.

5. Compression Time – The is a value in milliseconds (ms), which is the time

interval the computer uses to quickly advance the pumping cylinder in the forward
pumping direction.

6. Compression Time Output Pct. – This is a percentage of the actual material

pump output speed. This percentage will be used as a multiplier, to the material
pump speed, to set the speed for the compression time set in milliseconds (Setup
4). The percentage allowed is between 0-200%. The chart below will show the
factory default setting.

FACTORY SET DEFAULT

MATERIAL CYLINDER
PERCETANGE ( % )
3" DIA BORE X 16" STROKE 100
3" DIA BORE X 24" STROKE 100
4.5" DIA BORE X 30" STROKE 100
6" DIA BORE X 30" STROKE 100
6" DIA BORE X 39" STROKE 100

2-36
MAINTENANCE INTERVALS

Daily Weekly Monthly 6 Months Yearly

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

LUBRICATION
Diesel Engine - See Engine Manual …….X
Engine Oil Filter Change *
Engine Oil Level …….X
Electric Motor Bearings ………….……………………………………….X
Wheel Bearings ……….………………………………………….X
Material Pump Main shaft …….X
Material Pump Outlet …….X
Mixer/ Re-mixer Seal Housings …….X
Mixer/ Re-mixer Bearings ……………………………………X
Hydraulic Oil Filter *
Hydraulic Oil Drain, Clean tank ………………………………………………………………...X
Lubrication Washbox …….X
Mixer Pivot Bearings …………….……………………..X
Mixer Gear Box Oil ………….………………………..X

* - First 50 Hours of operation. Every 200 hours thereafter.

** - Interval dependant on use and severity of material pumped.

3-1
MATERIAL PUMP – ELITE 40

3-2
WEAR PARTS – REPLACEMENT AND ADJUSTMENT

1. Swing – Tube Adjustment – The initial adjustment of the Swing-Tube, Item 2, is made
with the 2 ¼” Nut, Item 32, on the shaft. The locking bolt and retainer plate, Item 33, must be
removed when adjustments are made. After the initial adjustment, the cutting ring, Item 12, in the
swing-tube will automatically adjust for wear. The cutting ring, Item 12, has a rubber expansion
band, Item 13, between the body of the swing-tube, Item 2, and the diameter of the cutting ring.
For proper sealing and operation, this rubber must be compressed the correct amount. The
correct adjustment is made by tightening the 2 ¼” nut, Item 32, on the shaft, rotate the nut one
flat at a time. When the cutting ring contacts the wear plate, continue adjustment by 1 or 2 flats of
the nut. Install the retainer plate, item 33, and locking bolt, item 35 to lock the nut adjustment in
place. There should be a minimum of 0.015” gap between the swing-tube extension, Item 6, and
the Outlet piece, Item 8. NOTE: Additional adjustment will be required when failure of the cutting
ring, Item 12, to seal on the wear plate, Item 11 is observed. Attempts to reduce leakage by
excessive torque on the nut, Item 32, will accelerate wear of these parts with negligible reduction
in leakage.
NOTE: (2) Outlet seals, Item 19, Item 22, and bearing, Item 23, must be in place when
the adjustments are made.

2. Outlet Seals, Item 19 and 22, and Bearing, Item 23 – Always replace the outlet seals
and bearing whenever wear parts are replaced. Replace seals and bearing by removing the
outlet body, Item 7, remove the (6) mounting bolts, Item 36, install two bolts in the threaded
jacking bolt holes located at 12 and 6 o’clock of the outlet to back it out of the hopper. Clean the
outlet body, Item 7, swing-tube extension, Item 6, and the hopper piloted area thoroughly before
reassembling. Wipe grease on the swing-tube extension, Item 6, and inside the outlet body, Item
7, prior to assembly. The hopper pilot should be coated with a lubricant or anti-seize compound
before assembling.

3. Wear Plate, Item 11 and Cutting Ring, Item 12 – The abrasives in pumping materials
and friction of the cutting ring, Item 12, sliding across the wear plate, Item 11, result in constant
wear of these parts. The loss of pumping pressure should result in a thorough inspection of these
parts. Replace the wear plate and cutting ring whenever deep grooves of wear develop causing
loss of sealing between the two surfaces. The inability to maintain a seal will allow the fines of
the mix to be discharged back into the hopper resulting in lost pumping pressure. Thoroughly
clean the mounting surface of the hopper, remove the “O”-ring face seals, Item 17, clean the
installation grooves and replace the “O”-rings before installing a new wear plate. The mounting
surface must be clean and flat to assure proper performance of the new wear parts.

4. Material Cylinders, Item 3 – The material delivery cylinders have a hard-chrome internal
finish for excellent abrasion resistance and provide a smooth sealing surface for the piston cups.
Inspect the internal chromed surface for wear, a worn cylinder will exhibit feathering of the bright
chrome into a dull gray surface. The loss of the chromed surface will reduce the sealing
characteristics and accelerate the wear of the piston cups. Exercise care when cleaning the
material cylinder ends before installing a new wear plate, do not trap hardened grout between the
two surfaces. Accidental chipping or cracking of the chromed surface will result in premature
failure. Replace the o-ring seals, Item 18 , in both the valve body and wash-box every time you
change or remove the cylinders.

3-3
5. Replace Piston Cups, Item 26, Wearband, Item 16, – Due to the abrasiveness of
materials pumped it will be necessary to periodically replace the piston cup, Item 26, and the
piston wearband, Item 16. Symptoms of worn piston cups are; excessive accumulation of cement
past in the wash box, lubricating fluid leaking from the wash box into the hopper overnight or loss
of wash box lubricant when pumping. Replace the piston cups through the hopper as follows:

a. Drain and clean the wash box.

b. Piston cup removal can be done through the hopper clean-out door and hopper top. The
hopper can also be unbolted and removed with appropriate equipment

c. Start the power unit. On the Operator Panel, put the Forward/Reverse switch in Reverse and
toggle the On/Off/Remote switch between “On and Off” to activate the accumulator circuit.

d. With the engine running (Idle RPM and flow control at low volume 1 ½ - 2 turns open) switch
the pump to “On” and hold the pressure test switch “On” until the piston is fully extended to the
hopper and stops. Turn the pump switch to “Off”. Check to see that the piston head that is
forward is not covered by the swing-tube.

e. If the swing-tube is in front of the forward piston head, turn the On/Off/Remote switch “On”
momentarily and move the Forward/Reverse switch to the opposite position to reposition the
swing-tube.

f. Stop the engine or electric motor. If the unit is engine powered, remove the ignition key from
the panel and the negative battery terminal to prevent starting. Lock out and tag the electric
motor controls.

g. The accumulator dump valve will automatically discharge the accumulator pressure; the gauge
must read “Zero”.
Never work in the hopper when the pump power source (engine or motor) is
operating or the accumulator circuit is pressurized, (which is stored power
for actuating the swing tube). Severe injury can result from inadvertent
actuation of moving parts. For your protection, take time to stop and disable
the engine power system and confirm the accumulator pressure gauge
reads “Zero” before putting hands in the hopper.

h. You should be able to see and feel the piston bolts, Item 45, and piston
cup plate, item 15, in the material cylinder. Chip away any material on and
around the bold heads.

i. Using an air impact gun, remove the 3/8”-24 x 1 ½” lg. Bolts, Item 45, with a 9/16” socket.

j. “Start” the engine and turn the pump switch “ON” for 2-3 seconds. This will retract the cylinder
rod and piston adapter from the piston cup.

k. Turn the On/Off switch to “Off” and stop and disable the power source.

3-4
l. Using a punch or blunt object tap the bottom of the piston cup, Item 26, until it turns side-ways
in the material cylinder, it can now be easily removed.

m. Using an air impact, remove the ¾”-16 x 2 ½” lg. bolt, Item 43, with a 1 1/8” socket which hold
the piston adapter to the cylinder rod.

n. Remove the steel piston adapter, Item 14 and clean thoroughly.

o. “Start” the engine, turn the pump switch “ON”. Toggle the Manual
Pumping Switch to bring the ram forward in the material cylinder you are
working on.

p. To install the new piston cup, Item 26 first replace the piston adapter,
Item 14, with piston wearband, Item 16, on the hydraulic cylinder rod and attach with the ¾”-16 x
2 ½” lg. Hex head bolt with a generous coating of anti-seize compound. Install two 3/8” studs in
the piston adapter used to align the piston cup and faceplate. Grease the piston cup and tap it
into the material cylinder and align on studs, do the same with the faceplate and reinstall the
3/8”-24 x 1 ½” lg bolts and lock washers.

q. Repeat all the above steps to change the opposite piston cup.

r. Always inspect all parts for wear and damage whenever working on
your pump. Early detection of problems will save time and money.

s. When both piston cups have been replaced, fill the wash box with
lubricant.

Never cycle the pump without lubricant in the wash box and
water or pumpable material in the hopper. This will cause damage
to the piston cups. If it is necessary to stroke the pump dry, always
do it very slowly, excessive friction will cause heat and damage
the piston cups.

t. Reinstall the hopper and mounting bolts.

3-5
 1 2
MIXER SHELL

SET SCREW
3

MIXER SHAFT

MIXER / RE-MIXER SEAL REPLACEMENT

The inner seal of the seal housing is exposed to severe operating conditions and
eventually will require replacement. The function of the grease filled seal housing is to
prevent solid particles from entering the flanged ball bearings. The seals need to
replaced when they can not retain grease in the Seal Housing, thus permitting eventual
premature bearing failure.

IT IS RECOMMENDED TO GREASE THE SEAL HOUSINGS AFTER EVERY

DAYS USE. THIS WILL HELP FORCE ANY FOREIGN MATTER OUT OF THE
HOUSING, WHICH WORKED BY THE SEAL.

TO REPLACE THE SEALS IN THE HOUSING:

1. Remove the gear box (mixer) or hydraulic motor (re-mixer) (NOT SHOWN).
2. Securely prop the mixer shaft inside the mixer to keep the shaft axially centered. This
is done to prevent seal damage during re-installation.
3. Remove the Flanged Ball Bearing (Item 1), and Seal Housing (Item 2).
4. Remove the Seal (Item 3) and O-ring (Item 4).
5. Clean the Seal housing and Mixer Shaft end of material build up.
6. Inspect Flanged Bearing for operation and clean or replace if required.
7. Grease the end of shaft and insert New Seal (Item 3).
8. Install new O-ring (Item 4) in Seal housing, then insert Housing unto shaft.
9. Install Flanged Bearing.
10. Lock shaft in position with set screws in the inner race of the Flanged Bearing.
11. Grease fill the Seal Housing until you see grease coming out of the seal.

3-6
PROXIMITY SENSOR ADJUSTMENT

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

3-7
RECOMMENDED LUBRICANTS
LUBRICATION / WASHBOX

Fill the Lubrication/Washbox to the mid point of the cylinder rods. There are three
recommended lubricants.

1. Water is commonly used. Using water will give the shortest life of piston cup
wear.
2. Soluble oil and water mix will improve the life of the piston cups.
3. Oil only as compared will water will almost double the life of the piston cups.
Oil greatly reduces the drag friction between the material cylinder and pistons.
This can be used oil, drain oil, vegetable oil, or any type of inexpensive oil. Oil
is recommended in freezing weather conditions.

HYDRAULIC TANK

Fill the hydraulic tank to the mid-point of the tank level indicator. Use clean SAE 5W-20
Hydraulic oil which is formulated for operation over a wide temperature range. This oil
contains anti-wear and anti-foam additives, and contains rust and oxidation inhibitors for
internal protection. Use the following typical test data if selecting an equivalent.

Viscosity Low Temp. Pumpability test …… Pass

cSt @ 40 deg. C …………23-27 Foam Test ……………………….. Pass
cSt @ 100 deg. C …….….5.4 Rust Test ………………………… Pass
Viscosity index ……………………155 Total Acid No …………………….. 0.6
API g Gravity @ 60 deg F ………..31.2 Zinc, % by weight …………....0.06-0.07
Flash point ………………………...370 deg F ISO Viscosity Grade ……………...370 F
Pour Point …………………………-45 deg F SAE Grade ………………………5W-20

GREASE FITTINGS

Use Multi-Purpose E.P. No. 2 grease, except electric motors

MIXER & RE-MIXER LUBRICATION

Pillow block bearings, flange bearings, and the seal housings should be maintained full
of grease and lubricated daily. Factory lubricant is NLGI Grade 2 lithium 12 –
hydroxystearate base grease.

Maintain oil level in the Gear Box for the Mixer. Fill to just below the fill/vent plug.
Use 80 to 90wt. Gear oil.

3-8
ENGINE MAINTENANCE

Change engine Oil and Filter:

- After the first 250 hours
- After every 1000 operating hours or annually.
- Refer to engine manual.

ELECTIRC MOTOR

Motors with grease fittings should be lubricated every 6 months. Add 1.0 cubic inches to
20 and 30 HP motors. Add 1.5 cu.in. of lubricate to 40 HP and above. Use the following
recommended lubricants:

Shell Oil company - Dollum R

Chevron Oil - SRI No.2
Texaco Inc. – Premium RB

Lubrication Procedure:
1. Clean the area around the grease fitting and remove protective cap.
2. With the motor warm and stationary, add the recommended volume as listed
above, and run the motor for 20 minutes.

Note: All used petroleum based lubricants should be recycled in accordance with
environmentally safe methods.

3-9
LUBRICATION- FLAT PACK
PHOTOS SHOWN WITH AUTO-LUBE SYSTEM (OPTIONAL)

SEAL HOUSING & BEARING

DRIVE SIDE

OUTLET

RE-MIXER HOPPER
SEAL HOUSING & BEARING
IDLE SIDE

MAIN BEARING &

FRONT SHAFT SEALS

** LUBRICATE ALL THESE POINTS DAILY . IT IS RECOMMENDED THAT YOU

LUBE AT THE END OF THE DAY, AFTER CLEAN-UP. THIS WILL REPLENISH, AND
FORCE OUT ANY GROUT WHICH MIGHT HAVE WORKED BY THE SEALS. **

3-10
TROUBLESHOOTING
Diesel Engine
Will not start ……………. • Confirm “E” stop is reset by turning the knob clockwise.
• Make sure the Re-mixer grate in down, and the ‘Grate
Lockout Pin’ is pushed in.
• Check fuel, prime if required.
• Battery voltage must be 10 VDC or greater for controller to
operate & supply voltage to open fuel shut off valve..
• Dirt or water in fuel, change filter & clean tank, if dirty.
• Check battery voltage, alternator output, battery cables are
clean and tight, and controller box cable is connected.
• Check continuity of ignition circuit through the engine temp.
switch, fuel shut off solenoid, ignition switch, and operator
panel connector & bulb of “Alternator” indicator.
• Starter fault, repair or replace.
• Refer to Engine Manufacturers manual, local Engine Mfg.
Service Center, or ALLENTOWN EQUIPMENT service
dept.

Diesel engine
Slow to start or
Rough running…………… • Clean or replace fuel injectors.
• Refer to Engine Manufacturers manual, local Engine Mfg.
Service Center, or ALLENTOWN EQUIPMENT service
dept.

Electric Motor
Will not start ……………. • Confirm power wiring, see “Set up of Equipment”
• Check the motor starter box for blown fuses. See “Motor
Starter Schematic”

Material pump
Does not cycle …………. • Volume (Flow) control, Item 80 of Hydraulic Schematic, must
be open.
• The ‘Accumulator’ system did not charge on start-up.
• Confirm “Pumping / Pressure Test” switch on the Operators
control panel is in the “Pumping” position.
• For local operation, confirm “Remote / Off / On” switch on
the operators control panel is in the “On” position.

3-11
 • For remote operation, confirm “Remote / Off / On” switch on
the operators control panel is in the “Remote” position.
• Fault sensors or sensors cables, adjust or replace. See
“Sensor Switch Adjustment”.
• Switching or continuity fault with Remote/Off/On or Pressure
Test switches. See Wiring Diagrams.
• Cycle Valve pumping, Item 10 of “Hydraulic Schematic” ,
requires cycling voltage to the solenoid coil, and continuity in
the coil winding.
• Spool of pumping cylinders Cycle Valve stuck. Shift
manually, clean spool if dirty.
• Confirm the Main Hydraulic Pump, Item 69 of “Hydraulic
Schematic”, will maintain pressure.
• Confirm the pumping circuit relief valve, Item 15, and the
sing tube relief valve, Item 55, are set in accordance with
specifications on the unit Data Tag.

Pump makes one

Stroke, but will not
Cycle …………………….. • If pump will cycle with “manual Pumping Switch”, adjust the
sensors. See “Sensor Switch Adjustment”
• If pump will not cycle with “Manual Pumping Switch”, refer
to “Material pump does not cycle” in this troubleshooting
guide.

Material pump
Stroke is short …………. • Pumping cylinder seals worm, and need replacing.
• The check valves, Item 79, must seal in the checked flow
direction, for the stroke adjustment circuit to maintain full
stroke. Clean or replace. If replacing the check valve,
refer to the hydraulic schematic for proper orientation.

Both material pump

Cylinders stroke
Forward under
“ Pressure test” ………… • Faulty check valve. Clean or replace.

3-12
Swing Tube does
Not swing ………………. • Confirm Remote/Off/On switch on operators panel is “On”
or in “Remote” if using a remote pendant for On/Off control.
• Confirm relief valve, Item 55 of the Hydraulic Schematic is
set as specified on the data tag.
• Confirm voltage, circuit and coil continuity, and the spool is
shuttling on the Swing Tube directional control valve.
• Confirm the ‘Dump’ and ‘On/Off’ valves, located in the
Swing tube manifold are working properly.
• Confirm pressure setting of the Pressure Switch, Item 25,
is set to the settings per the Data Tag.
• Confirm the accumulator’s pre-charge of Nitrogen is set per
the settings per the Data Tag.
• Swing tube circuit pump, Item 70, is worn and needs
replacement.
• Mechanical bind. Check freedom of rotation of the main
shaft, and outlet to S-tube Extension. Also check torque of
the 2 1/4" Main nut.
• Confirm there is no foreign objects, hardened material
obstructing travel of the Swing tube.

Accumulator
Pressure
Builds slow …………….
• Swing tube circuit pump worn. Needs replacing
• Accumulator bladder leaks. Needs replacing.

Swing tube
Out of timing ………….. • Confirm accumulator is pre-charged per Data Tag.
• Swing tube cylinder seals leak. Needs replacing.

Swing tube
Slow shifting …………… • Confirm accumulator circuit Relief Valve is set per Data
Tag.
• Swing tube cylinder seals leak. Needs replacing.

Material cylinders
Strokes but does
Not build pressure …… • Worn wear plate, Wear ring, and/or piston cups. See
“Wear Parts Replacement or Adjustment.

3-13
 • Confirm the relief valve, Item 15, is set per the settings
specified on the Data Tag.
• Swing tube out of timing. Confirm accumulator pre-charge,
and Swing tube cylinders seals for wear.
• Pumping cylinders seals are worn. Needs replacing.
• Main hydraulic pump is worn. Replace pump if the case
drain line is producing excessive oil. Consult factory prior
to replacing to confirm condition of the pump.

Fluctuating pumping
Pressure ………………. • Worn wear plate, Wear ring, and/or piston cups. See
“Wear Parts Replacement or Adjustment.
• Pumping cylinders seals are worn. Needs replacing.

Slurry in the
Lubrication/Wash
Box …………………….. • The Piston Cups and/or the Material Cylinder are worn,
and need to be replaced. See “Piston Cups”

Adjustment of flow
Control valve,
Item 80, does not
Change material
Pump speed …………. • Confirm the relief valve, Item 15, is set per the settings
specified on the Data Tag.
• Main hydraulic pump is worn. Replace pump if the case
drain line is producing excessive oil. Consult factory prior
to replacing to confirm condition of the pump.

3-14