CG-550/L4/GH

OPERATING & MAINTENANCE MANUAL

WITH

PARTS LIST

SERIAL # ______________________

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CG-550/L4/GH

EXPRESS INSTRUCTIONS The following express instructions are to help you get started using your new grouting machine as quickly as possible. For more complete operating and maintenance instructions, please refer to your manual. BEFORE STARTING Check engine oil level. If low, refill to mark with SAE Grade 10 W 40 or equal. Do not overfill. Check fuel level. Use UNLEADED PETROL ONLY, and fill tank with caution, being careful not to spill, especially if engine has been previously running. Place grout pump and mixer operating levers on NEUTRAL, or CENTER (OFF) position. Visually inspect machine to be sure there are no tools or other obstructions in mixer and machine is ready to run. STARTING 1. Open fuel valve. (Located at left side of engine, under air cleaner. Petrol pump

symbol.) 2. Close choke about 1/2 to 2/3 full travel. (Located just under fuel valve.) 3. Open throttle (large metal handle near top of engine) about 1/2 way. 4. Turn ignition switch (Located on fan shroud at right side of engine) to "ON"

position. Grasp starting cord handle and pull smartly. If electric start, turn key to “START” position to engage starter. Release after engine has started.

5. When engine has started, allow to warm up for a few moments, open choke

when engine is running smoothly and adjust throttle to desired operating speed. (About 3/4 throttle works well for most applications.)

SHUTDOWN With operating levers in neutral position, throttle engine back to idle position for a few moments to allow engine to cool slowly, then close fuel valve, allowing engine to run out fuel in carburetor. After engine has stopped, turn ignition switch to "OFF" position.

WARRANTY STATEMENT CChheemmGGrroouutt,, IInncc.. wwaarrrraannttss tthhaatt eeqquuiippmmeenntt sshhaallll bbee ffrreeee ffrroomm ddeeffeeccttss iinn mmaatteerriiaall,, wwoorrkkmmaannsshhiipp oorr ccoommppoonneennttss.. TThhee ppeerriioodd ooff tthhiiss wwaarrrraannttyy sshhaallll bbee lliimmiitteedd ttoo 9900 ddaayyss ffrroomm tthhee ddaattee ooff ppuurrcchhaassee aanndd tthhee eexxtteenntt ooff CChheemmGGrroouutt''ss lliiaabbiilliittyy sshhaallll bbee lliimmiitteedd ttoo rreeppllaacceemmeenntt ooff ccoommppoonneennttss tthhaatt hhaavvee bbeeeenn pprroovveenn ffaauullttyy.. NNoo ccllaaiimmss iinn eexxcceessss ooff ccoommppoonneenntt rreeppllaacceemmeenntt vvaalluuee wwiillll bbee rreeccooggnniizzeedd.. SSppeecciiffiiccaallllyy eexxcclluuddeedd ffrroomm tthhiiss wwaarrrraannttyy iiss nnoorrmmaall wweeaarr rreessuullttiinngg ffrroomm tthhee mmiixxiinngg aanndd ppuummppiinngg ooff aabbrraassiivvee sslluurrrriieess oorr ddaammaaggee ttoo tthhee eeqquuiippmmeenntt aass aa rreessuulltt ooff iimmpprrooppeerr uussee..

SSAAFFEETTYY VVaarriioouuss gguuaarrddss,, sshhiieellddss,, ggrraatteess aanndd ssccrreeeennss aarree pprroovviiddeedd oovveerr mmoovviinngg ppaarrttss,, ssuucchh aass:: sshheeaavveess,, ccoouupplliinnggss,, aauuggeerrss,, ppaaddddlleess,, bbeellttss,, eettcc.. ttoo gguuaarrdd aaggaaiinnsstt iinnjjuurryy ttoo ooppeerraattoorrss wwhhiillee tthhee eeqquuiippmmeenntt iiss iinn ooppeerraattiioonnss.. WWaarrnniinngg ssttiicckkeerrss aarree pprroovviiddeedd ttoo rreemmiinndd ooppeerraattoorrss ooff tthhee ppootteennttiiaall hhaazzaarrddss.. OOppeerraattoorrss aarree aaddvviisseedd ttoo uuttiilliizzee aapppprroopprriiaattee ppeerrssoonnaall ssaaffeettyy eeqquuiippmmeenntt iinncclluuddiinngg,, bbuutt nnoott lliimmiitteedd ttoo,, ssaaffeettyy ggllaasssseess oorr ggoogggglleess,, dduusstt mmaasskkss oorr rreessppiirraattoorrss,, gglloovveess aanndd // oorr rraaiinn ggeeaarr aanndd hhaarrdd hhaattss wwhheenn ooppeerraattiinngg tthhiiss eeqquuiippmmeenntt..

LLIIAABBIILLIITTYY IItt iiss uunnddeerrssttoooodd aanndd aaggrreeeedd tthhaatt CChheemmGGrroouutt iiss rreelliieevveedd ooff aannyy aanndd aallll lliiaabbiilliittyy tthhaatt mmaayy aarriissee ffrroomm ppeerrssoonnaall iinnjjuurryy oorr ddaammaaggee ttoo pprrooppeerrttyy aass aa ddiirreecctt oorr pprrooxxiimmaattee rreessuulltt ooff tthhee rreemmoovvaall ooff pprrootteeccttiivvee gguuaarrddss,, sshhiieellddss,, eettcc..,, tthhee iiggnnoorriinngg ooff wwaarrnniinngg ssiiggnnss aanndd tthhee llaacckk ooff ccoommmmoonn sseennssee pprroocceedduurreess..

Revision 1 April 10, 2006

SAFETY DATA PLEASE READ AND HEED THE FOLLOWING IMPORTANT SAFETY NOTICES BEFORE PLACING MACHINE IN SERVICE.

* * * * NOTICE * * * *

PROPER PERSONAL PROTECTIVE EQUIPMENT, INCLUDING, BUT NOT LIMITED TO: GOGGLES, DUST MASKS OR RESPIRATORS, GLOVES, HARD HAT, BOOTS AND RAINGEAR MUST BE WORN WHEN OPERATING THIS EQUIPMENT. * * * * NOTICE * * * * FOLLOW MATERIAL MANUFACTURER’S INSTRUCTIONS FOR PROPER MATERIAL USE AND RECOMMENDATIONS FOR SAFETY EQUIPMENT AND PROCEDURES.

* * * * WARNING * * * * NEVER PUT HANDS OR TOOLS IN MIXERS OR PUMP UNLESS PRIMARY POWER SOURCE IS SHUT OFF AND DISCONNECTED AND KINETIC ENERGY DISSIPATED. ON ELECTRICALLY POWERED EQUIPMENT, USE PROPER LOCK OUT/TAG OUT PROCEDURES. FAILURE TO OBSERVE THIS WARNING COULD RESULT IN SERIOUS PERSONAL INJURY AND/OR DAMAGE TO THE MACHINE.

* * * * WARNING * * * *

NEVER ATTEMPT TO DISCONNECT OR OPEN THE COUPLING ON ANY PART OF THE PUMP DISCHARGE SYSTEM WHILE PUMP IS IN OPERATION, OR IF THE DISCHARGE SYSTEM IS UNDER PRESSURE FOR ANY REASON.

* * * * WARNING * * * *

NEVER OPERATE MACHINE WITHOUT THE VARIOUS GUARDS, SHIELDS AND OTHER SAFETY EQUIPMENT WITH WHICH THE MACHINE WAS ORIGINALLY EQUIPPED IN PLACE AND FUNCTIONAL.

* * * * WARNING * * * * ALL ELECTRICAL CONNECTIONS MUST BE MADE BY A QUALIFIED ELECTRICIAN.

* * * * WARNING * * * * HYDRAULIC COMPONENTS, INCLUDING, BUT NOT LIMITED TO VALVES, FITTINGS, HOSES, MOTORS, RESERVOIR AND FILTERS MAY BE HOT. TO PREVENT INJURY, TOUCH ONLY THE HANDLES PROVIDED. LET THE HYDRAULIC COMPONENTS COOL BEFORE SERVICING THE EQUIPMENT.

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TABLE OF CONTENTS SECTION SUBJECT 1. GENERAL DESCRIPTION 2. OPERATING INSTRUCTIONS 3. GROUT SUGGESTIONS 4. DIAGRAM & REPAIR PARTS LIST 5. GROUT PUMP INSTRUCTIONS 6. DRIVE COMPONENTS 7. SCHEMATIC DIAGRAM 8. ACCESSORIES 9. SPECIAL INSTRUCTIONS

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SECTION 1

GENERAL DESCRIPTION

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CG-550 SERIES

GENERAL DESCRIPTION The ChemGrout CG-550 series grout machines are compact integral medium capacity grout mixing and pumping units with both mixer and pump mounted on a single skid frame. A single vertical shaft paddle mixer has been provided which very efficiently mixes batches of up to 30 gallons (4.0 cubic feet) and has an agitating capacity of up to 44 gallons (approximately 6.0 cubic feet). The mixer discharges by gravity into a generously sized pump hopper to allow for continuous operation at optimum production rates contingent upon the rate at which materials are introduced into the mixer. Sustained production rates of up to 2 bags per minute (approximately 1.0 C.F.M.) of pre-blended grout materials have been achieved with these machines. A variety of pump and power options as listed below are available to further enhance the already considerable versatility of these machines. These include closed throat two and three stage progressing cavity pumps for general applications and an open throat version which is ideal for latex or polymer modified grouts and other "sticky" materials. Two stage pumps produce discharge pressures of up to 174 PSI; three stage pumps up to 260 PSI. The discharge capacity of all pumps is approximately 8 to 10 GPM. Power options include compressed air, gasoline or diesel engine and single phase or three phase electric*. Propane fueled engines are also available. Designed for simplicity of operation, efficiency and easy of maintenance, these machines will provide years of profitable service with minimum maintenance. *Electric option includes hydraulic final drive; direct drive electric is available but usually not recommended.

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SECTION 2

OPERATING INSTRUCTIONS

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OPERATING INSTRUCTIONS

GENERAL

* * * * WARNING * * * * NEVER PUT HANDS OR TOOLS IN MIXERS OR PUMP UNLESS PRIMARY POWER SOURCE IS SHUT OFF AND DISCONNECTED. FAILURE TO OBSERVE THIS WARNING COULD RESULT IN SERIOUS PERSONAL INJURY AND/OR DAMAGE TO THE MACHINE. SET-UP In general, the most important factors in setting up are proximity to the work and access to materials and water supply; consideration should be given to the disposal of waste materials and wash-out residue. It is always best to keep grout lines as short as possible to reduce pumping distances. This is particularly important when pumping hard-to-pump materials, such as sanded grouts and pre-blended materials. The source of solid materials (cement, fly ash, sand, etc.) should be readily accessible and an adequate supply of water should be available for mixing and clean-up. When planning a project for high production rates, it is well to remember that the greatest consumption of time occurs when charging the mixers. A proper set-up can reduce this to a minimum. START-UP After set up, visually inspect that there are no foreign objects or old set up materials in either the pump or the mixer(s), then make all necessary connections. With operating levers, valves, or handles in either "NEUTRAL" or "OFF" position and the primary power source turned OFF, fill the pump hopper with clear water.

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OPERATING INSTRUCTIONS (cont'd) Turn on the primary power source and observe that conditions are normal and machine is ready to run. Check each mixer for proper operation by running the mixer in both forward and reverse directions, if unit is so constructed as to allow reverse direction. Next, start the delivery pump to discharge the water that was previously introduced into the pump hopper. This is an ideal opportunity to check the grouting system to determine that all lines and hoses are clear and unobstructed. Pump condition may also be checked at this time by testing discharge pressure. When it is determined that all systems are normal, shut off the pump and drain the water from the pump and all lines. NOTE: Some pre-blended materials and some on-site mixes of sand and cement tend to separate and clog the hoses upon contact with residual water in the hose. To prevent this, a good procedure is to mix and pump out a cement/water slurry prior to mixing and pumping the production material, to lubricate the pump and hoses. PRODUCTION During the production phase of the work, monitor pump and mixer performance continuously, being alert to any signs of abnormality. Keep mixers free of material build-up, keep the outside of the machine clean, and keep pump packing lubricated and just tight enough to prevent leakage. (Section 5) CLEAN-UP After disposing of excess production materials, carefully wash out mixer tanks, paddles and baffles into the pump hopper and pump the resulting washout material through the grout hoses to a suitable disposal site. Continue this operation until only clear water is discharged. It is advisable to drain all residual wash water from the pump and all hoses when washout is complete. CAUTION: NEVER RUN PUMP WITHOUT FLUID AS IT WILL CAUSE SEVERE DAMAGE TO STATOR AND ROTOR.

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SECTION 3

GROUT SUGGESTIONS

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TIPS REGARDING GROUT MIXES Any pumpable grout mix must have at least three characteristics: 1. A smooth, creamy appearance. 2. Must be the color of the cement used (usually gray). 3. Should be just wet enough to be pourable. When using sanded grout mixes, several factors must be considered such as the shape, size and gradation of the sand to be used. Well graded and round shaped sand must be used in the mix. Sand which is poorly graded or has a significant number of flat, sharp or angular particles, such as concrete sand, should not be used. In terms of gradation, the following sieve analysis is offered as an example of a good, pumpable sand: Sieve Size % Passing #8 100 #16 90-100 #30 55-80 #50 30-55 #100 10-30 #200 0-10 A sand comparison chart has been provided for fast reference. Mixing Procedure: Load approximately 80% of the water anticipated for the size batch to be mixed and with the mixer running, slowly add the required amount of cement. Allow sufficient time for the slurry to mix to a creamy consistency, before pumping or adding filler materials (sand, fly ash, etc.) Slowly add sand, if required, until the mix just begins to lose the cement color. This should be the maximum amount of sand the mix can accommodate and it may be necessary to use slightly less sand for subsequent batches. The water may be adjusted for the relative wetness or dryness of the sand to produce a grout that is just pourable.

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Suggested Mixes: Mix A: 94 lb. - Bag Cement 1-1/2 to 2 C.F - Fine Masonry Sand (if req'd) 5-1/2 to 6 Gallons - Water Occasionally, properly graded sand is not available and more fines are required to "carry" the sand in suspension; when that is the case, the following mix is suggested. Mix B: 94 lb. - Bag Cement 75 lb. - Bag Flyash 2-1/2 to 3 C.F. - Fine Sand 11 to 12 Gallons - Water Premix Grouts: Many building material suppliers manufacture pre-blended portland cement based grouts, some of which are pumpable and many of which are not pumpable. Before attempting to pump a pre-blended grout material, determine whether the material conforms to the criteria described above. It is also necessary to determine whether the material has a short working time before set because there may be insufficient working time to pump. Before pumping any pre-blended cement-based grout mix, it is good practice to first coat the pump and lines with a cement and water slurry mix as previously described, prior to pumping the grout mix. NOTE: Flyash is available from many sources, not all of which produce materials suitable for use in portland cement based grouts. It is recommended that before attempting to use flyash from a specific source, a trial mix be made using the flyash and the cement brand and type to be used in the work to determine the characteristics of the materials when mixed.

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10

51

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48

1630

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020

0

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. St

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ieve

Num

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0102030405060708090100

Percent Passing by Weight0 10 20 30 40 50 60 70 80 90 10

0

Percent Retained by Weight

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SECTION 4

DIAGRAM & REPAIR PARTS LIST

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CG

550/

L4/G

H

BF4-

A

IN

OUT

A B D

IN

OUT

A B D

1

2 2A

33A

3B

3130

33

28 33

2414

2318

19 19A

2020

A

3636

A

37 67

7A7B

8

99A

9B10

1111

A

27

1213

3435

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CG-550/L4/GH REPAIR PARTS LIST

NO. PART NO. DESCRIPTION 1 632L4CDQ 2 Stage Grout Pump 633L4CDQ 3 Stage Grout Pump 2 21L3/L4HOPSCN Hopper Screen 2A 21L3/L4HOP Hopper 3 846SLIDE Mixer Discharge Gate 3A 546GATEGASK Slide Valve Gasket 3B 33TBC7112 Slide Valve Clamp 4* 32BFG11/4 Bypass Hose 4A 07BYPASS1 Bypass Assembly (see separate drawing) 5* 841G Bypass Valve 6 34M1011027 Pump Motor 7 60L100X15/16 Grout Pump Drive Coupling 7A 60L100X1 Drive Motor Coupling 7B 60INSHY100 Coupling Insert 8 20GX240QA Manual Start Engine9 60L100X1 Engine Coupling 9A 60L100X5/8 Hydraulic Pump Coupling 9B 60INSUR100 Coupling Insert 10 34PE.84 Hydraulic Pump11 not used11A not used12 21HYD24 Hydraulic Reservoir 13 34TF10153 Suction Filter (inside reservoir) 14 34M1011032 Mixer Motor 18 21PADCPLGH Paddle Coupling 19 2127PAD Paddle 19A 21PADPIN Paddle Pin 20 21PADBUSH Paddle Bushing 20A 54BK1FLANGE Tank Flange 23 2130BAGBKR Bag Breaker / Mixer Guard 24 2127COV Mixer Cover 25.1* 33EV1ABR Grout Hose Coupling 25.2* 33EV2ABR Pump Discharge Fitting 26.2* 33EV2DBR Bypass Coupling 27 33EV2CAPBR Hopper Clean Out Cover 27.2 33EV2ABR Hopper Clean Out Fitting 28 2921/23000SS Hydraulic Pressure Gauge 30 34ZAF07150 Return Filter Head 31 34FAE10 Return Filter 33 34VSDCF755M18LF Control Valve (pump & mixer) 34 34VSDCFHANDLE Control Valve Handle 35 34SDCFK Seal Kit 36 34ELF3401.0 Hydraulic Tank Filler / Breather 37 34ALG3T Oil Level/Temp Gauge * SEE SEPARATE DRAWING ** Complete sets of warning labels are available upon request

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07BYPASS1

4

525.1

26.2

25.2

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SECTION 5

GROUT PUMP INSTRUCTIONS

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OPERATION - ASSEMBLY INSTRUCTIONS AND PARTS LIST FOR "L4" FRAME

SHORT TERM STORAGE Storage of six months or less will not damage the pump. However, to ensure the best possible protection, the following is advised:

- Store unit inside whenever possible or cover with some type of protective covering. Do not allow moisture to collect around pump.

- Remove drain plug and both inspection plates allowing the suction housing to

drain and dry completely. Replace inspection plates.

- Loosen the packing gland and inject a liberal amount of grease into the stuffing box. Tighten the gland nut only hand tight. When water flush systems are to be used, do not use grease. A small amount of light oil is recommended.

SEAL & LUBRICATION The standard and most common sealing used on is graphite impregnated packing with a lantern ring. Tapped holes on the side ribs of the suction housing provide access to the lantern ring for grease lubrication. Lubrication of the packing is essential. When new packing is placed on the drive shaft, often all but one ring will fit until pump operation compacts them. In such cases, a single packing ring is included in a small bag attached to the packing gland nut. After the pump has run and the packing has compressed, the final packing ring can be added. START-UP 1. The suction housing should be filled with liquid prior to starting to lubricate the rotor

and stator until flow is established. 2. Start Pump. 3. If excessive leakage is present after 15 minutes of operation, tighten the gland nuts

1/6 of a turn. Tighten the gland nuts 1/6 of a turn after an additional 15 minutes if necessary, and repeat until desired leakage of 1-2 drops per minute is obtained. Do not tighten until zero leakage is obtained.

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L4

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“L4” PUMP

REPAIR PARTS LIST

REF# PART # DESCRIPTION A 64A04291 Radial Ball Bearing B 64A04301 Thrust Ball Bearing C 64A04331 Bearing Spacer D 64A04581 Bearing Lock Nut E 64A04591 Bearing Lock Washer F 64A04611 Radial Grease Seal G 64A04621 Thrust Grease Seal H 64A04051 Bearing Housing I 64A04341 Bearing Cover Plate J 64A04371 Pump Support K 64A04491 Shaft Collar M 64A04571 Lantern Ring Half (2 req’d) N 64A04381 Stator Support P 64A04501 Pin Retainer Q 64A04731 Retaining Screw Washer R 64A04531 Connecting Rod Washer S 64B0425D Connecting Rod T 64B0445D Rotor Pin U 64B0446D Shaft Pin V 64B0454D Drive Pin Retainer Screw W 64B04021 Suction Housing X 64B04091 Reducer Y 64B04261 Drive Shaft Z 64B0441D Packing Gland AA 64B04421 Packing BB 64B0465D Packing Washer FF 64C4204Q Stator Frame 2L4 CDQ FF 64C4304Q Stator Frame 3L4 CDQ GG 64C72041 Rotor Frame 2L4 CDQ GG 64C73041 Rotor Frame 3L4 CDQ ** Complete sets of warning labels are available upon request

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DISASSEMBLY PROCEDURES A. Before you begin... 1. Operate pump (preferably with clean water) to ensure rotor and stator are

lubricated. 2. Shut off pump. 3. Disconnect power source. 4. Drain any fluid in suction housing. B. When removing stator... 1. Complete Section A. 2. Remove discharge hose attached to discharge reducer (X). 3. Remove discharge reducer (X) by unthreading from stator (FF). 4. Remove top half of stator support (N). 5. Unthread stator (FF) from suction housing (W) and pull stator (FF) off rotor (GG). 6. Check rotor (GG) and stator (FF) for wear (See STATOR AND ROTOR WEAR

Section for instructions).

L4 STANDARD HARDWARE ITEM SIZE # REQ. Packing Gland Stud 2 1/2L x 3/8D-16 2 Packing Gland Bolt Nut 2 1/2L x 3/8D-16 2 Nut 1 1/2L x 3/8D-16 2 Stator & Pump Support Screws 1 3/4L x 3/8D-16 4 Suction Housing Drain Plug 1/2NPT 3 Pipe Plug 1/8NPT 2 Grease Fitting 1/8NPT 1 Hex Key 5/16 1 C. When removing rotor and connecting rod... 1. Complete Sections A and B. 2. Remove both drive pin retaining screws (V). Using a punch, drive out shaft pin

(U). Slide shaft collar (K) toward stuffing box to expose and remove both retaining screw washers (Q).

3. Loosen packing gland nuts and pull entire rotor and connecting rod from pump.

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4. If space is not allotted for the above, pull assembly free from suction housing (W) far enough so that the rotor pin (T) can be removed, disconnecting the rotor (GG) from the connecting rod (S).

D. When disassembling rotor and connecting rod.... 1. Complete Section A, B and C. 2. Slide pin retainer (P) toward the connecting rod (S) to expose rotor pin (T). Using

a punch, drive out pin (T), and separate rotor from connecting rod. 3. Remove one connecting rod washer (R) from each end of connecting rod. E. When removing drive shaft and bearings... 1. Complete Sections A and C-3. 2. Remove bearing cover (I) with thrust grease seal (G) from drive end of bearing

housing (H). 3. Pull bearings and drive shaft from bearing housing. 4. Remove bearing locknut (D) and bearing lock washer (E). Using an arbor press,

remove thrust bearing (B) and radial bearing (A). Inspect grease seals (F) and (G), replace if needed.

F. When removing packing.... 1. Stop pump. 2. Complete Section A. 3. Remove gland adjustment nuts and packing gland (Z) from stuffing box. 4. Remove packing rings (AA). This is best done by using flexible packing

extractors. Use two extractors simultaneously on opposite sides of each ring. Pull evenly.

5. Remove lantern rings (M) in similar fashion. Twist split ring to remove from shaft.

Remove remaining packing.

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ASSEMBLY PROCEDURES The pump is reassembled in reverse order of dismantling. The following suggestions are offered: Note: While pump is dismantled, check all gaskets, "O" rings and packing. Replace all worn items. Connecting rod washers (R) should be replaced each time conveyor assembly is disconnected from the rotor. A. Bearing/Drive Shaft Assembly. 1. Lubricate all bearing parts and pack bearings. The following is a list of approved

lubricants: Keystone Lubricating ................... .......... ..........Keystone #89 Texaco ........ .......... .................... .......... ..........Regal AFB2 Shell Oil Co . .......... .................... .......... ..........Cyprina #3 Humble Oil & Refining Co ........... .......... ..........Beacon #325 American Oil Co .... .................... .......... ..........Supermil American Oil Co ..... .................... .......... ..........Grease #A72832 Mobile ......... .......... .................... .......... ..........EP1 Shell Oil Co . .......... .................... .......... ..........Alvania #2 2. Bearings (A) and (B), with spacer (C), should be pressed onto drive shaft (Y) with

an arbor press applying pressure to inner races only. Make sure bearings are seated fully on shaft, install a new bearing lock washer down into wrenching slot to prevent loosening of nut.

3. Install new radial grease seal (F) in bearing housing (H) and new thrust grease

seal (G) in bearing cover (I). 4. Carefully insert bearing shaft assembly into housing, so as not to damage the

grease seal (F). Slide shaft collar (K) and packing gland (Z) onto leading end of drive shaft, as it is extended through the grease seal.

5. Install the bearing cover plate (I) with grease seal (G). Tighten all capscrews

evenly to prevent damage to bearing cover plate and grease seal. B. Packing assembly. 1. Insert packing rings (AA) and lantern ring halves (M) into stuffing box and around

the drive shaft (Y), using quantities and positioning as shown in packing diagram for your specific size pump.

2. Insure that the packing rings are installed with splits staggered at 90 degree

intervals and that the flat side of the lantern ring halves face the packing.

3. All but the last packing ring may fit into the stuffing box. As the pump operates, the packing will compress and the last ring can be added.

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C. Assembly of rotor and connecting rod. 1. Seat on connecting rod washers (R) on each end of the connecting rod (S). 2. Insert connecting rod (S) into rotor (GG) aligning retaining pin holes and insert

lightly lubricated pin (T). 3. Slide pin retainer (P) into place on end of the rotor (GG). 4. Slide shaft collar (K) towards stuffing box. Slide connecting rod and rotor

assembly through suction housing and into drive shaft. Aligning retaining holes insert lightly lubricated retaining screw washers (Q) onto drive shaft. Slide shaft collar towards bearing housing and align over holes. Insert lightly lubricated shaft pin (U) and thread drive pin retainer screws into shaft collar.

E. Installation of stator (FF). 1. Coat rotor (GG) and interior of stator (FF) with a generous amount of waterless

hand cleaner, baby oil or other lubricant compatible with rubber. Grease or motor oil is not recommended.

2. Thread stator (FF) onto rotor (GG) and into suction housing (W). 3. Install top half of stator support (N). 4. Thread discharge reducer (X) on end of stator. Install all discharge hoses

removed at disassembly. MAINTENANCE

The pump has been designed for a minimum of maintenance, the extent of which is routine lubrication of the bearings. The pump is one of the easiest to work on in that the main elements are very accessible and require few tools to disassemble. Packing The packing is lubricated through a grease fitting in the stuffing box. Packing gland adjusting nuts should be evenly adjusted so they are little more than finger tight. Over-tightening of the packing gland may result in premature packing failure and possible damage to the shaft and gland. When the packing is new, frequent minor adjustments are recommended for the first few hours of operation in order to compress and seat the packing. Greasing the packing often but with limited quantities of grease is the best practice. This can be done through a grease fitting which leads to a lantern ring in the mid-section of the packing. Do not use a one-piece spiral wrap of packing.

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Bearings The pump is equipped with ball bearings in the drive end. The bearings are lubricated at the factory and do not need additional lubrication for at least 1500 hours of normal operation. When re-lubricating the bearings, the bearing-shaft assembly should be removed (See Disassembly instructions) and cleaned of old grease. Add only enough grease to fill the area between the bearings 1/3 full. Add a few drops of oil to bearings to run warm to the touch for the first few hours of operation. Any type of EP Lithium soap base grease is satisfactory for bearing lubrication. The use of Sodium or Calcium base grease is not recommended. ROTOR WEAR The rotor should be replaced if:

a. The rotor pin hole is excessively worn. b. The rotor surface is cracked, pitted, deeply grooved (1/32" or more), corroded or if the finish has been worn off.

STATOR WEAR If stator is worn it may be in need of replacement. Test wear by noting how easily the rotor can be removed. If the rotor slips out easily the stator should be replaced. RECOMMENDED SPARE PARTS The pump has been designed and built with all wearable parts replaceable. A recommended inventory of spare parts is dependent upon the application and importance of continued operation. For the shortest possible downtime, we recommend the following parts to be stocked:

1 - Rotor 1 - Stator

The above is only a suggested list. For further assistance in determining what you'll need for your application contact your ChemGrout representative.

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CHECK CHART FOR ROTARY - PUMP TROUBLES Possible Cause of Trouble [Each number is defined Symptoms in the list below]

Pump fails to discharge: 1, 2, 3, 4, 5, 6, 13

Pump is noisy 4, 7, 8 ,14, 15

Pump wears rapidly: 8, 9, 10, 18

Pump not up to capacity: 3, 4, 6, 13, 16

Pump starts, then loses suction 1, 2, 4, 7

Pump takes excessive power 11, 12, 14, 17

Suction Troubles: 1. Not properly primed 2. Suction not submerged 3. Suction lift too high 4. Air leaks in suction

System Problems: 5. Wrong direction of rotation 6. Low speed 7. Insufficient liquid supply 8. Excessive pressure 9. Grit or dirt in liquid 10. Pump runs dry 11. Viscosity higher than specified 12. Obstruction in discharge line

Mechanical Troubles: 13. Pump worn 14. Bent drive shaft 15. Coupling out of balance or alignment 16. Air leak at packing 17. Packing too tight 18. Corrosion

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SECTION 6

DRIVE COMPONENTS

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CG-550GH

COMPONENT PARTS LIST PART NUMBER DESCRIPTION 20GX240QA 8 HP Honda 20GX390K1QNE 13 HP Honda 20GTG225L Battery(13HP-HONDA) 21BAT550 Battery Box(13HP-HONDA) 20ZE2 8 HP Air Element 20ZE3 13 HP Air Element 34BF4C35.63 Hydraulic Pump Mount 34BF4COV Plastic Covers (Pump Mt. & Motor Mt.) 60L100X1 Lovejoy 1" (Honda & Pump Motor) 60L100X5/8 Lovejoy 5/8" (Hydraulic Pump) 60INSUR100 Lovejoy Insert 34PE.84 Hydraulic Pump 21HYD24 Hydraulic Tank 34ELF3401.0 Hycon Filler Cap 34TF10153 Suction Filter 60L100X15/16 Lovejoy 15/16" (Grout Pump) 34BF4 Hydraulic Motor Mount

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SECTION 7

SCHEMATIC DIAGRAM

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CG-550 / CG-555 Hydraulic Schematic Diagram

6

10

13

28

3333

14

30 31

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SECTION 8

ACCESSORIES

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CG-550 SERIES

AVAILABLE ACCESSORIES P/N DESCRIPTION 03WATERPUMP* WATER PUMP 03HYDREMOTE* REMOTE PUMP CONTROL (ON/OFF) 03GPIGALS WATER METER (GALLONS) 03GPIQTS WATER METER (QUARTS) 03HEADER1 GROUT HEADER 03PROGA1 PROTECTED PRESSURE GAUGE 03SPRAYER SPRAY WAND *These accessories available only for hydraulically driven machines.

GROUT HOSE 32GRT 1 X 12 1/2 QUARTER LENGTH GROUT HOSE 32GRT 1 X 25 HALF LENGTH GROUT HOSE 32GRT 1 X 50 FULL LENGTH GROUT HOSE

GROUT HOSE COUPLINGS 33EVIABR MALE COUPLING HALF 33EVIDBR FEMALE COUPLING HALF

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SECTION 9

SPECIAL INSTRUCTIONS

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CHEMGROUT HYDRAULIC POWER UNITS

GENERAL OPERATING INSTRUCTIONS

Many CHEMGROUT grouting equipment models are driven hydraulically from power supplied by stand alone power units, either manufactured by CHEMGROUT or by others. The following instructions are intended to offer some general operating procedures which should be observed whatever stand alone power unit is utilized. CHEMGROUT power units usually consist of at least the following skid mounted components: A prime mover (gasoline or diesel engine or electric motor), an hydraulic pump, hydraulic fluid reservoir, relief valve, suction and return filters and pressure and return fluid quick disconnect fittings compatible with the hose used to couple the power unit to the equipment being driven. Some units, depending upon their particular application, may incorporate additional components, such as pressure or flow rate adjusting valves, oil coolers, etc., but all function virtually the same; that is, to provide a source of hydraulic medium at flow rates and pressures within the limits of the prime mover horsepower rating in order to drive production grouting equipment. Perhaps the single most important consideration in operating equipment of this kind is safety; hydraulic power is very efficient, but is particularly unforgiving if not applied with care and understanding. In this regard, two general cautions are in order: NEVER PUT HANDS OF TOOLS IN HYDRAULICALLY OPERATED MACHINERY UNLESS PRIMARY POWER SOURCE IS TURNED OFF AND DISABLED. FAILURE TO OBSERVE THIS WARNING COULD RESULT IN SERIOUS PERSONAL INJURY OR DAMAGE TO THE EQUIPMENT. NEVER ATTEMPT TO START OR ENERGIZE A POWER UNIT UNTIL IT HAS BEEN DETERMINED THAT ALL HOSES ARE PROPERLY CONNECTED AND ALL VALVES AND OPERATING LEVERS ARE IN NEUTRAL OR “OFF” CONDITION, PROVIDING AN UNRESTRICTED FLUID FLOW PATH. Before starting engine powered equipment, always ascertain that engine lubricating oil is at safe operating level and that sufficient fuel is available for the operation. Operate the engine in accordance with engine manufacturer’s recommendations as presented in the appropriate engine operating manual. Particular attention must be paid to electrically driven power units, since it is often possible to inadvertently reverse the prime mover direction of rotation; protracted running in reverse rotation will destroy the hydraulic pump. IF, AFTER STARTING THE MOTOR, POSITIVE HYDRAULIC PRESSURE IS NOT NOTED WITHIN A FEW SECONDS, STOP THE MOTOR AND INVESTIGATE THE CAUSE. (Additional information with regard to electrically powered equipment is to be found under the section “Special Instructions” elsewhere in this manual, if appropriate.)

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HYDRAULIC FILTER REPLACEMENT DATA The return filter for your hydraulic system should be replaced frequently to insure the longevity and continued proper operation of the equipment. The unit is fitted with a Filtration Products FPE30-10N replaceable canister style filter assembly, for which replacement cartridges are easily obtained. The following list is a cross-reference to some of the most popular manufacturer's parts numbers. MANUFACTURER REPL. PART NUMBER AC PF16 American Parts 618 AP AP3232 Baldwin BT83910 Case S62427 Champ LFP51 Clark/Michigan 6515541 Deluxe 277 or 451 Dril Tech 001044167 Fiat-Allis 72532042 Fleetguard HF6056 Fram P1653 P1653V15A P1653A GMC 6436232 Hyster 180595 Intern 501021C1 Joy Mfg. 1228372 Mopar L318 Motorcraft (Ford) FH10 NAPA 1551 Perry PL451 Purolator PER20 Quaker State QS1653 Ryco Z136 Savara 92821017 Sullair 44773 Toro 239740 Towmotor 665934 WIX 51551 CW1551MP Zinga AE10

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HYDRAULIC FLUIDS In keeping with ChemGrout's intent to provide our customers with the best, most trouble free equipment possible, the reservoir of the hydraulically driven machine you have purchased has been filled at the factory with SAE 5 W 30 motor oil rather than commercially produced hydraulic oil. There are several advantages that accrue to the use of motor oil as an hydraulic medium. First, hydraulic systems run at temperatures which are typically in excess of 120 degrees Fahrenheit; hydraulic oils, produced from asphaltic crude oil, tend to break down and deteriorate at temperatures around 150 degrees, which is not hard to attain when equipment is in continuous heavy production use. The problem is then compounded when heat generated by work reduces the oil viscosity, resulting in a loss of efficiency, causing the unit to work still harder, producing more heat. Motor oils are produced from paraffin based crude, and are rated effective for temperatures of up to 440 degrees Fahrenheit. In addition, motor oils also contain the anti-wear, anti-foaming and corrosion inhibiting additives that are used in most hydraulic fluids. Some other important considerations are these: from time to time hydraulic oil should be changed, just as you change the oil in a vehicle or equipment engine; the United States Environmental Protection Agency treats used hydraulic oil as a hazardous waste, whereas used motor oil is not. This means that it's much more difficult to dispose of used hydraulic oil than used motor oil. Of course, another obvious consideration is that motor oils are pretty much universally available, where it may be difficult to obtain hydraulic oil in some locations. Fleet owners, who purchase motor oils in bulk, will experience an additional advantage of not having to warehouse or stock large quantities of another product. To replace the oil in your ChemGrout hydraulically operated unit, any commercially available motor oil with a service rating of SE, SG or SF and an SAE Grade 5 W 30 or higher is recommended.

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SPECIAL INSTRUCTIONS

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HYDRAULICALLY DRIVEN EQUIPMENT Many models of ChemGrout equipment feature hydraulically driven mixers and/or pumps. Several advantages accrue to this arrangement; namely, positive independent control of mixer and pump speeds, the ability to reverse mixer or pump rotations, if necessary, and automatic distribution of available primary power to every function as required. In general, the hydraulic drive systems are very simple, consisting of a primary power source (gasoline or diesel engine or electric motor), a direct coupled positive displacement pump, control valves, drive motors, (or cylinders) and a generously sized hydraulic reservoir with both suction and return filters. Circuitry is generally in series with oil flowing from the reservoir through the pump, to the first function, then the second function, etc. for as many functions as are incorporated in the machine, then returning, through the return filter, to the reservoir. Directional and speed control is provided for each function through the use of three position, 4-way directional control valves. Engaging the valve in one position produces function rotation in one direction; engaging the valve in the opposite direction reverses rotation. The convention that ChemGrout uses for valve position vs. rotation is "DOWN" or "IN" (depending on valve position) corresponds to "FORWARD" and "UP" or "OUT" corresponds to "REVERSE". Speed control is obtained by engaging the valve only to the extent needed to yield the desired function speed. Open center metering spools within the valve directs variable amounts of hydraulic fluid to the function, bypassing remaining fluid to the next function or directly back to the reservoir. Some larger units are equipped with a secondary bypass flow control between functions. This is done in cases where there is considerable difference in the volume of fluid required by the functions. The flow control allows excess fluid not needed by the secondary functions to return directly to the reservoir; thus reducing heat generation. The control valves also incorporate integral pressure relief to protect the system against excessive hydraulic pressure. Larger, more complex machines may also be equipped with separate, supplemental pressure relief valves.

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* * * * CAUTION * * * * WHENEVER IT IS NECESSARY TO REACH INTO THE MIXER OR PUMP FOR ANY REASON, MAKE SURE THE PRIMARY POWER SOURCE IS SHUTDOWN AND DISABLED. IF THE EQUIPMENT IS ENGINE POWERED, SHUT OFF THE ENGINE AND REMOVE THE KEY; IF IT'S ELECTRIC POWERED, TURN OFF THE MOTOR AND DISCONNECT THE POWER. A MOMENT OF TIME SAVED IS NOT WORTH THE RISK OF SEVERE PERSONAL INJURY SHOULD A VALVE BE INADVERTENTLY ENGAGED WHILE THE HYRAULIC SYSTEM IS ACTIVE.