SS2-017 - Shotcrete Sprayer - Operator Manual - v001 - r0

Mining Division
Operator’s Manual
SS2-017
AURELIAN RESOURCES INC.
Fruta del norte, Ecuador, S.A.
FOR INFORMATION OR ASSISTANCE

Toll Free 1-866-856-3626 • International +1-705-445-5707 • www.macleanengineering.com
Manufactured by MacLean Engineering & Marketing Co. Limited
PROPRIETARY NOTICE
The proprietary information contained in this document is the property of

MacLean Engineering (MEMCO) and shall be limited in distribution to
MEMCO’s customers, resellers and subcontractors as required to fulfill the
terms of the relevant contract. Distribution outside of these terms requires
the express written permission of MEMCO.
SS2-017
AURELIAN RESOURCES INC.
Fruta del norte, Ecuador, S.A.
MEM-SS2-017/018/019 – SHOTCRETE SPRAYER
AURELIAN – Fruta del norte, Ecuador, S.A.
OPERATOR’S MANUAL
Module # Rev Date Topic

Safety
OM-UTV-S1 B 04/09/2008 General Safety
OM-UTV-S2 I 10/25/2010 Operating Safety
OM-UTV-S3 E 10/25/2010 Servicing Safety
OM-UTV-S4 B 04/09/2008 Fire Prevention Safety
Layout
OM-SS2-V1 Original 11/30/2012 Machine Configuration
OM-SS-V2 Original 11/30/2012 Machine Safety Items
OM-SS2-V3 Original 11/30/2012 Operator’s Compartment Layout
OM-933-V4 Original 11/30/2011 Driver’s Instrument Panel & Enclosed Cab Related Controls
OM-SS2-V5 A 10/02/2014 System Layout & Auxiliary Controls
Operations
OM-SS2-O1 Original 11/30/2012 Pre-Operation Inspection
OM-SS-O2 B 10/02/2014 Modes of Operation & Interlocks
OM-UTV-O3-MERC D 10/24/2017 Carrier Operation
OM-UTV-O4 H 01/10/2013 Brake Test Procedure
OM-SS-O5 Original 11/30/2012 Recommended Lubricants and Fluids
OM-SS2-O6-MERC Original 11/30/2012 Lubrication Chart
OM-SS2-O7 Original 11/30/2012 Shotcrete Sprayer Operations
OM-SS2-O8 Original 11/30/2012 Water Scaler Operation
Training
OM-SS3-T1 Original 11/16/2009 Operator Training Topics and Checklist
OM-SS3-T2 Original 11/16/2009 MEM-SS3 Shotcrete Sprayer Operator Training Test
Revision: Original Revision Date: 21-DEC-2018 By: VMR

Title: GENERAL SAFETY
Number: OM-UTV-S1
Machine Model(s) Affected: ALL APPLICABLE
Revision: B
Creation Date: 04/05/2005 Revision Date: 04/09/2008
Written By: Steve Czerny Revised By: J. Earl Graham
Checked By: Checked By: Joe Agombar
Approved By: Stan Wilson Approved By: Anthony Griffiths
FOLLOW MINE SPECIFIC RULES AT ALL TIMES!

WHEN IT COMES TO SAFETY, NOTHING WILL EVER TAKE THE PLACE OF A
CAREFUL OPERATOR. Therefore, study the following safety measures carefully and
apply them on the job.
• Only operate the Utility Vehicle once you have been fully trained and qualified.
• Get to know the capabilities and limitations of the equipment. Use this manual as
a basis to become an efficient operator.
• Use recommended safety devices and personal protective equipment, i.e.

gloves, safety boots, hard hats, glasses/goggles, ear protection, and protective
clothing when and where required.
• Operate the equipment only when physically fit and not under the influence of
alcohol or drugs.
• Keep floors, steps and running boards clean and free of oil, ice, mud and loose
objects.
• Carry no passengers unless the vehicle is provided with approved seating and
proper authority has been obtained.
• Never remove any elements of the engine’s exhaust system or any supplied
guards and safety covers when the machine is in operation.
• Follow the recommended daily inspection procedure outlined in this manual as

well as on the Pre-op card.
• Comply with the instructions in this manual, all applicable laws, and your
company’s regulations for the operation of this vehicle.
• NEVER operate a machine that has been tagged “Out of Service”.
Always notify operator when approaching the utility vehicle!
OM-UTV-S1 Page 1 of 2
Title: GENERAL SAFETY
Number: OM-UTV-S1
Revision: B
Notes:
If any questions or problems arise, please contact Maclean Engineering Technical

Service for assistance.
Phone: 1-866-856-3626
Email: service@macleanengineering.com
Page 2 of 2 OM-UTV-S1
Title: Operating Safety
Number: OM-UTV-S2
Revision: I
Written By: Kyle Beaudoin Revised By: JanPaul Brenner
Checked By: Lynn Mitchell Checked By: Joe Agombar
Approved By: Steve Czerny Approved By: Darren Bowins
OPERATING SAFETY
FOLLOW MINE SPECIFIC RULES AT ALL TIMES!
• Adhere strictly to ALL regulations at the work site pertaining to the operation of this
equipment including ALL local mining regulations.
• Maintain a safe operating distance between the equipment and other personnel and
use only approved signaling practices.
• When operating the machine, ensure that the articulation area is clear. Do not allow
personnel between potential pinch points.
• Ensure all hoses are disconnected from mine air and water lines, and that they are
properly secured before tramming.
• Keep head, hands, feet and loose clothing away from rotating parts.
• NEVER place yourself under a suspended load.
• If the Utility Vehicle you are operating is a Cassette Truck, with no cassette in place,
the operator must be aware that the machines cornering stability is affected.
Travelling at a slower speed is recommended.
• Always ensure that excess grease and oil accumulation, including spillage, are
cleaned up immediately. Dispose of soiled rags, gloves, etc., according to local laws
and regulations.
• Keep hands and feet inside the driver or passenger compartment at all times.
• Test all EMERGENCY STOP buttons at the beginning of each shift to ensure that they
are functioning correctly.
• Never use the emergency/parking brake to slow down, or stop the vehicle unless it is
an emergency situation.
• When parking the machine and shutting down the engine, set the MAIN BATTERY
DISCONNECT switch to the OFF position.
• If the Utility Vehicle you are operating is equipped with an ANFO CHARGER unit,
ensure that the anti-static drag chains are in place and in good condition.
Title: Operating Safety
Number: OM-UTV-S2
Revision: I
• If the Utility Vehicle you are operating is equipped with a TRANSMIXER unit, it must
only be driven in 1st or 2nd gear when travelling on the ramp with the drum loaded
with shotcrete.
• If the Utility Vehicle you are operating is equipped with a scissor lift, NEVER place
yourself under the scissor deck while the deck is in the raised position without first
engaging the scissor lock mechanism.
• ALWAYS FOLLOW GOVERNMENTAL, MINE AND BULK COMMODITY
SUPPLIER REGULATIONS WITH REGARD TO HANDLING AND LOADING OF
EXPLOSIVES.
• When connecting mine air lines, properly secure the lines with whip checks.
• Some units may be equipped with directional indicator lights. These lights are color
coded either to governmental or site specific requirements. Always follow the
policies related to these indicator lights when working around or near equipment.
ALWAYS NOTIFY THE MACHINE OPERATOR WHEN

APPROACHING THE UTILITY VEHICLE!
Notes:
If any questions or problems arise, please contact MacLean Engineering Technical

Phone: 1-866-856-3626
Title: Servicing Safety
Number: OM-UTV-S3
Revision: E
Approved By: Steve Czerny Approved By: Darren Bowins
SERVICING SAFETY
Before performing maintenance or repair work on any equipment stop and think “Are
you qualified to carry out these repairs?” Know YOUR limits. Consult the maintenance
bulletins provided and follow the recommended procedures.
• Follow the mine site’s lock-out and tag-out procedures.

• When servicing or repairing the equipment, shut down the engine unless it is
required to be running for adjustment purposes.
• Always use the proper tools for the job. Repair or replace any broken or damaged
tool(s), including lifting equipment, immediately.
• Keep your head, hands, feet and loose clothing away from all rotating parts.
• Pressure can be maintained in the hydraulic circuits long after the power source has
been shut down. Relieve ALL trapped pressures before performing any service work
on hydraulic components. Some valves are used to hold components in place.
Removal of these valves or hosing could result in the load dropping or coming down
onto yourself or others. Support all such components and ensure that there is a zero
energy situation before work continues.
• If your Utility Vehicle is equipped with a scissor lift, NEVER place yourself under the
scissor deck while the deck is in the raised position without first engaging the scissor
lock mechanism. This mechanism prevents the deck from falling in the event that
there is a loss of hydraulic pressure. Failing to do so could cause severe injury or
death.
• If your Utility Vehicle is equipped with a boom, NEVER perform maintenance on a
boom that is in the raised position without either first placing a support stand
underneath the boom, or lowering the boom onto the cradle or boom storage area
on the unit. This prevents the boom from falling in the event that there is a loss of
hydraulic pressure. Failing to do so could cause severe injury or death.
• When troubleshooting a hydraulic system for leaks, use a piece of cardboard or
other material as a detector, NEVER USE your hand. Pressurized hydraulic fluid
escaping from a faulty component can penetrate the skin and cause serious injury.
• Do not change the pressure or flow setting of any hydraulic valves unless authorized
instruction has been obtained.
Title: Servicing Safety
Number: OM-UTV-S3
Revision: E
• Use caution when draining hot fluids from the machine. Splashing hot fluid can
cause serious injury.
• Ensure that all tire and rim parts are undamaged and correctly assembled before
inflating the tires (applicable only to pneumatic tires).
• Use an inflation cage, safety cables or other approved safety device when inflating
the tires. Do not exceed the tire manufacturer’s recommended pressure (applicable
only to pneumatic tires). See the applicable Utility Vehicle’s parts manual for the
correct tire pressure.
Always follow mine specific regulations with regards to tire
inflation.
Notes:

Phone: 1-866-856-3626
Title: FIRE PREVENTION SAFETY
Number: OM-UTV-S4
Revision: B
Written By: Kyle Beaudoin Revised By: J. Earl Graham
Approved By: Steve Czerny Approved By: Anthony Griffiths
FIRE PREVENTION SAFETY

Fires can create severe emergencies where both human life and property may be lost.
Even when confined, a fire may cause very expensive damage to your equipment. Fire
can strike at any time, not only when the equipment is used, but also when left
unattended between work shifts and nobody is around to put it out.
When working in a confined environment, it is impossible to prevent combustive dust

from collecting in tight corners of the machine. This dust, in itself, may not cause a fire;
however, when mixed with fuel, oil or grease in a hot and confined place, it can become
a fire hazard. To reduce the chances of a fire occurring, follow the preventative
instructions listed below:
• Inspect the machine daily for potential fire hazards and make any necessary repairs
immediately.
• Always ensure that excess grease and oil accumulation, including spillage, are
cleaned up immediately.
• Set up, and follow a wash schedule. Use only non-flammable cleaning agents for
cleaning the machine or machine components.
• Discard oily rags and other combustible materials in the proper designated location;
do not store them on the Utility Vehicle.
• Before performing repair work such as welding, the area surrounding the repair
location should be cleaned and a fire extinguisher positioned close by.
• Ensure that you are familiar with the location of the machine’s fire suppression
system actuators and KNOW HOW TO USE THEM.
• Maintain a charged fire extinguisher on or near the Utility Vehicle at all times and
KNOW HOW TO USE IT.
• Follow the mine site’s procedures for transporting and loading explosives. (If
applicable to your Utility Vehicle).
Title: FIRE PREVENTION SAFETY
Number: OM-UTV-S4
Revision: B
Notes:

Phone: 1-866-856-3626
Title: MACHINE CONFIGURATION
Number: OM-SS2-V1
Machine Model(s) Affected: MEM-SS2
Revision: Original
Creation Date: 11/30/2012 Revision Date:
Written By: JanPaul Brenner Revised By:
Checked By: René Dubois Checked By:
Approved By: Bill Tytaneck Approved By:
SS2 SHOTCRETE SPRAYER OVERVIEW

The layout of the operator’s side of the vehicle is shown in Figure 1.
Operator’s
Compartment
Electrically
Form Oil and Driven
Pressure Power Pack
Washer
Hose Reels Cable Reel
Fire
Front Suppression
Platform System
and Boom
Assembly
Figure 1 – Typical Operator’s Side Layout
OM-SS2-V1 Page 1 of 8
Number: OM-SS2-V1
Revision: Original
The layout of the passenger’s side of the vehicle is shown in Figure 2.
Mine Air
Inlet
Air
Compressor
Accelerant
Tank
Battery
Charger
Shotcrete
Process Work Lights
Control
Panel Air
Conditioner
Main (If Equipped)
Electrical Boom Control
AC Panel Panel
Accelerant Front
pump Hydraulic
Controls
Outriggers
Figure 2 – Typical Passenger’s Side Layout
Page 2 of 8 OM-SS2-V1
Number: OM-SS2-V1
Revision: Original
The layout of the rear of the vehicle is shown in Figure 3.
Hopper/Grate
Work Vibrator
Light Water Wand
and Hose
Pump
Grease Pressure
Station Washer Wand
Ball Valve
Cable Reel
Switch Mine Water
Inlet
Tail lights
Accelerant
Transfer In
Compressed
Air Out
Shotcrete Drive Lights
Pump and
Hopper Shotcrete
Discharge
Hopper
Piping
Dump Gate
Figure 3 – Typical Rear View Layout
Number: OM-SS2-V1
Revision: Original
The layout of the front of the vehicle is shown in Figure 4.

 Head and Nozzle Assy.  Pressure Washer and Form Oil Reels
 Shotcrete, Air and Water Hosing  Work Lights
 Form Oil Tank  Boom Assy.
 Drive Lights  Head Positioning Actuators
 Nozzle Oscillator
Head and
Nozzle Assy.
Nozzle
Oscillator
Boom Assy.
Work Lights
Shotcrete, Air and

Water/Accelerant
hosing
Pressure Washer and

Form Oil Hose Reels
Form Oil Tank
Front Drive
and Work
Lights
Figure 4 – Typical Front View Layout
Number: OM-SS2-V1
Revision: Original
The layout of the front support platform as viewed from the operator’s side of the vehicle
is shown in Figure 5.
Boom Support
Form Oil and Swing
Tank Fill Drive
Point
Water Scaler
Form Oil Motor (Behind
Pump Curtain, If
(Beside Equipped)
Form Oil
Tank) Pressure
Washer Pump
(Behind
Curtain)
Figure 5 – Typical Front Support Platform
Number: OM-SS2-V1
Revision: Original
Figure 6 below illustrates the overall envelope and articulation radius for the Shotcrete
Sprayer. (Graphics are not to scale, actual layout may vary.)
Figure 6 – Typical Articulation and Envelope
Refer to the Ventilation Requirements label located on the

Shotcrete Sprayer for specified ventilation rates.
Refer to the Maximum Speeds label located on the Shotcrete
Sprayer for specified maximum speeds.
Number: OM-SS2-V1
Revision: Original
Notes:
Number: OM-SS2-V1
Revision: Original
Notes:

Phone: 1-866-856-3626
Email:service@macleanengineering.com
Title: MACHINE SAFETY ITEMS
Number: OM-SS-V2
Machine Model(s) Affected: MEM-SS2 and MEM-SS3 Shotcrete Sprayer
Revision: Original
MACHINE SAFETY ITEMS

There are a few safety items that every operator must be aware of with regards to the
Shotcrete Sprayer. These safety items include the location and usage of the fire
extinguisher, fire suppression system, articulation lock, EMERGENCY/PARK BRAKE button,
MAIN BATTERY DISCONNECT switch and EMERGENCY STOP button(s).Additionally, several
other items such as the shotcrete pump hoist lock, hydraulic safety, and shotcrete hose
clamps are covered in this section.
FIRE EXTINGUISHER AND FIRE SUPPRESSION
The vehicle is equipped with a portable fire extinguisher and fire suppression system. It
is the operator’s responsibility to become familiar with the fire safety systems present on
their specific vehicle. For SS3 non-enclosed cab vehicles, the fire extinguisher is
located outside the operator’s compartment near the entrance as shown in Figure 1.
The fire extinguisher is accessible from both the operator’s compartment and the
ground. For SS3 enclosed cab vehicles, the fire extinguisher may be located inside the
operator’s compartment. For SS2 vehicles, it is located outside the cab, by the
articulation area as shown in Figure 1.
Portable Fire
Extinguisher
Articulation
Lock Bar
Figure 1 – Typical Portable Fire Extinguisher Location

The fire suppression system includes a dry chemical tank, expellant bottle, nozzles, and
manual palm actuators. The expellant and dry chemical bottles are located in front of
the operator’s compartment for the MEM-SS3 Shotcrete Sprayer. On MEM-SS2
Shotcrete Sprayers, the expellant and dry chemical bottles are located on the operator
side front of the vehicle. See Figure 2.
OM-SS-V2 Page 1 of 24
Number: OM-SS-V2
Revision: Original
Fire Suppression Fire Suppression

Fire Suppression
System Expellant System Manual Palm
System Dry Chemical
Bottle Actuator
Bottle
Fire Suppression
System Expellant
Bottle
Fire Suppression
System Manual Palm
Actuator
Figure 2 – Typical Fire Suppression System Layout

One manual palm actuator for the fire suppression system is typically located inside the
operator’s compartment. See Figure 2. A second manual palm actuator is typically
located in front of the passenger compartment, or on the front passenger side bedside
the boom control panel as shown in Figure 3. A third manual palm actuator is located
on the rear fender passenger side of the vehicle as shown in Figure 4. Some vehicles
may come equipped with another manual palm actuator located by the cable reel.
It is the vehicle operator’s responsibility to know how to use the fire suppression system
properly. In order to activate the fire suppression system, refer to Fire Suppression
System Maintenance Information for further details.
Page 2 of 24 OM-SS-V2
Number: OM-SS-V2
Revision: Original
If your vehicle is equipped with a power pack, and your fire

suppression system is activated, all AC power to the vehicle may
become isolated as well.
Fire Suppression
System Manual Palm
Actuator
Figure 3 – Front Passenger Side Fire Suppression Manual Palm Actuator
Rear Fender Passenger Side Fire

Suppression Palm Actuator
Figure 4 – Rear Fender Passenger Side Fire Suppression Manual Palm Actuator
Number: OM-SS-V2
Revision: Original
If the fire suppression system is activated, the pressure switch

located in the operator’s compartment must be reset by
qualified maintenance personnel. DO NOT ATTEMPT TO
RESET THE SWITCH WITHOUT FIRST CONTACTING THE
MAINTENANCE DEPARTMENT.
A Checkfire® fire detection system (if equipped) may be installed on your vehicle. It
provides automatic fire detection for designated areas of the vehicle. The Checkfire®
fire detection system is integrated with the existing fire suppression system and
activates the existing ANSUL™ system if initiated.
The Checkfire® fire detection systems originally installed prior to September of 2009
utilizes a Squib which is located in one of the manual palm actuators. Systems built in
September of 2009 or later use a protracting actuation device (PAD) device actuator
that is typically integrated into the palm actuator in the operator’s compartment. For
more information about the Squib system, see maintenance bulletin MB-FIR1013. For
more information about the PAD system see Maintenance Bulletin MB-FIR1856.
These two different styles of actuators are recognizably different from each other and
the parts are not interchangeable.
The Squib and/or PAD (if equipped) are devices used to initiate
the Checkfire® fire suppression system. Do not inspect or
attempt any maintenance on the Checkfire® fire detection
system or any of its components unless you are fully trained
and qualified. If the Checkfire® fire detection system is
activated contact the appropriate mine personnel.
Number: OM-SS-V2
Revision: Original
There are typically six fire suppression system nozzles on the Shotcrete Sprayer. Their
locations are shown in Figure 5. Make yourself familiar with their locations. During your
Pre-Operation inspection, always check to ensure that the nozzles are clean and free of
damage.
Figure 5 – Typical Nozzle Locations (MEM-SS2 Shown)
Each customer has their own requirements for fire suppression.

Because of this individual requirement, your equipment may be
equipped with additional nozzles not shown in Figure 5. Information
about any additional fire suppression equipment can be found in the
Service Manual and is covered during your training on this vehicle.
Number: OM-SS-V2
Revision: Original
ARTICULATION LOCK
The articulation point lies in the mid-ship of the vehicle and
presents a possible pinch point. The machine operator must
ensure that the articulation area is clear when operating the
machine and must ensure that the articulation lock is used
whenever any work in the articulation area is being done.
The articulation lock consists of a bar and pins (painted red), which are installed across
lugs welded onto the vehicle’s frame on the operator side of the articulation area. The
lock must be in place when doing any inspections or work in the articulation area of the
vehicle, as shown in Figure 6. When not in use the articulation lock bar must be stored.
Depending upon your vehicle configuration, the storage locations shown in Figure 7
may vary slightly.
Articulation
Lock Bar
Figure 6 – Typical Articulation Lock Bar
Typical
Typical
MEM-SS2
MEM-SS3
Articulation
Articulation
Lock Bar
Lock Bar
Storage
Storage
Figure 7 – Typical Articulation Lock Bar Storage Location
Number: OM-SS-V2
Revision: Original
EMERGENCY/PARK BRAKE BUTTON

The Shotcrete Sprayer is equipped with one (1) EMERGENCY/PARK BRAKE button, which
is located on the driver’s instrument panel. Both the MEM-SS2 and MEM-SS3 Shotcrete
Sprayer’s driver’s instrument panel are shown in Figure 8. This is a three-position
button push/pull/reset style. By pushing this button in the operator applies the vehicle’s
secondary braking system. The EMERGENCY/PARK BRAKE button must be used whenever
parking the machine, or in the event of an emergency stopping situation. To release the
brakes, pull the button all of the way up to the reset position and then release the
button.
See section OM-UTV-O3-MERC titled Carrier Operation for the complete parking and
shutdown procedure.
IGNITION SWITCH
The IGNITION switch on the driver’s instrument panel can be used to power down the
vehicle’s ignition circuit in the event of an emergency. If the ignition switch is turned to
the Off position, the vehicle’s secondary brakes apply. Steering controls no longer
function as power to the vehicle’s ignition circuit turns OFF, but the batteries are not
disconnected. Both the MEM-SS2 and MEM-SS3 Shotcrete Sprayer’s driver’s
instrument panel are shown in Figure 8 –Typical Emergency/Park Brake Button &
Ignition Switch.
Emergency
/Park
Brake
Button
Ignition
Switch
Figure 8 – Typical Emergency/Park Brake Button & Ignition Switch
Number: OM-SS-V2
Revision: Original
MAIN BATTERYDISCONNECT SWITCH (Master Switch)

Serious damage to the engine control module and
components may result if the batteries are not disconnected
prior to any welding being done on the vehicle. Contact
maintenance personnel.
The batteries on the Shotcrete Sprayer can be disconnected (fully isolated, parking light
circuit excepted on some vehicles) from the vehicle’s electrical system by using the
MAIN BATTERY DISCONNECT switch. The vehicle can also be shut down (in an
emergency) if required, by turning the MAIN BATTERY DISCONNECT switch to the Off
position. Figure 9 illustrates the location for the MAIN BATTERY DISCONNECT switch and
lock-out, located on the driver’s side of the vehicle in front of the operator’s
compartment.
Main Battery
Disconnect
Switch with
Lockout
Figure 9 – Typical Main Battery Disconnect Switch & Lockout
Number: OM-SS-V2
Revision: Original
EMERGENCY STOP BUTTONS

The EMERGENCY STOP buttons interrupt all 24V power to the engine and to the vehicle’s
control circuit. In the event of an emergency, push one of the EMERGENCY STOP buttons
and all power to the Shotcrete Sprayer is interrupted. To reset the EMERGENCY STOP
button(s), twist the button clockwise and it releases.
On hard wired remote pendant equipped vehicles, pressing the
EMERGENCY STOP button on the remote pendant interrupts all 24V
power to the engine and to the vehicle’s control circuit.
On CAN remotes, pressing the EMERGENCY STOP button on the remote
pendant disables the boom and the communication link between the
remote reciever and remote pendant.
The Shotcrete Sprayer may be equipped with EMERGENCY STOP buttons in various
locations on the vehicle. One is typically located in the operator’s compartment as
shown in Figure 10.
Emergency
Stop Button
Figure 10 – Typical Operator’s Compartment Location
Number: OM-SS-V2
Revision: Original
A second is located on the boom control panel as shown in Figure 11.
Emergency
Stop Button
Figure 11 – Typical Boom Control Panel Location

A third EMERGENCY STOP button is located on the main AC electrical panel (if equipped),
or by the process control panel and a fourth (if equipped) is located on the remote
pendant as shown in Figure 12. On some vehicles, there may be one located by the
cable reel. It is the operator’s responsibility to become familiar with their vehicle.
Emergency
Stop Button
Figure 12 – Typical Main AC Electrical Panel and Remote Pendant Location
Number: OM-SS-V2
Revision: Original
SHOTCRETE PUMP TILT LOCK (IF EQUIPPED)

SS2 sprayers and some SS3 sprayers may be equipped with counter balance valves on
the cylinders that lock the pump mount in position. Sprayers without the counter balance
valve on the tilt cylinders will have a mechanical lock. The pump tilt lock is designed to
do two things. It supports the pump frame in the fully raised position for either transport
or maintenance under the pump frame, or can secure the pump in one of several
positions between transport and the ground (MEM-SS3 only). If service work needs to
be performed in or around the pump and hopper, the pump hoist lock must be used to
prevent inadvertent movement. See Figure 13.
Lock Bar
Lock Pin
Figure 13 – MEM-SS3 Pump Lock- Up/Down Position

For some MEM-SS2 Shotcrete Sprayers, a pump lock is located on either side of the
pump frame. When the pump frame is raised, these locks can be swung into their
locking position onto the vehicle frame via a mechanical lever. See Figure 14.
Figure 14 – MEM-SS2 Pump Lock - (shown in the down, unlocked position)
Number: OM-SS-V2
Revision: Original
SHOTCRETE PUMP POSITION SENSOR

To prevent damage to the shotcrete pump, a proximity sensor is used to sense if the
pump is in the Transport position or not. This sensor is connected to an amber warning
indicator light and buzzer on the driver’s instrument panel (for MEM-SS3 Shotcrete
Sprayer, for MEM-SS2 Shotcrete Sprayer they are located on the application junction
box) and may also be interlocked with the braking system (if equipped). If the pump is
not in the fully raised (transport/tram) position the light on the DIP, or application
junction box is illuminated, an audible alarm sounds and the brakes do not release. If
the pump is fully raised the light goes OUT and the brakes can be released (DRIVE
mode). See Figure 15.
Hopper
Lowered
Indicator Light
Figure 15 – Typical Hopper Lowered Indicator Light Location
The sensor for the shotcrete pump hopper light is located under the rear of the vehicle
just behind the right rear tire and above the pump frame. See Figure 16.
Pump Interlock
Sensor
Figure 16 – Pump Interlock Sensor Location
Number: OM-SS-V2
Revision: Original
HOPPER GRATE SAFETY DEVICES

Do not reach inside the hopper with the power pack or engine
running. Serious injury or death may occur. Use of the grate
interlock switch must only be used for small jobs in the
hopper such as removing a lump of foreign material, etc., and
must be carried out with a tool such as a shovel. No service
work must ever be done in the hopper with the grate open and
while the engine, or power-pack is running. Refer to local or
site policy regarding this interlock.
The shotcrete pump hopper is covered with a grate to prevent access into the hopper
while operating. The grate is equipped with two safety features. The first feature is a
latch pin that holds the grate closed. The second feature is a safety chain to hold the
grate open and prevent it from falling while working inside the hopper.
The latch pin is equipped with an interlock switch that prevents the hydraulics from
operating if the latch pin is pulled out to allow the grate to be opened. This prevents
inadvertent movement of the remixer, or prevents the shotcrete pump from operating
while working inside the hopper. The latch pin cannot be pushed in while the grate is
open as it is blocked by a tab on the grate. A red light on the shotcrete process control
panel illuminates to indicate that the grate is open or that the pin is pulled out. This item
must be checked for proper functionality with your pre-operation inspection. See Figure
17 and Figure 18.
Grate
Safety
Pin
Interlock
Switch
Figure 17 – Grate Pin Locked Figure 18 – Grate Pin Unlocked
Number: OM-SS-V2
Revision: Original
The grate safety chain is a short chain and hook bolted to the aluminum splash guard
on the hopper. When the grate is fully raised the hook can be placed through the grate
and hooked where ever it is secure and convenient. See Figure 19.
Safety Chain
Hook
Figure 19 – Grate Safety Chain
Number: OM-SS-V2
Revision: Original
SHOTCRETE HOSE CLAMP SAFETY PINS

The working pressures and volumes of the shotcrete system
are high. Always make sure your hose clamps are adjusted
properly and have a safety pin or equivalent installed before
attempting to pump any material through the system. Failure
to check the clamp and install safety pins could result in
serious injury or death as well as equipment and property
damage.
The Shotcrete Sprayer is equipped with a sectional shotcrete hose system. Each
section is joined to the next with an adjustable quick-latch clamp. To prevent the clamps
from opening during operation, each clamp is equipped with a safety pin. Any time
material is going to be pumped through the system, ensure that the clamps all have the
safety pins or equivalent installed. See Figure 20.
Safety Pin
Figure 20 – Shotcrete Hose Clamp and Safety Pin
Number: OM-SS-V2
Revision: Original
HYDRAULIC AND WATER SYSTEMS SAFETY

Some parts of the hydraulic and water systems use very high
volumes of oil and water in short periods of time. In particular
the shotcrete pump and swing tube, the water scaler pump,
ride control and brake circuits use large amounts of high
pressure oil. When replacing any hosing related to these
circuits make sure that equivalent high pressure hoses are
installed.
Before performing work on any of the following systems, their
accumulators and systems must be completely drain of all
pressure and then locked and tagged out of service (where
required). Only qualified maintenance personnel must service
the hydraulic and water systems.
The hydraulic and water system on the MacLean Engineering Shotcrete Sprayer
operates at high pressures and volumes. Anytime service work is to be performed on
these systems, all accumulators and systems must be completely discharged of oil and
water. Do not continue work until the corresponding pressure gauges reads 0 psi, or 0
psi within the applicable system is verified.
Brake Accumulator
To discharge the oil from the brake accumulators and emergency steering system (if
equipped), open the hydraulic compartment under the operator’s compartment and pull
out and hold the black knob on the pressure control manifold. See Figure 21. You can
hear the oil drain back to the tank. The knob returns to the closed position when
released. For MEM-SS2 Shotcrete Sprayers, this is a valve handle that can be turned.
Verify all pressure is relieved from the system by viewing the brake accumulator
pressure gauges located in the operator’s compartment. These gauges must read zero.
Brake Accumulator
Discharge Valve
Figure 21 – Brake Accumulator Discharge Valve
Number: OM-SS-V2
Revision: Original
Swing Tube Accumulator

The swing tube accumulator is located at the base of the shotcrete pump control valve
stand. See Figure 22. To drain this accumulator, lift the drain ball valve handle and then
turn it to the OFF position. The valve handle is perpendicular to the valve body when
closed. Once pressure is relieved, lock out and tag out the valve handle. Verify pressure
is relieved by reading the corresponding pressure gauge. It must read zero.
Swing Tube
Accumulator
Drain Ball
Valve Handle
and Pressure
Gauge
Figure 22 – Swing Tube Accumulator
Number: OM-SS-V2
Revision: Original
Swing Tube Equalizer Valve (MEM-SS3 Only, if equipped)

The swing tube equalizer valve is located on a panel behind the swing tube accumulator
(it may be covered by a rubber protector cover). See Figure 23. This valve is opened by
maintenance personnel (the valve handle is parallel to the to the valve body when open)
to ensure that the swing tube cannot not be accidentally pressurized during
maintenance. This valve is closed during normal operation.
Swing Tube
Equalizer
Ball Valve
Handle
Swing Tube
Cylinder
Figure 23 – Swing Tube Equalizer Valve
Number: OM-SS-V2
Revision: Original
Ride Control Accumulator

For vehicles equipped with the MacLean Engineering boom, there is a ride control
accumulator located on the side of the boom’s column. See Figure 24. The ride control
accumulator may also be located on the passenger, or operator side front outrigger
frame. To drain this accumulator, lift the drain ball valve handle and then turn it to the
OFF position. The valve handle is perpendicular to the valve body when closed. Once
pressure is relieved, lock out and tag out the valve handle. Verify pressure is relieved by
reading the corresponding pressure gauge. It must read zero.
On some vehicles, the ride control accumulator drain ball valve may
be mounted on the process control panel housing. See Figure 25.
Ride Control
Drain Ball Valve
Accumulator
Handle and
Pressure Gauge
Figure 24 – Typical Ride Control Accumulator
Number: OM-SS-V2
Revision: Original
Process
Control Panel Pressure
Housing Gauge
Drain Ball
Valve Handle
Figure 25 – Alternate Ride Control Accumulator Drain Ball Valve Location
Number: OM-SS-V2
Revision: Original
Water Scaler Pump Pressure Relief (if equipped)

For vehicles equipped with the high pressure water scaler pump option, there is a water
scaler pump pressure relief valve located in front of the water tank. See Figure 26. To
drain this stored pressure, lift the drain ball valve handle and then turn it to the OFF
position. The valve handle is perpendicular to the valve body when closed. Once
pressure is relieved, lock out and tag out the valve handle. Verify pressure is relieved by
reading the corresponding pressure gauge. It must read zero.
Water Scaler
Water Scaler Pump Pressure
Pump Pressure Relief Drain Ball
Gauge Valve Handle
Figure 26 – Typical Water Scaler Pump Pressure Relief
Number: OM-SS-V2
Revision: Original
MAIN HIGH VOLTAGE BREAKER (IF EQUIPPED)

The main breaker must not be used to disconnect the source
power under full load (unit operating). In an emergency, isolate
the vehicle by pressing one of the EMERGENCY STOP buttons
located around the vehicle. This breaker must only be used to
stop the machine during an emergency, only when it is
absolutely necessary.
The main AC electrical panel on the pump end of the vehicle contains the MAIN
DISCONNECT breaker for high voltage electricity on the vehicle. The breaker shown in
Figure 27, has three positions: ON, OFF and RESET/OPEN. Placing the switch in the
OFF position disconnects power coming in from the cable reel to the rest of the vehicle.
Depending on how your vehicle is wired, it may also signal the ground fault panel the
unit is plugged into to completely shut OFF power to the vehicle. Any time service
needs to be performed on the vehicle’s electrical system, this breaker must be turned
OFF and locked-out according to local or site regulations.
Main AC Electrical
Panel Circuit
Breaker
(Arrow pointing to
OFF position)
Figure 27 – Main AC Electrical Panel Breaker
Number: OM-SS-V2
Revision: Original
GROUND CHECK SYSTEM (IF EQUIPPED)

If the ground check test fails and the ground fault panel does
not shut off the power to the unit, the unit and the ground fault
panel must be tagged out of service until repairs are made.
Contact your maintenance department for repairs of this
nature. Under no circumstances is the Shotcrete Sprayer to be
operated on electric power if the ground fault test fails.
Serious injury or death may occur.
The Shotcrete Sprayer is equipped with a ground check system as part of the main high
voltage supply circuits that feed power to the unit from the mine’s electrical system. See
Figure 28. The purpose of this system is to electrically verify that the unit is electrically
connected to ground should something fail in the high voltage electrical system. The
ground check circuit is designed so that if a good ground is not detected to the unit, the
ground fault panel that the unit is plugged into does not supply the unit with power until
the ground connection is repaired.
The ground check circuit must be tested every time that the unit is plugged into a
ground fault panel to verify that the circuit works as intended.
Main Power Reset

Button Ground Check
(Depends on Mine Test Button
Power System)
Figure 28 – Ground Check Test Button

In order to verify that the Shotcrete Sprayer is properly grounded, plug the unit in and
reset the power. This step may vary according to the power system in your mine. Once
the unit is powered up, press the GROUND CHECK TEST button on the main AC electrical
panel. The ground fault panel must shut all high voltage power off to the machine
immediately when this button is pushed. If the power does not shut OFF immediately
the unit cannot be used. The machine must be taken out of service until the problem is
corrected. Follow your local and site policies for taking the unit and the ground fault
panel out of service. Contact your maintenance department to correct the problem.
Number: OM-SS-V2
Revision: Original
EMERGENCY STEERING SYSTEM (IF EQUIPPED)

As an option, the vehicle may be equipped with an emergency steering system. This
system provides hydraulic pressure and flow to the steering system if the vehicle looses
main hydraulic pressure and normal operation of the steering is not possible.
This system is designed and tested to conform to SAE Standard J1511. The system is
completely automatic and requires no input from the operator to activate. It does alert
the operator that the system is activated via the EMERGENCY STEER ACTIVE indicator light
on the driver’s instrument panel, or application junction box. See Figure 29. This
indicator light also performs a self-test when the IGNITION switch is turned ON but the
engine is not running.
A pressure gauge (Figure 29) is also provided either on the fire wall (non-enclosed cab
vehicles) or on the console to the right of the driver’s instrument panel (enclosed cab
vehicles) to indicate the charge pressure in the emergency steering system. Fully
charged, the gauge reads approximately 3000 PSI. When the gauge reads
approximately 1000 - 1200 PSI the emergency steering system reserve is empty and
steering is no longer possible.
Pressure
Emergency Gauge
Steer
Active
Indicator
Light
Figure 29 – Typical Emergency Steer Active Indicator and Gauge

When the emergency steering system is active, you may steer the vehicle as you
normally would, but keep in mind that the amount of reserve fluid available for steering
is limited. The vehicle can be steered approximately three times stop-to-stop (stick steer
or wheel steer) depending on the charge state of the accumulators. It is recommended
that you steer the vehicle gently and only as necessary until you can bring the vehicle to
a complete stop. To discharge the pressure from the system, see Figure 21.

Phone: 1-866-856-3626
Title: OPERATOR’S COMPARTMENT LAYOUT
Number: OM-SS2-V3
Machine Model(s) Affected: MEM-SS2 Shotcrete Sprayer
Revision: Original
OPERATOR’S COMPARTMENT
This section of the Operator’s Manual provides a general review of the vehicle’s layout,
key components and their locations. Your particular vehicle may be equipped with an
open compartment, a canopy, or an enclosed cab.
The operator’s compartment contains a driver’s instrument panel, an application
junction box, a steering joystick, an accelerator pedal and service brake pedal,
transmission gear/direction selector switches, a driver’s seat, a fire suppression system
manual palm actuator, an EMERGENCY STOP button, and hydraulic pressure gauges.
The operator’s compartment for the canopy and enclosed cab are shown in Figure 1
and Figure 2 below.
Figure 1 – Typical Operator’s Figure 2 – Typical Operator’s

Compartment - Canopy Compartment– Enclosed Cab
Number: OM-SS2-V3
Revision: Original
Whether your vehicle is equipped with a canopy, or an enclosed cab, a typical

operator’s compartment layout is shown below.
Driver’s Fire Suppression

Instrument Panel System Palm
(DIP) Actuator (various
locations
Steering Control
Valve/Stick Emergency Stop
Button
Fire Suppression Auto
Shutdown Switch Application
(various locations) Junction Box
(APP JB)
Accelerator/Throttle
Pedal Hydraulic and Brake
Service Brake Pedal System Pressure
Gauges
Operator’s Seat Information and
Warning Labels
Figure 3 -Typical Operator's Compartment Layout
Number: OM-SS2-V3
Revision: Original
The Driver’s Instrument Panel - is located in front of the operator when sitting in the
operator’s seat and has various switches, gauges and indicators that control and display
information for the different vehicle functions. For more information see section
OM-933-V4 titled Driver’s Instrument Panel & Enclosed Cab Related Controls.
Application Junction Box (APP JB) - is located to the right of the operator when
sitting in the operator’s seat. This panel contains an EMERGENCY STOP switch, indicator
lights and alarms as well as machine specific controls. For more information see section
OM-933-V4 titled Driver’s Instrument Panel & Enclosed Cab Related Controls.
The Steering Joystick - is located in front of the operator when sitting in the operator’s
seat. Moving the handle in the direction required articulates the machine in that
direction.
The articulation point for the Shotcrete Sprayer lies in the mid-
ship of the vehicle and presents a possible pinch point. The
operator must ensure that the articulation area is clear before
operating the vehicle and must also ensure that the
articulation lock is installed prior to any work performed in the
articulation area.
The Accelerator Pedal - By pressing this

accelerator pedal the engines RPM increases.
The Service Brake Pedal - By pressing the

service brake pedal the axle service brakes are
applied.
Figure 4 - Accelerator and Service Brake Pedals
Number: OM-SS2-V3
Revision: Original
The Fire Suppression System Manual Palm Actuator - is located within the
operator’s reach as typically shown in Figure 3. For more information, refer to
OM-SS-V2 titled Machine Safety Items.
Emergency Stop Button - For operation information, refer to OM-SS-V2 titled Machine
Safety Items.
Transmission Gear/Direction Selector Switches (not shown) - allow directional and
gear selection of the transmission.
Some vehicles may have higher gears locked out.
Operator’s Seat (Figure 5) - suspension system (if equipped) can be adjusted with the
tension knob located on the front of the seat or, if equipped with an air seat option, by
using the air compressor control switch located on the seat. The position of the seat can
be adjusted by releasing the lock lever located at the side of the seat and moving it back
and forth. The back of the seat can be tilted forward and backward by lifting the tilt
adjust lever. The seat can also be adjusted to suit the weight of each operator by using
the weight setting actuator lever. In behind the seat is a lumbar support adjustment
knob that allows the operator to adjust the lumbar support in and out and up and down.
The seat is equipped with a seat belt which must be used at all times when travelling.
Lumbar Support
Adjustment Knob
Weight Setting
Actuator Lever Seat Belt
Tilt Adjust
Lever
Lock Lever
Figure 5 – Typical Operator’s Seat
Number: OM-SS2-V3
Revision: Original
Information and Warning Labels - Located under the hydraulic/brake gauge cluster is
a group of warning and informational labels. These labels list critical information such as
the vehicle’s prescribed daily brake test, tramming speed information, diesel ventilation
requirements, recommended lubricants, etc. These labels must all be installed and
legible for the vehicle to be serviceable.
Fire Suppression System Auto Shutdown Switch
If your vehicle is equipped with the Ansul™ fire suppression option, this switch is
installed to automatically shut down the engine. If the fire suppression system is
discharged, this switch needs to be reset in order for the engine to start. This switch
must only be reset by a properly trained and qualified individual or under the direction of
this individual.
Hydraulic Pressure Gauges
The hydraulic pressure gauges in the operator’s compartment measure the main
hydraulic system pressure, and various brake system pressures. A typical hydraulic
pressure gauge cluster is shown in Figure 6.
The specific operating pressures for each particular unit can be
found in the main hydraulic schematic.
Typical Hydraulic
Pressure Gauge
Cluster
Figure 6 – Typical Hydraulic Pressure Gauge Cluster
Number: OM-SS2-V3
Revision: Original
The hydraulic pressure gauges in the operator’s compartment measure the following:
Engine End Brake Accumulator Pressure and Deck/Boom End Brake Accumulator
Pressure: These two gauges measure the amount of stored accumulator pressure
available to the engine end brakes and to the boom/deck end brakes.The working range
is 1850-2300 PSI.
Engine End Service Brake Pressure and Deck/Boom End Service Brake Pressure:
These two gauges indicate the pressure being supplied to the service brakes. When the
service brake pedal is depressed the pressure increases and the brakes are applied in
proportion to the pedals actuation. The gauges must read zero (0) PSI when the service
brake pedal is not actuated.The working range is 0–1500 PSI.
Main Hydraulic System Pressure: This gauge measures the total hydraulic system
pressure. The brake accumulator charge valve cycles at predetermined pressures
causing the total hydraulic system pressure to fluctuate as the accumulators are
charged. Working pressures are between 400-3000 PSI. This gauge moves any time a
hydraulic function is used.
Engine End Axle/Park Brake Release Pressure and Deck/Boom End Axle/Park
Brake Release Pressure: These two gauges measure the amount of hydraulic
pressure being supplied to release the engine end axle park brakes and to release the
boom/deck end axle park brakes. The working pressure is equal to the current charge
pressure of the brake accumulators.
Number: OM-SS2-V3
Revision: Original
ENCLOSED CAB (OPTIONAL)

The enclosed cab, if equipped, helps to protect the operator from the elements.
Additional features that are included with an enclosed cab is an entry/exit door,
windshield wipers with windshield washer fluid reservoir, cab heater (optional), cab air
conditioning (optional) and a rear window. The enclosed cab is also fitted with an
emergency entrance. The glass facing towards the engine end of the vehicle has a
sealed insert around the outside perimeter of the window that is designed so that it may
be quickly removed in an emergency situation, such as accessing an incapacitated
operator inside the cab. If equipped, the fly rock needs to be lowered if it is raised. A red
handle on the end of the sealed insert can be pulled to break the seal of the window.
The window can then be removed, allowing access to the operator inside the cab. Refer
also to the vehicle labeling on the window with regards to removing the window. From
inside the operator’s compartment, the operator can kick the window out in an
emergency situation. If it is necessary to break the glass from inside the operator’s
compartment, a hammer designed for this purpose is also provided. Figure 7 shows the
emergency exit and Figure 8 shows the hammer.
The front and rear windshield wipers ON/OFF maintained switches are located on a
control panel inside the cab beside the front windshield.
Fly Rock
Guard Rear and
(If equipped) Side
Windshield Windows
Wiper
Air
Red Handle
Conditioner
and Pull
Cord
Windshield
(Also Entry/Exit
Emergency Door
Exit)
Figure 7 - Typical Enclosed Cab
Number: OM-SS2-V3
Revision: Original
The interior of the enclosed cab (Figure 8) contains a driver’s seat, driver’s instrument
panel, application junction box (APP JB) steering control, accelerator and service brake
pedals, heating (if equipped), wiper controls, fire suppression manual palm actuator (not
shown), hydraulic pressure gaugesand a hand held fire extinguisher (not shown) and an
interior light.
Hammer Cooling and

Ventilation, Interior
Steering Control Light, and Controls
Wiper Switches
Driver’s Instrument
Panel Application Junction
Hydraulic Pressure Box (APP JB)
Gauges Driver’s Seat
Hand Held Fire
Extinguisher
Heater (Not Shown)
Accelerator and
Service Brake
Pedals
Figure 8 - Typical Enclosed Cab Interior

Notes:

Phone: 1-866-856-3626
Title: DRIVER’S INSTRUMENT PANEL & ENCLOSED
CAB RELATED CONTROLS
Number: OM-933-V4
Machine Model(s) Affected: MEM-AC2, MEM-BT2, MEM-SL2, MEM-SSB,
MEM-SS2, and MEM-TM2
Revision: Original
Checked By: Joe Agombar Checked By:
DRIVER’S INSTRUMENT PANEL (DIP)

Figure 1 illustrates a typical driver’s instrument panel. It is the operator’s responsibility
to become familiar with their specific vehicle. The following section explains the
functions of the various switches and indicators that are commonly found on the DIP.
Figure 1 – Typical Driver’s Instrument Panel
OM-933-V4 Page 1 of 8
Number: OM-933-V4
Revision: Original
1. Wait To Start Indicator Light/Engine Start Switch

 Wait To Start Indicator Light – This indicator light illuminates when the engine’s
pre-heat system is active. Once the pre-heat system is finished, the indicator light
goes OUT.
It is recommended to wait until the WAIT TO START indicator
light goes OUT before starting the engine.
 Engine Start Switch –Toggle and hold the top of the switch to crank the engine
over. Once the engine starts, release the ENGINE START switch. For the engine
starting procedure, refer to section titled Carrier Operation of your applicable
Operator’s Manual.
2. Horn Bypass Switch – Toggle and hold the top of this switch to silence the horn.
3. Horn On Switch – Toggle and hold the top of the switch to sound the horn.
4. Ignition ON Indicator Light - This indicator light illuminates when the IGNITION
switch is turned to the ON position.
5. Brake System Indicator Lights
 Applied Indicator Light - This indicator light illuminates when the
emergency/park brakes are applied.
If the BRAKE SYSTEM IMPENDING indicator light illuminates during
normal vehicle operation, be prepared for an automatic brake
application.
 Impending Indicator Light – This indicator light illuminates when either the
hydraulic pressure in the brake system, or the transmission pressure drops to a
critical level below which it is unsafe to operate the vehicle. The light indicates
that the emergency/park brakes may apply.
Page 2 of 8 OM-933-V4
Number: OM-933-V4
Revision: Original
6. Engine Protection Warning/Alarm Indicator Lights

It is the operator’s responsibility to become familiar with their
vehicle’s engine protection system and to take action to avoid
engine damage.
 Engine Protection Alarm Indicator Light (Mercedes engine only) - This
indicator light illuminates whenever there is a critical engine fault detected. This
indicator light is interlocked with the vehicle’s horn. If the indicator light
illuminates during operation and the horn sounds, shut down the vehicle and
contact the maintenance department. For more information on engine protection,
refer to the section titled Modes of Operation & Interlocks of your applicable
 Engine Fault/Diagnostic Indicator Light (Deutz engine only) - If a fault is
detected, this indicator light illuminates solidly, or flashes evenly depending on
the seriousness of the fault. This indicator light is interlocked with the vehicle’s
horn. If the indicator light illuminates solidly or flashes during operation and the
horn sounds, shut down the vehicle and contact the maintenance department.
For more information on engine protection, refer to the section titled Modes of
Operation & Interlocks of your applicable Operator’s Manual.
 Engine Protection Warning Indicator Light (Mercedes engine only) - This
indicator light illuminates whenever a minor engine fault is detected. If the
indicator light illuminates during operation, contact the maintenance department.
For more information on engine protection, refer to the section titled Modes of
Operation & Interlocks of your applicable Operator’s Manual.
7. Low Engine Coolant Indicator Light (if equipped) - This indicator light illuminates
when a low engine coolant level condition exists. Optionally, it may be interlocked
with the engine protection system. For more information on this interlock, refer to the
section titled Modes of Operation & Interlocks of your applicable Operator’s Manual.
8. Driveline Brake Test Switch (if equipped) – This switch is used to test the
driveline brake. Refer to the Brake Test label on the vehicle’s firewall, or to section
OM-UTV-O4 titled Brake Test Procedure.
9. Axle Brake Test Switch (if equipped) – This switch is used to test the axle brakes.
Refer to the Brake Test label on the vehicle’s firewall, or to section OM-UTV-O4 titled
Brake Test Procedure.
10. Drive/Auxiliary Mode Switch - Toggle the top of this switch to illuminate the
indicator light within the switch and place the vehicle into AUXILIARY mode. Toggle
the bottom of the switch to turn the indicator light OFF and to place the vehicle into
DRIVE mode. For mode change conditions, refer to the section titled Modes of
Operation & Interlocks.
Number: OM-933-V4
Revision: Original
11. Fast Idle Switch (AUXILIARY Mode) (if equipped) - Toggle the top of the switch to
illuminate the indicator light within the switch and increase the engine’s RPM to a
pre-programmed speed. Toggle the bottom of the switch to turn the indicator light
OFF and decrease the engine’s RPM to normal idle.
The fast idle function is disabled as soon as the vehicle is
switched back to DRIVE mode.
Mercedes engine only – When the EMERGENCY/PARK BRAKE switch
is pulled up or the vehicle’s transmission is switched out of
Neutral, the fast idle feature is disabled.
12. Engine Diagnostics Test Switch (Deutz engine only) – This switch is used to
display a sequence of blink codes on the ENGINE FAULT/DIAGNOSTIC INDICATOR light
to troubleshoot active engine faults. See Maintenance Bulletin MB-ENG2057 for
complete information with regards to the ENGINE DIAGNOSTIC TEST switch.
13. Emergency/Park Brake Switch – This illuminated three position (Push/Pull/Reset)
switch allows the operator to apply and release the emergency/park brakes. See
Figure 2.
 PUSH- Maintained pressed position allows the operator to apply the brakes for
parking the vehicle, or in an emergency stop situation. The EMERGENCY/PARK
BRAKE switch illuminates when the brakes are applied.
 PULL – Maintained position allows the brakes to remain released after the Reset
function is used.
 RESET – Momentary position, also called Prime position (pulled out past the
maintained positions), energizes the emergency brake relay (EBR) circuit. This
circuit verifies that all operating conditions are adequate before allowing the
brakes to remain released.
For the required conditions for releasing the brakes, refer to the section titled
Modes of Operation & Interlocks of your applicable Operator’s Manual.
Figure 2 – Emergency/Park Brake Switch
Number: OM-933-V4
Revision: Original
14. Ignition Switch - Turning the IGNITION switch clockwise (CW) enables battery power
to the ignition circuit. Turning the switch, counter-clockwise (CCW) disables battery
power to the ignition circuit.
15. Engine Drive Lights Switch - Toggle the top of the switch to illuminate the indicator
light within the switch and turn the lights ON. Toggle the bottom of the switch to turn
the indicator light and lights OFF.
16. Deck Drive Lights Switch - Toggle the top of the switch to illuminate the indicator
17. Parking Light Switch (If equipped) - Toggle the top of the switch to illuminate the
indicator light within the switch and turn the light(s) ON. Toggle the bottom of the
switch to turn the indicator light and light(s) OFF. Depending on customer
requirements, this switch may work with the MAIN BATTERY DISCONNECT switch either
in the ON or OFF position.
18. Interior Light Switch (enclosed cab only, if equipped) - Toggle the top of the
switch to illuminate the indicator light within the switch and turn the light ON. Toggle
the bottom of the switch to turn the indicator light and light OFF.
19. Engine Monitor Display - This monitor displays engine data in various formats.
Refer to the operator’s manual section titled Carrier Operation for normal operating
ranges. Additionally, several diagnostic screens are available. The operator is able
to switch between various displays using the soft pushbuttons located on the bottom
of the display.
For vehicles equipped with a Deutz or Caterpillar engine, at any time during
operation, the engine electronics detects a fault; the display warns the operator by
flashing an alarm on the screen. The operator can acknowledge on-critical alarms
(warning) and report it to maintenance later. If the alarm is critical, the operator must
stop the vehicle and shut it down immediately, and contact the appropriate
personnel.
For information on the engine protection interlocks, see section titled Modes of
For more information concerning the engine monitor display, see maintenance
bulletin MB-ELE1470.
20. Transmission Pressure Gauge – This gauge displays the current pressure that the
transmission is operating at. For normal operating ranges, refer to the section titled
Carrier Operation of your applicable Operator’s Manual.
21. Transmission Temperature Gauge – This gauge displays the current temperature
that the transmission is operating at. For normal operating ranges, refer to the
section titled Carrier Operation of your applicable Operator’s Manual.
Number: OM-933-V4
Revision: Original
22. Engine Hourmeter - Records the total amount of time the diesel engine has run.
If your vehicle is equipped with an ELECTRONIC MONITOR DISPLAY
and you access the engines operating hours through that display,
there may be a difference in the recorded operating hours. Unless
otherwise specified by mine site policy, ensure that the ENGINE
HOURMETER is used to record and track maintenance intervals.
23. Transmission Direction Selector Switch - This switch selects between Forward,
Neutral, and Reverse. The back-up alarm sounds when the Reverse direction is
selected. On some vehicle’s, the deck drive lights automatically turn ON as well
when Reverse is selected.
24. Transmission Gear Selector Switch - This switch selects between first and
second, and if equipped, third gear.
Number: OM-933-V4
Revision: Original
ENCLOSED CAB CONTROLS (IF EQUIPPED)
1 3
4
5
2 6
Figure 3 – Typical Enclosed Cab Controls

1. Air Conditioning Temperature Control Switch (if equipped) - Turning the switch
clockwise (CW) turns the air conditioner on and decrease the air temperature inside
the cab. Turning the switch, counter-clockwise (CCW) increases the air temperature
inside the cab and turns the air conditioning system off.
The AIR CONDITIONING BLOWER SPEED switch must be in one of the
ON positions for the temperature control to work.
2. Air Conditioning Blower Speed Switch (if equipped) - When the switch is turned
completely counter-clockwise (CCW) the blower motor is OFF. Turning the switch
clockwise (CW) each increment, increases the blower motor speed.
3. Light and Light Switch (if equipped) - This switch is used to turn the light,
mounted on the air conditioning system ON or OFF.
Number: OM-933-V4
Revision: Original
4. Windshield Wipers Switch (if equipped) - When the W INDSHIELD W IPERS switch is
turned completely counter-clockwise (CCW) the wipers are OFF. Turning the
W INDSHIELD W IPERS switch clockwise (CW) one position from OFF sets the
windshield wipers to low speed. Turning the W INDSHIELD W IPERS switch clockwise
(CW) two positions from OFF sets the windshield wipers to high speed. Pushing the
switch in, sprays windshield washer fluid onto the two front cab windshields.
5. Rear Windshield Wiper Switch (if equipped) - When the REAR W INDSHIELD W IPER
switch is turned completely counter-clockwise (CCW) the rear windshield wiper is
OFF. Turning the REAR W INDSHIELD W IPER switch clockwise (CW) one position from
OFF sets the rear windshield wiper to low speed. Turning the REAR W INDSHIELD
W IPER switch clockwise (CW) two positions from OFF sets the rear windshield wiper
to high speed. Pushing the switch in, sprays windshield washer fluid onto the rear
cab window.
6. Heater Fan Switch (if equipped) - When the switch is turned completely counter-
clockwise (CCW) the heater motor is OFF. Turning the switch clockwise (CW) each
increment, increases the heater motor speed.
NOTES:

Phone: 1-866-856-3626
Title: SYSTEM LAYOUT & AUXILIARY CONTROLS
Number: OM-SS2-V5
Revision: A
Written By: JanPaul Brenner Revised By: JanPaul Brenner
Checked By: René Dubois Checked By: Craig Marchand
Approved By: Bill Tytaneck Approved By: Bruce Mackereth
SHOTCRETE SPRAYER COMPONENTS

This section of the Operator’s manual presents a short description of the Shotcrete
Sprayer components such as the shotcrete pump, controls, compressor, boom and
nozzle assemblies together with instructions for the operation and usage of the
components. This section does not cover how to prepare the vehicle for spraying,
applying product to a surface, or vehicle cleanup when the job is complete.
Number: OM-SS2-V5
Revision: A
GENERAL OPERATOR’S SIDE LAYOUT

The general layout of the components for the Shotcrete Sprayer’s operator’s side can
be seen in Figure 1.
Main Battery
Disconnect Switch
and Breaker Box
Hydraulic Oil
Boom Work
Tank and Manual
Lights
Dispense Crank
Water and/or
Air Hose Reel
Cable Reel
Hydraulic Power
Form Oil Tank and Pack Motor and
Fill Point, Pump Pump
and Hose Reel Master Divider
Grease Station
Pressure Washer
Engine Drive Hose Reel and
Lights Pump
Engine Work Boom Bulkhead
Lights Grease Station
(Behind Curtain)
Figure 1 - Typical Operator’s Side Layout
Number: OM-SS2-V5
Revision: A
A brief description of each component identified in Figure 1 is as follows:

Hose Reels - The Shotcrete Sprayer has two hose reels mounted on the front of the
vehicle. These hose reels are connected to the form oil spraying system and the high
pressure washer system. Each hose is terminated with a quick-connect coupler. A spray
wand attaches to these hoses for coating the vehicle in form oil, or washing the vehicle.
Each wand accepts interchangeable tips for different spray patterns.
WHEN WINDING THE HOSE ONTO THE APPLICABLE HOSE
REEL, WALK THE NOZZLE/HOSE END BACK TO THE REEL.
DO NOT ALLOW THE HOSE REEL TO RETRACT
UNATTENDED. FAILURE TO COMPLY MAY RESULT IN
EQUIPMENT DAMAGE, OR POSSIBLY INJURY TO
PERSONNEL.
Main Battery Disconnect Switch – The master switch box contains the MAIN BATTERY
DISCONNECT switch and several resettable breakers to feed power to various circuits on
the vehicle. The MAIN BATTERY DISCONNECT switch is lockable in the OFF position.
Master Divider Grease Station – If equipped with an automatic greasing station, a
central grease station is provided to lubricate the front of the articulation cylinders and
the front walking beam. The master divider also supplies grease to the boom bulkhead
and articulation bulkhead grease stations.
Boom Bulkhead Grease Station - A grease station for the boom is provided to
lubricate all components associated with the boom. Optionally, this station may be
connected to an automatic greasing system.
Drive and Work Lights - The front drive lights are used to illuminate the front of the
vehicle while tramming. They are operated independently of the work lights. The drive
lights do not illuminate when the vehicle is operating in AUXILIARY mode.
Hydraulic Oil Tank with Manual Fill Crank – The hydraulic oil tank stores all the
hydraulic oil used by the many components on the vehicle. When it is necessary to add
hydraulic oil to the hydraulic oil tank, a manual fill crank is provided. Also available is the
electric oil fill option (not shown).
Form Oil Tank, Pump and Hose Reel - This vehicle is equipped with a form oil tank at
the front of the vehicle. This tank holds form oil or other lubricant to be sprayed on the
vehicle prior to spraying operations to prevent Shotcrete from accumulating on the
vehicle. It is filled through the fill port on the top of the tank. A hydraulically driven form
oil pump is located directly beside the form oil tank. The pump feeds form oil to a spray
wand through a hose reel mounted to the top cover plate by the pressure washer hose
reel. The reel is spring retracted. The pump is controlled from the front auxiliary valve.
Number: OM-SS2-V5
Revision: A
Cable Reel (if equipped) - The cable reel contains the AC trailing cable that makes it
possible for the vehicle to operate on mine power supply when connected. There are
several ways in which the cable reel can be operated. It can be operated using the
CABLE REEL switch at the rear of the vehicle, or by using the hydraulic control valve lever
on the rear auxiliary control valve. The cable reel can also be wound back onto the reel
by using the CABLE REEL IN switch on the application junction box (APP JB) in the
operator’s compartment. Indicator lights and an audible alarm are also provided to warn
the operator when the cable reel reaches the last three wraps and the last wrap of AC
trailing cable on the cable reel.
Air and Water Hose Reel (if equipped) – Some vehicles are equipped with an air and
water spring retractable hose reel. Each hose can be unwound from its reel by pulling it
out to the desired length. To retract the hose onto its reel, gently pull the hose until the
ratchet mechanism of the reel disengages. Each hose reel may also be hydraulically
controlled so that the hose can be automatically wound onto the reel. As the reel winds
the hose, help guide it into place.
Pressure Washer Pump and Hose Reel - A hydraulically driven high pressure water
pump is mounted in front of the vehicle on the operator’s side and feeds high pressure
mine water to a wash wand through a hose reel mounted to the top cover plate. The
reel is spring retracted.
Electrical Power Pack Motor and Pump (if equipped) – The electrical power pack
motor is used to operate the hydraulic system via a pump on the end of the unit. The
electrical power pack motor is used when the vehicle is required to operate on mine
supply power instead of diesel power. This helps to preserve ventilation, prevent heat
build-up in the mine, and to reduce fuel consumption.
Number: OM-SS2-V5
Revision: A
GENERAL REAR END LAYOUT

The general layout of the components for the Shotcrete Sprayer’s rear end can be seen
in Figure 2.
Grate Latch
Pin and
Interlock
Hopper Grate,
Vibrator and
Safety Chain
Shotcrete
Pump and
Hopper
Remixer motor
and paddles
Rear Wash
(not shown)
Wand
Cable Reel
Services
Switch
Connectors
Tail Lights Rear Drive and
Work Lights
Pump Grease
Station
Hopper
Dump Gate
Figure 2 - Typical Rear End Layout
Number: OM-SS2-V5
Revision: A
A brief description of each component identified in Figure 2 is as follows:
Hopper and Pump Assembly – The heart of the MEM-SS2 Shotcrete Sprayer is a
swing pump. A hopper is located on top of the pump inlet/outlet ports to hold shotcrete
being fed into the pumping cylinders. The pump is hydraulically driven and computer
controlled for maximum control over the shotcreting process.
Hopper Grate, Safety Chain and Vibrator – The top of the hopper is covered with a
grate to keep personnel and large material from entering the hopper during operation. If
the grate is opened a safety chain is provided to prevent the grate from falling. The
hopper vibrator is mounted to the grate. The vibrator helps to keep material flowing
through the grate and into the pump.
Cable Reel Switch (if equipped) - This switch is a three position
momentary/maintained switch. The default position is center (OFF). The switch is
intended for the operator to either wind or unwind cable from the reel.
Drive, Tail and Work Lights - The rear drive lights are used to illuminate the rear of the
vehicle while reversing. They are operated independently of the work lights. The drive
lights do not illuminate when the vehicle is operating in AUXILIARY mode. The tail lights
illuminate any time the MAIN BATTERY DISCONNECT switch is in the ON position.
Optionally, the tail lights illuminate brighter when the service brake pedal is pressed.
Grate Latch Pin and Interlock Switch – To prevent the grate from opening during
pumping operations, a latch pin blocks the grate. The latch pin inserts through the side
of the hopper. An interlock switch mounted beside the latch pin is wired into the system
to prevent the shotcrete pump and remixer from operating if the latch pin is in the Open
or Out position.
WHENEVER WORKING INSIDE THE HOPPER, ALWAYS SHUT
DOWN THE VEHICLE AND APPLY LOCKS AND TAGS
ACCORDING TO LOCAL, OR SITE POLICY. FAILURE TO LOCK
OUT THE VEHICLE MAY CAUSE SEVERE INJURY OR EVEN
DEATH TO PERSONNEL.
Remixer – A paddle type remixer is located in the hopper to keep the shotcrete
uniformly mixed before it enters the pump. The remixer is driven by a hydraulic motor on
the outside of the hopper. The remixer operates in either direction.
Rear Wash Wand – A high volume, low pressure wash wand is provided on the rear of
the vehicle to rinse off the pump and hopper, or fill the hopper with water for line slicking
or system cleanout. Mine water must be connected for this wand to be used.
Hopper Dump Gate – A dump gate is provided on the bottom of the pump/hopper
assembly to quickly dump hopper contents in an emergency, or for cleaning. A lever
type latch holds the gate closed.
Number: OM-SS2-V5
Revision: A
WHEN THE GATE IS OPENED, BE CAREFUL NOT TO LOWER

THE PUMP ONTO THE GATE, OR HANDLE AS DAMAGE TO
THE HANDLE, GATE AND HOPPER/PUMP MAY OCCUR.
Pump Grease Station - A central grease station for the shotcrete pump is provided to
lubricate all the bearings located on the hopper and pump. Optionally, this station may
be connected to an automatic greasing system.
The shotcrete pump’s grease station contains both grease fittings
and grease vents. The swing tube bearings located at the bottom of
the hopper must have these vents installed so old grease can be
moved out of the bearings without contaminating the shotcrete. DO
NOT REPLACE THE VENTS WITH FITTINGS, OR PLUGS!
Number: OM-SS2-V5
Revision: A
GENERAL REAR SERVICES AND CONNECTORS LAYOUT

The general layout of the rear services connectors can be seen in Figure 3.
Pressure
Washer Mine Air
Wand Ball Inlet Point
Valve
Mine Water
Inlet Point
Water
Box Fill
Valve Compressed
Air Outlet
Accelerant Point
Transfer
Inlet Point
Figure 3 - Typical Rear Services and Connectors Layout
The Shotcrete Sprayer is designed to be used in conjunction with a Transmixer.

Therefore, a conveniently grouped set of connectors is mounted on the rear of the
Shotcrete Sprayer to connect either to mine services, or interface with the Transmixer.
A brief description of each component noted in Figure 3 is as follows:
Your particular vehicle may be equipped with a water hose reel and
air hose reel for mine supply.
Mine Water Inlet Point – Connect mine water to this port to supply the nozzle for
washer, high pressure washer pump, rear wash wand and shotcrete pump water box fill
line (if equipped). This point has a quarter-turn ball valve to shut OFF the flow.
Accelerant Transfer Inlet Point – This connector provides a convenient connection for
transferring accelerant from the optional accelerant transport tank on the Transmixer to
the on-board accelerant tank. This point has a quarter-turn ball valve to shut OFF the
flow.
Mine Air Inlet Point – (Located by the articulation area), connect mine air to this point
to supply compressed air for shotcrete spraying, or wall washing operations if the on-
board compressor cannot be used. A quarter-turn ball type selector valve near the
compressor selects either the use of mine air, or the on-board compressor.
Compressed Air Outlet Point (if equipped) – Connect the auxiliary air driven
components of a Transmixer to this point for a supply of compressed air from the on
board compressor. This point has a quarter-turn ball valve to shut OFF the flow.
Number: OM-SS2-V5
Revision: A
GENERAL PASSENGER’S REAR SIDE LAYOUT

The general layout of the components for the Shotcrete Sprayer’s passenger’s rear side
can be seen in Figure 4.
Shotcrete Process Main Electrical Battery Air Compressor Bulk Grease Drum
Control Panel AC Panel (High Charger and Grease
Voltage AC) Transfer Hose Reel
Compressor
Air Filter
Rear Auxiliary Accelerant Pump

Control Valve and Tank (not
always as shown)
Figure 4 - Typical Passenger’s Rear Side Layout of an Electric/Hydraulic Sprayer

Air Compressor Filter (if equipped) – This is a typical canister style air intake filter,
similar to that used for the engine air intake. This air filter can be equipped with a simple
rain cap or a pre-cleaner type of cap for extended filter life. This air filter filters the air
that feeds the compressor.
Air Compressor (if equipped) – Compressed air for spraying operations is provided by
an onboard rotary air compressor. The compressor is driven by its own electric motor
and is controlled from the main AC electrical panel. Compressed air is also available for
use at the rear of the vehicle through the compressed air outlet point. A line can be
connected at this point and then connected to the Transmixer so that its auxiliary power
pack, or optional air powered accelerant pump can be operated.
Accelerant Pump and Tank - The accelerant tank is filled through a port on the top of
the tank and has a one way vent. The tank feeds the accelerant pump. The accelerant
pump is a variable speed peristaltic pump designed to handle corrosive products such
as concrete accelerant. Pump speed is controlled by the adjustable ACCELERATOR PUMP
SPEED control knob located on the process control panel. Refer to Figure 11. The
accelerant system also has several quarter-turn ball valves incorporated into it to control
accelerant flow and circuit flushing. See the end of this document for details on the
valves.
Number: OM-SS2-V5
Revision: A
Bulk Grease Drum Assembly (if equipped)

ON SPRING TYPE REELS, NEVER REMOVE THE COVER
CONTAINING THE SPRING. COILED SPRINGS ARE UNDER
TENSION AND REMOVAL OF COVER CAN RESULT IN
SEVERE PERSONAL INJURY.
WHEN REWINDING THE HOSE ONTO THE HOSE REEL WALK
THE NOZZLE / HOSE END BACK TO THE REEL. IF THE HOSE
IS RETRACTED UNATTENDED, PERSONAL INJURY OR
DAMAGE TO EQUIPMENT COULD OCCUR.
ALWAYS USE GLOVES WHEN HANDLING HOSES.
The grease drum assembly consists of a grease drum and pump fastened in place with
a tie down assembly. The assembly has quick-disconnect fittings to allow for a quicker
drum change. The hydraulic driven air compressor must be running to transfer grease.
Air flow to the bulk grease drum assembly is controlled by a shut-off ball valve and an
air filter/regulator/lubricator assembly located below the accelerant tank. For dispensing
and replacement procedures, see section OM-SS2-O7 titled Shotcrete Sprayer Operations.
Grease
Tie Down Transfer Pump
Assembly
Bulk Grease
Drum
Figure 5 – Typical Bulk Grease Drum Assembly
Number: OM-SS2-V5
Revision: A
Grease Transfer Hose Reel (if equipped) - Is located beside the main AC electrical
panel. It is a spring retractable type hose reel with an internal ratcheting mechanism
that keeps the reel from retracting when the hose is manually unwound. The hose can
be unwound from the reel by pulling it out to the desired length. To retract the hose
back onto the reel, gently pull the hose until the ratchet mechanism of the reel
disengages, then let the reel wind the hose back on while guiding it into place.
Main AC Electrical Panel (if equipped) – The main electrical panel provides several
functions to the Shotcrete Sprayer. Primarily, it provides an enclosure for all high
voltage controls such as motor starters and breakers. It also contains 24V controls and
circuits to control the high voltage system. The front of the panel has displays, indicator
lights, switches and buttons for control and information about these systems.
Main AC
24V Indicators and Power
Circuit Breakers Breaker
Power Pack
Hourmeter Volts
Air Compressor Hydraulic Pump

Hourmeter Load Amps
Power Pack Air Compressor

Controls and Load Amps
Indicators Phase Selector
Emergency Switch
Stop Button Air Compressor
Controls and
120V GFI Indicators
Receptacle
Figure 6 - Typical Main AC Electrical Panel
Main AC Power Breaker – The main power breaker is a three phase circuit breaker
designed to be used as both a circuit breaker and an ON/OFF switch. This breaker trips
if an over-current condition exists on the machine. It has three possible positions, ON,
OFF, and RESET/OPEN. Placing the handle in the OFF position disconnects power
coming in from the cable reel. Placing the handle in the ON position connects power
coming in from the cable reel. If the breaker trips because of an over current condition,
moving the handle to the RESET/OPEN position resets the breaker so that it can be
placed in the ON position.
Number: OM-SS2-V5
Revision: A
ONLY QUALIFIED AND AUTHORIZED ELECTRICAL

MAINTENANCE PERSONNEL ARE TO ENTER THE MAIN
ELECTRICAL PANEL. DEPENDING ON YOUR MINE POWER
SYSTEM THE VOLTAGE INSIDE THIS PANEL CAN BE AS HIGH
AS 1000VAC. SERIOUS INJURY CAN OCCUR.
Maintenance personnel use the RESET/OPEN position to allow the right hand door to
open and gain access to the inside of the panel for maintenance or repair. This breaker
is lockable in the OFF position.
Hydraulic Pump Load Amps Ammeter – This digital display shows the amount or
amperage that the motor driving the power pack is drawing. Optionally this may be an
analogue gauge. This display may also be wired to display total amperage for the unit.
This display is generally for use by maintenance personnel.
Air Compressor Load Amps Ammeter – This digital display shows the amount or
amperage that the motor driving the air compressor is drawing. Optionally this may be
an analogue gauge. This display may also be wired to display total amperage for the
unit. This display is generally for use by maintenance personnel.
Volts – This display shows the incoming line voltage. The VOLTMETER PHASE SELECT
selector switch directly below this display is used to select the line pairs the display
measures. This display is generally for use by maintenance personnel.
Voltmeter Phase Select Selector Switch – This switch is used to select line pairs for
measuring line voltage. The positions are OFF, L1-L2, L2-L3 and L1-L3. The OFF
position causes the display to read zero (0) volts. Switching to any other position causes
the display to show the voltage it measures between the two lines to which it is
connected. This switch is generally for use by maintenance personnel.
120V GFI Receptacle (Figure 6) – A 120V ground fault interrupt (GFI) receptacle is
provided on the main AC electrical panel to plug in small power tools, work lights, etc. It
can provide up to 15 amps of power. The plug is ON any time the vehicle is plugged into
mine power. Before using the receptacle, test the GFI function by pressing the TEST
button on the face of it. Press the RESET button to complete the test. If the receptacle
does fail the test, DON’T use it and contact the appropriate personnel immediately.
Power Pack Hourmeter (Figure 6) – An hourmeter is provided to record the
accumulated run time of the power pack.
Air Compressor Hourmeter (Figure 6) – An hourmeter is provided to record the
accumulated run time of the air compressor.
Number: OM-SS2-V5
Revision: A
1
4
5
2
6
3
Figure 7 - 24 Volt Indicators and Breakers

1. Hydraulic Power Pack Ready – This indicator light illuminates to indicate to the
operator that the hydraulic powerpack is ready to be started.
2. All Emergency Stops Closed – When this indicator light is illuminated, it indicates
that all EMERGENCY STOP buttons are closed and that the circuit is functioning
correctly. This indicator light must be illuminated at all times unless an emergency
stop circuit is open.
3. 24 VDC ON – This indicator light illuminates if the output from the DC power supply
in the AC panel is ON. If this indicator light is not illuminated, check to see if the 24
VDC power supply circuit breaker is tripped. Try to reset the breaker. If this light is
not illuminated the vehicle is inoperable on electric power. Contact maintenance
personnel if this light is not illuminated.
4. 120 VAC Receptacle ON – This light illuminates when the GFI receptacle at the
lower right of the main electrical panel is powered. If this indicator light does not
illuminate, the 120VAC receptacle circuit breaker may be tripped.
5. 24 VDC Power Supply Circuit Breaker – This is a 40 amp manual reset circuit
breaker for the output of the DC power supply. If the indicator light directly above this
breaker is not illuminated when the vehicle is plugged in to mine power, try resetting
this breaker. If this breaker is tripped, the vehicle does not function on electric.
THE 120VAC RECEPTACLE LIGHT AND BREAKER ARE
GROUPED WITH THE 24 VDC INDICATOR LIGHTS FOR
CONVENIENCE. THE 120VAC RECEPTACLE LIGHT AND
BREAKER OPERATE AT 120 VAC.
6. 120 VAC GFI Receptacle Circuit Breaker – This is a 15 amp manual reset circuit
breaker supplying the GFI receptacle on the lower right of the main electrical panel.
If the indicator light directly above this breaker is not illuminated, try resetting this
breaker. If the breaker trips again, reduce the load on the plug or contact
Number: OM-SS2-V5
Revision: A
8 9 10 4 5
6 7 1 2 3
Figure 8 - Main Electrical Panel - Typical Power Controls and Indicators

1. Emergency Stop Button – This a two position push/twist-unlock button switch. To
cut all power to the vehicle, press this button. This button opens the emergency stop
circuit to disconnect the carrier 24VDC system as well as the ground check circuit for
the mine power supply. To reset this button gently twist the button clockwise and
release. The button returns to its closed position.
2. Main Power Reset Button – Once the unit is plugged into a compatible GFI panel
and all breakers are closed, press this button until the GFI panel sends power to the
unit. Release the button once you see the volt meter or ammeter turn ON. If this
button is pushed in and you still see power on to any part of the machine, tag the
unit down and contact maintenance personnel immediately.
3. Ground Check Test Button - This button is used to verify that the ground check
system is operating correctly. Once you have started the power to the unit, press this
button. When you press this button, mine power to the unit must shut off
immediately. If you press this button and the mine power to the unit stays ON,
manually shut the power OFF immediately and contact the appropriate personnel.
Number: OM-SS2-V5
Revision: A
THE GROUND CHECK SYSTEM ON THE SHOTCRETE

SPRAYER AND ALL OTHER MOBILE EQUIPMENT THAT USES
HIGH VOLTAGE POWER SUPPLY FROM THE MINE’S
ELECTRICAL SYSTEM IS THERE TO PREVENT ELECTRICAL
SHOCK TO THE OPERATOR OR OTHER PERSONNEL. IF THIS
SYSTEM IS NOT WORKING CORRECTLY THERE IS A RISK OF
ELECTRICAL SHOCK AND SEVERE PERSONAL INJURY.
4. Voltage Monitor Under Voltage Indicator Light – The Shotcrete Sprayer is
equipped with a device to monitor the incoming high voltage power. The voltage
monitor turns ON this light if it detects that one or more phases has an under voltage
condition. If this light is illuminated, the electric power pack does not start, or shut
down if it is running. This indicator light may also illuminate in conjunction with the
VOLTAGE MONITOR OVER VOLTAGE light to indicate a phase problem. It is normal for
this indicator light to come ON prior to resetting the main power. If this indicator light
illuminates, or stays illuminated, contact the appropriate personnel.
5. Voltage Monitor Over Voltage Indicator Light – The Shotcrete Sprayer is
equipped with a device to monitor the incoming high voltage power. The voltage
monitor turns ON this indicator light if it detects that one or more phases has an over
voltage condition. If this indicator light is illuminated, the electric power pack does
not start, or shut down. This indicator light may also illuminate in conjunction with the
VOLTAGE MONITOR UNDER VOLTAGE indicator light to indicate a phase problem. It is
normal for this indicator light to come ON prior to resetting the main power. If this
indicator light illuminates, or stays illuminated, contact the appropriate personnel.
6. Power Pack Start Push Button – Pressing the push button in starts the power pack
motor that drives the power pack hydraulic pump.
7. Power Pack Stop Push Button - Pressing the push button in stops the power pack
motor that drives the power pack hydraulic pump.
8. Power Pack Run Indicator Light – This indicator light illuminates when the electric
motor driving the power pack hydraulic pump is running.
9. Hydraulic Oil Level Indicator Light – This indicator light illuminates when the
system detects a low hydraulic oil level condition in the hydraulic tank. If this
indicator light is illuminated, the electric power pack does not run.
10. Hydraulic Oil Temperature Indicator Light – This indicator light illuminates when
the system detects a high hydraulic oil level condition in the hydraulic tank. If this
indicator light is illuminated, the electric power pack does not run.
Number: OM-SS2-V5
Revision: A
1 6
2
3 7
8
4
Figure 9 – Typical Air Compressor Controls and Indicators

IF THE COMPRESSOR SHUTS OFF FOR ANY REASON, DO
NOT ATTEMPT TO RESTART IT UNTIL THE COMPRESSOR
HAS FINISHED BLEEDING DOWN TO AVOID DAMAGE TO THE
COMPRESSOR.
1. Hydraulic Pump O/L Reset Button – The hydraulic powerpack electric motor is
protected by an overload device. This device trips whenever the motor is drawing
too much current. It can be reset by pushing this button in.
2. Air Comp. Start Button – Pressing this button starts the compressor that the panel
controls.
3. Air Comp. Stop Button – Pressing this button stops the compressor that the panel
controls.
4. Compressor O/L Reset Button – The air compressor electric motor is protected by
an overload device. This device trips whenever the motor is drawing too much
current. It can be reset by pushing this button in.
5. Air Comp. Run Indicator Light – This indicator light illuminates when the
compressor is started and is running. If this indicator light illuminates, but the
compressor is not running, or does not start, contact your maintenance department.
When the air compressor is stopped, the AIR COMP RUN indicator light
flashes for 30 seconds. During this time, the air compressor cannot
be restarted.
6. Air Comp Oil Fault – This indicator light illuminates if the air compressor oil level is
too low, or if the oil temperature is too high.
Number: OM-SS2-V5
Revision: A
7. Air Comp. Cool O/L Reset Button – The air compressor cooler motor is protected
by an overload device. This device trips whenever the motor is drawing too much
current. It can be reset by pushing this button in.
This button does not pop out if the overload has tripped. Try
resetting the overload if any motors fail to start, or shut down for no
apparent reason. If you have to keep resetting any of the overloads,
contact the appropriate personnel immediately.
8. Air Comp MTR Fault Reset – This is a button as well as an indicator light. If the air
compressor electric motor overheats this button illuminates. To reset this condition,
press the button in.
Battery Charger (if equipped) – The battery charger prevents the batteries from
discharging and supplies 24 VDC power to the vehicle when it is plugged into mine
power.
1
3
Figure 10 - Battery Charger

1. 24VDC Circuit Breaker – This 50 amp manual reset breaker protects the DC side of
the battery charger. If the load exceeds 50 amps this breaker trips. Push the breaker
in to reset it. If the circuit breaker continues to trip, contact maintenance personnel.
2. 120 VAC Circuit Breaker – This 15 amp manual reset circuit breaker protects the
AC input of the battery charger. If the battery charger is not working, try resetting this
breaker by pushing it in. If it trips again, or still does not work contact the appropriate
personnel.
3. DC Ammeter – This analogue gauge displays the current output of the battery
charger in amps. Any time the unit is plugged into mine power, the DC ammeter
shows a charging rate in amps. The normal operating range is between 0 and 30
amps.
Number: OM-SS2-V5
Revision: A
4. DC Volt Meter - This analogue gauge displays the system voltage. It shows the
battery voltage any time the MAIN BATTERY DISCONNECT switch is turned ON. It must
read between 24 and 28 VDC.
Shotcrete Process Control Panel – This control panel allows the operator to control all
functions related to the shotcrete pump, accelerator dosing pump, etc. It has two
displays to indicate total pumps strokes and accelerator pump speed. It also contains
the shotcrete pump computer.
THERE ARE DUPLICATE CONTROLS ON THE SHOTCRETE
PROCESS CONTROL PANEL AND THE SHOTCRETE BOOM
CONTROL PANEL. BECAUSE OF THIS, CLEAR
COMMUNICATION MUST BE USED IF THERE IS MORE THAN
ONE PERSON OPERATING THE SHOTCRETE SPRAYER.
FAILURE TO COMMUNICATE COULD CAUSE PLUGGING OF
LINES, OR INCORRECT ADJUSTMENTS TO THE
SHOTCRETING PROCESS RESULTING IN POOR PRODUCT
APPLICATION.
1 and Reset
Button 2
3
4
5
6
9
7 10
8
11
12
17
13
16
14
15
Figure 11 – Typical Shotcrete Process Control Panel
Number: OM-SS2-V5
Revision: A
1. Shotcrete Pump Stroke Counter - This digital display counts the total number of
strokes the shotcrete pump made since the last time the counter was reset. To reset
the stroke count to zero, depress the small grey button immediately to the right of
the display. The display resets to zero. This display remains ON at all times as it is
powered by its own built-in battery. If you don’t see anything on the display, the
battery needs replacing.
2. Shotcrete Pump Hour Meter (if equipped) - This digital display counts the total
number of hours the shotcrete pump has ran. This display may remain ON at all
times as it can be powered by its own built-in battery. If you don’t see anything on
the display, the battery needs replacing.
3. Accelerator Pump Speed Display – This display indicates the speed of the
accelerant dosing pump. The lower the number, the slower the pumps speed and
the lower the volume of accelerant being delivered into the shotcrete stream. The
higher the number, the more accelerant being delivered to the shotcrete stream. It is
normal for this number to vary up and down slightly during operation. The display
resets to zero. This display also remains on at all times as it is powered by its own
built-in battery. If you do not see anything on the display, the battery needs to be
replaced.
4. Shotcrete Pump Flow Control Knob – This dial controls speed at which the
shotcrete pump operates at. This control is infinitely variable between positions 0
and 10. Changing the position of this control, signals the pump to stroke at a
different speed. Generally a setting between three and four on the dial is the lowest
speed of the pump and is dependent on the initial setup programming of the pump
ECM.
5. Accelerator Pump Speed Control Knob - This dial controls the volume at which
the accelerator dosing pump delivers accelerant to the nozzle. This control is
infinitely variable between positions 0 and 10. As the ACCELERATOR PUMP SPEED
control knob is adjusted, the accelerator pump speed display increases, or
decreases.
6. Shotcrete Pump Pressure Test Switch (if equipped) - Press this button and hold
to pressure test the pump. This button runs each pump element to the end of its
stroke and holds it there under maximum system pressure so the hydraulic pressure
in the pump circuit can be tested. This switch is also used to test the blockage
detection system This function is generally for use by maintenance personnel.
7. Shotcrete Pump Forward/Reverse Switch – Placing the SHOTCRETE PUMP switch
to the Forward position illuminates the switch and puts the shotcrete pump in
FORWARD which is used for spraying operations. Placing the SHOTCRETE PUMP
switch to the Reverse position places the pump in REVERSE and the light within the
switch goes out. This is used for various operations such as mixing the line slicking
agent in the hopper, or helping clear blockages in the shotcrete delivery line.
Number: OM-SS2-V5
Revision: A
8. Shotcrete Pump Start/Stop Switch – To start the shotcrete pump, press the green
START portion of the button and release. The white/clear indicator LED illuminates
and the switch returns to its outer position. To stop the shotcrete pump, press the
red STOP portion of the button and release. The indicator light goes OUT and the
switch returns to its outer position. This switch does not start the pump if the unit is
placed in REMOTE mode, it must be in MANUAL mode. You may stop the shotcrete
pump using this switch if you are in either MANUAL or REMOTE mode.
9. Manual Cycle A/B Switch – This switch is used to manually control the pumping
cycle. This is useful while unplugging lines, cleaning the delivery circuit, etc.
Essentially this switch is the manual version of the automatic pumping control. The
pump works in either FORWARD or REVERSE just as the automatic pumping
control does.
10. Fast Idle Switch – Placing the FAST IDLE switch to the ON position places the engine
at high idle and illuminates the LED. Placing the FAST IDLE switch to the OFF position
places the engine at low idle and extinguishes the LED. This switch does nothing if
you are operating on electric.
The fast idle function is available only in AUXILIARY mode. When the
unit is switched back to DRIVE mode, the fast idle function is
disabled.
11. Accelerator Pump Start/Stop Switch – To start the accelerator pump, press the
green START portion of the switch and release. The white/clear indicator LED
illuminates and the switch returns to its outer position. The accelerator pump starts
and runs at the speed set by the ACCELERATOR PUMP SPEED control knob. To stop
the accelerator pump, press the red STOP portion of the button and release. The
indicator extinguishes, the switch returns to its outer position and the accelerator
pump stops. The accelerator pump may be started in either MANUAL or REMOTE
mode.
The accelerator pump does not come on if the water enable function
is on.
12. AUXILIARY Mode – This LED indicator light illuminates to indicate that the vehicle
is in AUXILIARY mode and is ready for shotcrete spraying operations. If the LED is
not illuminated, the vehicle is in DRIVE mode and can be trammed. If this indicator is
illuminated and pumping functions do not operate correctly, make sure the Hopper
Grate Open indicator light is not illuminated, or contact your maintenance
department.
Number: OM-SS2-V5
Revision: A
13. Water Enable On/Off Switch – To allow water flow to the nozzle, press the green
and the switch returns to its outer position. To stop the water flow, press the red
STOP portion of the button and release. The indicator extinguishes, the switch
returns to its outer position and the water flow stops. The water flow may be enabled
in either MANUAL or REMOTE mode.
The water enable does not come on if the accelerator pump is on.
14. Air Enable On/Off Switch – To allow air flow to the nozzle press the green START
portion of the button and release. The white/clear indicator LED illuminates and the
switch returns to its outer position. To stop the air flow, press the red STOP portion of
the button and release. The indicator light extinguishes, the switch returns to its
outer position and the air flow stops. The air flow may be enabled in either MANUAL
or REMOTE mode.
15. Shotcrete Pump Blockage Indicator Light (if equipped) – This indicator light
illuminates to alert the operator that the shotcrete process paused due to a possible
blockage within the shotcrete pump system. For more information, see section
OM-SS-O2 titled Modes of Operation & Interlocks.
16. Hopper Grate Open Indicator Light – This LED illuminates if the grate latch pin is
in the UNLATCHED position indicating that the grate may be open and the interlock
function of the latch pin is active. The remixer and shotcrete pump do not operate if
this LED is ON. If this LED remains illuminated even if the latch pin is in the
LATCHED position, contact your maintenance department.
17. Hopper Vibrator On/Off Switch – Placing the HOPPER VIBRATOR switch to the ON
position turns the hopper vibrator ON and illuminates the indicator LED. Placing the
HOPPER VIBRATOR switch to the OFF position turns the hopper vibrator OFF and
extinguishes the indicator LED. The vibrator can be turned ON or OFF any time the
machine is in AUXILIARY mode.
Number: OM-SS2-V5
Revision: A
Rear Auxiliary Control Valve – This valve provides control flow for the remixer,
hopper/pump tilt cylinders, cable reel (if equipped), water and and/or air hose reel (if
equipped) and hydraulic oil cooler fan. Only the remixer, pump tilt, reel functions and
cable reel have control levers. The fan functions are controlled electrically.
1
5
2
6
7
4 8
Figure 12 - Typical Rear Auxiliary Control Valve
1. Swing Tube Pressure Release Valve Handle (if equipped) – This valve handle is
used to release the swing tube pressure from the accumulator.
2. Swing Tube Pressure Gauge – The swing tube pressure gauge displays the
pressure that the swing tubes are operating at. Normal operating pressure is 2200
PSI (152 bar).
3. Hydraulic Cooler Control Valve – This valve turns the hydraulic oil cooler fan ON
and OFF. The valve is controlled by a thermal switch and normally no operator input
is required. A manual override is provided, however a handle is not installed as it is
not normally required.
4. Shotcrete Pump Tilt Control Valve – To raise the pump, push the control handle.
To lower the pump, pull the control handle.
5. Shotcrete Pump Lowering Speed Control – This is a one-way infinitely variable
needle flow control valve used to adjust the descend speed. The valve must not be
adjusted unless the pump lowering rate is too fast, or too slow to be practical. Once
adjusted, the control must be locked with the setscrew to avoid self-adjustment.
Number: OM-SS2-V5
Revision: A
UNNECESSARY, OR IMPROPER ADJUSTMENT OF THE

SHOTCRETE PUMP LOWERING SPEED CONTROL VALVE
CAN CAUSE EQUIPMENT/PROPERTY DAMAGE, OR INJURY
TO PERSONNEL. ONLY QUALIFIED MAINTENANCE
PERSONNEL MUST MAKE ADJUSTMENTS TO THIS SPEED
CONTROL VALVE.
6. Shotcrete Hopper Remixer Control Valve – Pull the control handle to turn on and
adjust the speed of the remixer in the shotcrete pump hopper. If necessary, push the
control handle to rotate the remixer in the opposite direction. During normal
operation it is best to pull the control handle as indicated on the label.
7. Cable Reel Control Valve (if equipped) – To unwind the AC trailing cable, pull the
control handle. To wind the AC trailing cable, push the control handle. The cable reel
is also controlled from either the driver’s instrument panel, or the CABLE REEL
selector switch on the rear of the vehicle.
8. Water/Air Reel Control Valve (if equipped) – To wind the air hose onto the air
hose reel, pull the control handle. To wind the water hose onto the water hose reel,
push the control handle.
Number: OM-SS2-V5
Revision: A
GENERAL PASSENGER’S FRONT SIDE LAYOUT

The general layout of the components for the Shotcrete Sprayer’s front passenger side
can be seen in Figure 13.
Air Enable
Valve
Parking
Strobe Shotcrete
Light Hose
Air Control
Valve
Transmission Boom Control

Fill Point Panel
Remote
Pendant
Holders
Boom Control
Fuel Valve
Tank and
Water/Accelerant
Fill Cap
Selector Valve
Front
Auxiliary
Control
Valve
Figure 13 - Typical Passenger’s Front Side Layout

Parking Strobe Light – The parking strobe light illuminates any time the PARKING LIGHT
switch on the driver’s instrument panel is turned ON (regardless of whether the vehicle
is completely shut down, or not).
Air Enable Valve – This valve is controlled by the AIR ENABLE ON/OFF switch located on
both the boom control panel and the process control panel. When enabled, the air
pressure supply is fed to the Shotcrete Sprayer’s nozzle.
Number: OM-SS2-V5
Revision: A
Remote Pendant Holders (if equipped) – There are remote pendant holders located
on either side of the vehicle. They are adjustable and can be used to hold the pendant
during the shotcreting process. For more information on the remote pendant, see
Remote Pendant Layout section.
Transmission Fill Point – If you need to add oil to the transmission the fill point is on
the right rear corner of the passenger’s compartment. Consult the lubrication data tag
on your vehicle.
Fuel Tank and Fill Cap – The fuel tank is located under the opposite side of the
operator’s compartment. The tank is filled through the spring loaded fuel fill cap, or
optional high pressure fast fill port.
Air and Water/Accelerant Selector Control Valves – There are several manual ball
valves located near the front right corner of the vehicle. The mounting positions of these
valves vary with customer requests. These valves control the flow of compressed air,
and switch between accelerant and wash water. These valves are discussed later in this
section.
Shotcrete Hose – The vehicle generally uses 10 foot lengths of flexible rubber delivery
hose for shotcrete. However, depending on requirements and options, the hose may be
different sizes, or may consist of different lengths. The hoses are joined with over-center
latching clamps with safety pins.
Boom Control Valve – The boom control valve controls all boom functions with the
exception of nozzle oscillation. The valve can be operated manually using the attached
handles or remotely from a remote. This valve operates only in AUXILIARY mode.
Operational details are discussed later in this section.
2 3 4
1 5
Figure 14 - Typical Boom Control Valve
Number: OM-SS2-V5
Revision: A
The following is a description of the boom control valve manual functions. When the
remote is in use, this valve still operates all boom functions however, you are not able to
manually actuate the valves. Please note that multiple functions can be used at once.
However, depending on pressure requirements and lever positions for each individual
circuit, operational results may vary.
1. Boom Rotation To Driver Side/To Passenger Side Control Valve – Pull the lever
up to rotate the boom toward the operator’s side of the vehicle. Push the lever down
to rotate the boom toward the passenger side of the vehicle.
2. Boom Up/Down Control Valve – Pull the lever up to lift the boom up. Push the
lever down to lower the boom.
3. Boom Extend/Retract Control Valve – Pull the lever up to extend the boom. Push
the lever down to retract the boom.
4. Nozzle Rotation 360°Control Valve - Pull the lever up to rotate the nozzle
clockwise as viewed from behind the boom. Push the lever down to rotate the nozzle
counter-clockwise.
5. Nozzle Rotation 240° Control Valve - Pull the lever up to rotate the nozzle counter-
clockwise (left) as viewed from the top. Push the lever down to rotate the nozzle
clockwise (right).
Number: OM-SS2-V5
Revision: A
Front Auxiliary Control Valve – This valve controls the outriggers, nozzle oscillation,
form oil pump, high pressure washer pump, accelerator and water pump. Everything but
the form oil pump/power wash control valve is operated electrically. This valve operates
only in AUXILIARY mode. Operational details are discussed later in this section.
2 3 4
1 5
Figure 15 - Typical Front Auxiliary Valve

The front auxiliary valve controls various functions that are not directly related to the
spraying process with one exception. This valve has both manual and electro-hydraulic
controls on all but one section.
1. Outrigger Up/Down (Passenger’s Side) Control Valve - This valve is controlled
from the driver’s instrument panel. There is no manual control of the valve.
2. Outrigger Up/Down (Operator’s Side) Control Valve - This valve is controlled
from the driver’s instrument panel. There is no manual control of the valve.
3. Nozzle Oscillation Control Valve - To operate this valve, turn ON the NOZZLE
OSCILLATION switch on the boom control panel or the remote pendant (if equipped).
4. Form Oil Pump/Power Wash Control Valve – To operate the form oil pump, pull
the lever up and it holds its position. To operate the high pressure washer pump,
push the lever down and it holds its position. To turn OFF either pump, move the
lever back to its center (neutral) position.
5. Accelerator In/Water In/Control Valve – This valve actuates a hydraulic motor
which operates a ball valve that directs either accelerant, or water to the nozzle. This
valve is controlled from either the boom control panel, or the process control panel.
There is no manual control for this valve.
Number: OM-SS2-V5
Revision: A
Boom Control Panel – This panel is located in the control stand at the front of the
vehicle and duplicates some of the controls available on the shotcrete process control
panel. It also contains an EMERGENCY STOP button. Operational details are discussed
later in this section.
THERE ARE DUPLICATE CONTROLS ON THE SHOTCRETE
PROCESS CONTROL PANEL AND SHOTCRETE BOOM
CONTROL PANEL. BECAUSE OF THIS, CLEAR
COMMUNICATION MUST BE USED IF THERE IS MORE THAN
ONE PERSON OPERATING THE SHOTCRETE SPRAYER.
FAILURE TO COMMUNICATE COULD CAUSE PLUGGING OF
LINES, OR INCORRECT ADJUSTMENTS TO THE
SHOTCRETING PROCESS RESULTING IN POOR PRODUCT
APPLICATION.
2
5
3
6
4
7
8
9 10
11
12
13
Figure 16 - Typical Shotcrete Boom Control Panel
Number: OM-SS2-V5
Revision: A
1. Emergency Stop Button – To cut all power to the unit push this button in. This
button disconnects the emergency stop circuit for the 24 VDC system. For more
information, see section OM-SS-V2 titled Machine Safety Items.
2. Nozzle Oscillation On/Off Switch - Placing the NOZZLE OSCILLATION switch to the
ON position turns ON the nozzle oscillation. Placing the NOZZLE OSCILLATION switch
to the OFF position turns the nozzle oscillation OFF.
3. Shotcrete Pump Forward/Reverse Switch – Placing the SHOTCRETE PUMP switch
to the FORWARD position illuminates the switch and puts the shotcrete pump in
FORWARD which is used for spraying operations. Placing the SHOTCRETE PUMP
switch to the REVERSE position places the pump in REVERSE and the light within the
switch goes out. This is used for various operations such as mixing the line slicking
agent in the hopper, or helping clear blockages in the shotcrete delivery line.
4. Shotcrete Pump Start/Stop Switch – To start the shotcrete pump, press the green
and the switch returns to its outer position. To stop the shotcrete pump, press the
red STOP portion of the button and release. The indicator extinguishes and the
switch returns to its outer position. This switch does not start the pump if the unit is
placed in REMOTE mode, it must be in MANUAL mode. You may stop the shotcrete
pump using this switch if you are in either MANUAL, or REMOTE mode.
5. Auxiliary Mode Indicator – This LED indicator light illuminates to indicate that the
vehicle is in AUXILIARY mode and is ready for shotcrete spraying operations. If the
LED is not illuminated, the vehicle is in DRIVE mode and can be trammed. If this
indicator is illuminated and pumping functions do not operate correctly, make sure
the HOPPER GRATE OPEN indicator light is not illuminated, or contact your
maintenance department.
6. Fast Idle Switch – Placing the FAST IDLE switch to the ON position places the engine
at high idle and illuminates the LED. Placing the FAST IDLE switch to the OFF position
places the engine at low idle and extinguishes the LED. This switch does nothing if
you are operating on electric.
The fast idle function is available only in AUXILIARY mode. When
the vehicle is switched back to DRIVE mode, the fast idle function is
disabled.
7. Accelerator Pump Start/Stop Switch – To start the accelerator pump, press the
green START portion of the button and release. The white/clear indicator LED
illuminates and the switch returns to its outer position. The accelerator pump starts
and runs at the speed set by the ACCELERATOR PUMP SPEED control knob. To stop
the accelerator pump, press the red STOP portion of the button and release. The
indicator extinguishes, the switch returns to its outer position and the accelerator
pump stops. The accelerator pump may be started in either MANUAL or REMOTE
mode.
Number: OM-SS2-V5
Revision: A
is on.
8. Air Compressor Start/Stop Switch (if equipped) – When START is selected the air
compressor turns ON. When STOP is selected the air compressor turns OFF.
9. Hydraulic Power Pack Start/Stop Switch (if equipped) – When START is selected
the hydraulic power pack turns ON. When STOP is selected the hydraulic power pack
turns OFF.
10. Manual/Remote Mode Switch – Placing the MODE switch to the REMOTE position
places the vehicle in REMOTE mode and illuminates the LED. Placing the MODE
switch to the MANUAL position places the vehicle in MANUAL mode and extinguishes
the LED. Releasing the switch returns it to center. Refer to OM-SS-O2 titled Modes of
11. Air Enable On/Off Switch – To start the air pump, press the green START portion of
the button and release. The white/clear indicator LED illuminates and the switch
returns to its outer position. To stop the air pump, press the red STOP portion of the
button and release. The indicator light extinguishes, the switch returns to its outer
position and the air pump stops. The air pump may be started in either MANUAL or
REMOTE mode.
12. Water Enable On/Off Switch – To start the water pump, press the green START
portion of the button and release. The white/clear indicator LED illuminates and the
switch returns to its outer position. To stop the water pump, press the red STOP
portion of the button and release. The indicator extinguishes, the switch returns to its
outer position and the water pump stops. The water pump may be started in either
MANUAL or REMOTE mode.
The water pump does not come on if the accelerator pump is on.
13. Shotcrete Pump Blockage Indicator Light (if equipped) – This indicator light
illuminates to alert the operator that the shotcrete process paused due to a possible
blockage within the shotcrete pump system. For more information, see section
OM-SS-O2 titled Modes of Operation & Interlocks.
Number: OM-SS2-V5
Revision: A
GENERAL FRONT END LAYOUT

The general layout of the components for the Shotcrete Sprayer’s front end can be seen
in Figure 17.
Injection Ring
Assembly
Nozzle Oscillation
Assembly
Nozzle Positioning
Actuators
Fly Rock Guard

(If equipped)
(not shown)
Ride Control
Accumulator
Boom Lift Cylinder

Manifold and Ride
Control System
Water Scaler Option

(if equipped)
Figure 17 - Typical Front End Layout

Injection Ring – The injection ring combines the flow of shotcrete from the shotcrete
pump with compressed air and accelerant before it is sprayed on the back, wall or face
of the heading. For washing the work surface prior to spraying shotcrete, water can be
injected instead of accelerant through the ring.
Number: OM-SS2-V5
Revision: A
Water Scaler Option - The water scaler option on the Shotcrete Sprayer utilizes a high
pressure, low volume piston pump to push water through a group of nozzles mounted
on the shotcrete nozzle oscillating mount located at the working end of the boom. For
more information on the water scaler option, refer to the Operator’s Manual section
OM-SS2-O8 titled Water Scaler Operation.
Nozzle Oscillation Assembly – The nozzle can be oscillated to create a more uniform
spray pattern. Oscillation is achieved with a hydraulic motor and an eccentric bearing.
Nozzle Positioning Actuators – Two rotary actuators support the complete head
assembly including the nozzle. One actuator rotates the nozzle in the around the center
of the boom, the other rotates the nozzle perpendicular to the center of the boom.
Fly Rock Guard (if equipped) – The fly rock guard is available to protect the operator
from flying debris during the shotcreting and water scaling process. The fly rock guard is
installed in the upright position by means of a ball and socket.
Boom Ride Control System - The boom ride control system uses a hydraulic
accumulator that absorbs the boom lift cylinder shock loading during tramming. This
helps reduce the forces exerted on the pins, bushings, and other mechanical
components. This increases the components life and improves operator comfort. Figure
17 shows a typical ride control system which consists of a boom lift cylinder and boom
lift cylinder manifold. Also included are the control panel and ride control accumulator.
The boom lift cylinder manifold and ride control accumulator are described below.
• Boom Lift Cylinder Manifold - this manifold contains two cartridge valves and is
sandwiched between the boom lift cylinder and boom lift counterbalance valve.
• Ride Control Accumulator – this accumulator is used to absorb the hydraulic
fluid from the cap end of the boom lift cylinder when a tramming load is applied to
the boom (e.g. pot hole) and then push the hydraulic fluid back into the lift
cylinder to bring the boom back to its original position.
Number: OM-SS2-V5
Revision: A
REMOTE PENDANT LAYOUT

15
1
14
13 2
12
3
4
11
5
10 6
Figure 18 - Typical Remote Pendant

The Shotcrete Sprayer comes with a remote pendant to control the positioning of the
boom and basic control of the shotcrete pump. The remote pendant plugs into the
remote receiver on the left of the front control stand.
Although the Shotcrete Sprayer can be operated from the front control station, the
remote pendant gives the operator much better control of the boom, better visibility of
the nozzle and generally more comfort and convenience. No functions on the remote
pendant (except for the EMERGENCY STOP button) work unless the vehicle is placed in
REMOTE mode.
IF ANY PART OF THE REMOTE PENDANT, CABLE OR PLUG IS
FOUND TO BE DEFECTIVE DURING YOUR PRE-OPERATIVE
INSPECTION, OR IF THE REMOTE PENDANT FAILS TO
OPERATE CORRECTLY AT ANY TIME DURING THE
OPERATION OF THE VEHICLE, STOP USING THE REMOTE
PENDANT IMMEDIATELY AND REMOVE IT FROM SERVICE.
TAG THE REMOTE PENDANT AS DEFECTIVE AND CONTACT
THE APPROPRIATE PERSONNEL AT YOUR SITE. FAILURE TO
DO SO MAY CAUSE EQUIPMENT AND/OR PROPERTY
DAMAGE, SERIOUS INJURY, OR EVEN DEATH TO
PERSONNEL.
Number: OM-SS2-V5
Revision: A
WHEN PLACING THE VEHICLE IN REMOTE MODE, BE SURE

THAT ALL OF THE JOYSTICKS ARE IN THEIR SPRING
NEUTRAL POSITIONS. IF A JOYSTICK IS NOT IN ITS
NEUTRAL POSITION WHEN POWERED UP, OR IS DEFLECTED
AT ALL DURING THE LINK PROCESS, THE REMOTE DOES
NOT LINK.
1. Accelerant Pump Speed Control Dial – This dial controls the volume at which the
accelerator dosing pump delivers accelerant to the nozzle. As the ACCELERATOR
PUMP SPEED control knob is adjusted, the accelerator pump speed display increases
or decreases.
The accelerant pump does not come on if the water pump is on.
2. Boom Disable Button/Emergency Stop Switch – Press this button to disable the
remote pendant in an emergency. To reset this button, gently twist the knob
clockwise and release. The button returns to the out or operating position.
On some transmitters, this switch is hardwired to the vehicle’s
emergency stop circuit. Pressing this button cuts all 24VDC power to
the vehicle.
3. Power/Communications Indicator Light – This indicator light is located in the
centre of the faceplate. It indicates when the remote pendant power is ON, and
when it establishes communication with the remote receiver. The indicator light
flashes quickly when the pendant key switch is first turned ON. The light then flashes
slowly once the LINK button is pressed and communication is established. When the
battery is low, an audible alarm sounds, and the light illuminates yellow.
4. Water On/Off Toggle Switch - This toggle switch allows the operator to turn the
water flow to the nozzle ON and OFF from the remote pendant without having to
return to the boom shotcrete control panel. Toggle the switch to the bottom position
to stop the water flow. Toggle the switch to the top position to enable the water flow.
The water pump does not come on if the accelerator pump is on.
5. Nozzle Oscillation ON/OFF Toggle Switch – Toggle the switch to the top position
to turn nozzle oscillation ON. Toggle the switch to the bottom position to turn nozzle
oscillation OFF.
6. Pendant Key Switch – The pendant key switch is used to power up the remote
pendant. When power is ON, the POWER/COMMUNICATIONS INDICATOR light flashes
quickly.
Number: OM-SS2-V5
Revision: A
7. Link Button – Pressing this button initiates communication between the remote
pendant and Shotcrete Sprayer’s remote receiver, establishing a link. When the link
is established, the POWER/COMMUNICATIONS INDICATOR light flashes slowly. The
pendant key switch must be turned ON before pressing the LINK button. Once the
link is established, this button can also be used to sound the deck end horn as a
means to communicate with an operator at the hopper/transmixer.
8. Nozzle Rotation Joystick – The proportional feature allows the operator to feather
the control the same way a manually operated hydraulic valve is feathered. This
joystick controls two rotary actuators that position the nozzle at the end of the boom.
To operate the 240° (side to side) actuator, move the joystick up and down. Moving
the joystick down rotates the nozzle left (as viewed from behind the boom) and
moving the joystick up moves the nozzle right. To operate the 360° actuator, move
the joystick left and right. To rotate the nozzle clockwise (as viewed from behind the
boom) push the joystick right. To rotate the nozzle counter-clockwise, push the
joystick toward left.
On some vehicles, the controls for the nozzle rotation functions may
be different than that stated above. It is the Operator’s responsibility
to be aware of their specific vehicle configuration.
9. Boom Extend Joystick – The proportional feature allows the operator to feather the
control the same way a manually operated hydraulic valve is feathered. This joystick
controls the boom extension. To extend the boom, push the joystick away from you
(up). To retract the boom, pull the joystick toward you (down).
10. Boom Swing/Lift Joystick – The proportional feature allows the operator to feather
the control the same way a manually operated hydraulic valve is feathered. To
swing the boom toward the operator’s (left) side of the unit move the joystick left. To
swing the boom toward the passenger’s (right) side of the unit move the joystick to
the right. To lift the boom up, pull the joystick toward you (down). To lower the boom,
push the joystick away from you (up).
11. Shotcrete Pump On/Off Toggle Switch – This toggle switch allows the operator to
turn the shotcrete pump ON and OFF from the remote pendant without having to
return to the boom shotcrete control panel. Toggle the switch to the bottom position
to stop the shotcrete pump. Toggle the switch to the top position to start the
shotcrete pump.
12. Accelerator Pump On/Off Toggle Switch – This toggle switch allows the operator
to turn the accelerator pump ON and OFF from the remote pendant without having
to return to the boom shotcrete control panel. Toggle the switch to the bottom
position to stop the accelerant pump. Toggle the switch to the top position to start
the accelerant pump.
is on.
Number: OM-SS2-V5
Revision: A
13. Air On/Off Toggle Switch – This toggle switch allows the operator to turn the air
flow to the nozzle ON and OFF from the remote pendant without having to return to
the boom shotcrete control panel. Toggle the switch to the bottom position to stop
the air flow. Toggle the switch to the top position to enable the air flow.
14. Shotcrete Pump Forward/Reverse Selector Switch – This selector switch is used
to place the shotcrete pump into forward, or reverse.
15. Shotcrete Pump Speed Control Dial – This is a rotary dial control that is infinitely
variable between positions. Changing the position of this control, signals the pump to
stroke at a different speed.
Number: OM-SS2-V5
Revision: A
APPLICATION JUNCTION BOX (APP JB)

The application junction box provides controls and indicators that typically are used
when in AUXILIARY mode. These functions include some lighting controls and boom
controls. Figure 19 below illustrates a typical application junction box (APP JB).
Figure 19 – Typical Application Junction Box (APP JB)
Number: OM-SS2-V5
Revision: A
APPLICATION JUNCTION BOX FUNCTIONS

1. Left Engine Outrigger Up/Down Switch – Toggle the top of the switch to raise the
outrigger. Toggle the bottom of the switch to lower the outrigger.
2. Right Engine Outrigger Up/Down Switch – Toggle the top of the switch to raise
the outrigger. Toggle the bottom of the switch to lower the outrigger.
3. Boom Extension Extend/Retract Switch (if equipped) – Toggle the top of the
switch to extend the boom. Toggle the bottom of the switch to retract the boom.
The BOOM ENABLE switch must be activated in order for this function
to work. This function allows the boom to be extended and retracted
while in DRIVE mode, transmission in neutral and the
emergency/park brakes applied. For more information, see section
OM-SS-O2 titled Modes of Operation & Interlocks of this Operator’s
Manual.
4. Boom Swing CCW/CW Switch – Toggle the top of the switch to swing the boom
counter-clockwise. Toggle the bottom of the switch to swing the boom clockwise.
to work. This function provides boom manipulation while in DRIVE
mode when tramming in the mine.
5. Boom Enable Switch – Toggling and holding the switch upwards allows the
operator to move the boom swing and lift, while in MANUAL and DRIVE modes.
6. Boom Lift Up/Down Switch – Toggling the top of the switch lifts the boom. Toggle
the bottom of the switch to lower the boom.
to work. This function provides boom manipulation while in DRIVE
mode when tramming in the mine.
7. Hydraulic Tank Warning Indicator Lights (if equipped)
Level - This W ARNING indicator light illuminates when the hydraulic oil level in the
reservoir drops below the normal operating level. If this happens, the vehicle must
be shutdown. The reservoir either needs to be filled with oil and/or the system
checked for possible leaks. If the problem cannot be corrected, notify the
appropriate maintenance personnel immediately.
Temperature – This WARNING indicator light illuminates when excessive heat build-
up in the hydraulic system occurs. If this happens, the vehicle must be shut down
and the appropriate maintenance personnel notified immediately to determine the
cause of overheating.
Number: OM-SS2-V5
Revision: A
8. Manual/Remote Mode Switch – Toggle the top of the switch to place the vehicle
into MANUAL mode. Toggle the bottom of the switch to place the vehicle into
REMOTE mode.
9. Water Scaler Enable Switch – Toggle the top of the switch to enable the water
scaler. Toggle the bottom of the switch to disable the water scaler and indicator light.
The indicator light within the switch illuminates once the water scaler is ON and goes
out once the water scaler is OFF.
In order to enable the water scaler, the operator must be sitting in the
operator’s seat. As soon as the operator leaves the seat, the water
scaler is immediately disabled.
10. Emergency Stop Button - The EMERGENCY STOP button disables the engine and
interrupts all 24V power to the machine control circuits on the vehicle. For more
information, see section OM-SS-V2 titled Machine Safety Items.
11. Cable Reel Wind Warning/Alarm Indicator Lights (if equipped) - This indicator
light group warns the operator if the cable reel reached the last three wraps and the
last wrap of cable. The W ARNING indicator light illuminates when the last three wraps
of cable are remaining on the cable reel and works in conjunction with the CABLE
REEL W ARNING audible alarm. The ALARM indicator light illuminates when the last
wrap of cable is remaining on the cable reel. When this indicator light illuminates, the
emergency/park brakes are automatically applied.
12. Cable Reel In Switch (if equipped) - This switch is operable in either DRIVE or
AUXILIARY mode. Toggle and hold the top of the switch to illuminate the indicator
light within the switch (if equipped) and wind the AC trailing cable onto the cable
reel. Release the switch and the indicator light goes OUT and the cable reel
automatically stops.
AFTER DISCONNECTING THE AC TRAILING CABLE FROM
MINE POWER SUPPLY, ENSURE THAT ALL PERSONNEL ARE
CLEAR OF THE AREA WHILE WINDING THE LAST BIT OF AC
TRAILING CABLE ONTO THE CABLE REEL. ALSO ENSURE
THAT THERE ARE NO OBSTRUCTIONS AROUND THAT THE
CONNECTOR END OF THE AC TRAILING CABLE COULD GET
CAUGHT ON.
13. Cable Reel Override Switch (if equipped) - Toggle and hold the top of this switch
to allow the vehicle’s emergency/park brakes to be released when the CABLE REEL
WIND ALARM indicator light is illuminated. The TRANSMISSION DIRECTION SELECTOR
Switch must be in the Reverse position for the CABLE REEL OVERRIDE switch to be
functional. For more information, see section OM-SS-O2 titled Modes of Operation &
Interlocks of this Operator’s Manual.
Number: OM-SS2-V5
Revision: A
14. Hopper Lowered Indicator Light - This indicator light illuminates if the concrete
pump/hopper is not in the fully raised position. This light also has an accompanying
audible alarm.
15. Emergency Steer Active Indicator Light (if equipped) - This indicator illuminates
when the emergency steer function is active. The ignition switch must be ON and
low hydraulic system pressure detected to activate the emergency steering system.
16. Engine Work Lights Switch - Toggle the top of the switch to illuminate the indicator
17. Deck Work Lights Switch - Toggle the top of the switch to illuminate the indicator
18. Hopper Lowered Warning Audible Alarm - This audible alarm alerts the operator
that the hopper is not in the fully raised position.
19. Cable Reel Warning Audible Alarm (if equipped) - To protect the cable reel from
damage, a switch in the reel measures when the last few wraps of cable is left on
the reel. When approximately three wraps of cable are left on the drum, this warning
alarmturns ON. The alarm is only active in DRIVE mode.
On some vehicles, this may be a BRAKE SYSTEM IMPENDING WARNING
audible alarm. If so, this audible alarms sounds when either the
hydraulic pressure in the brake system, or the transmission drops to
a critical level below which it is unsafe to operate the vehicle. The
light indicates that the emergency/park brakes may apply.
IF THE BRAKE SYSTEM IMPENDING WARNING AUDIBLE
ALARM SOUNDS DURING NORMAL VEHICLE OPERATION, BE
PREPARED FOR AN AUTOMATIC BRAKE APPLICATION.
Notes:

Phone: 1-866-856-3626
Title: PRE-OPERATION INSPECTION
Number: OM-SS2-O1
Revision: Original
SHOTCRETE SPRAYER DAILY PRE-OPERATION MAINTENANCE

This procedure is a guide for mines that do not have a standard
pre-start circle check procedure. FOLLOW MINE SPECIFIC RULES
AND REGULATIONS AT ALL TIMES.
Note that the layout of your vehicle may vary from that shown.
Figure 1 – Daily Pre-Operation Maintenance Diagram
OM-SS2-O1 Page 1 of 22
Number: OM-SS2-O1
Revision: Original
The following is a list of the daily checks required for the Shotcrete Sprayer. Follow
Figure 1 as a reference guide when performing the pre-operation maintenance checks.
DAILY PRE-OPERATION MAINTENANCE PROCEDURES
1. Walk around inspection, general condition of Shotcrete Sprayer. Look for leaks,
loose hardware, damage, etc.
2. Check diesel fuel level, transmission oil pre-start level, automatic lube system
reservoir (if equipped). Fill as required. If no automatic lube system is present,
manually grease the unit at all grease stations and grease points.
3. Inspect tires, wheel assemblies and visually inspect wheel mounting bolts.
4. Inspect engine belts, hoses, air intake, and exhaust system for damage.
5. Visually inspect all controls for damage, leaks, loose, or missing parts, etc.
6. Check engine oil level, engine coolant level and coolant hoses. Fill as required. Look
for and correct leaks.
7. Visually inspect fire suppression system dry chemical tank, lines/hoses, nozzles, and
palm actuators. Ensure actuation bottles are attached and secure.
8. Inspect operator’s compartment or cab for mud or objects that could jam pedals or
cause slips. Inspect the seat belt; grab handles, safety chains and steps (as
equipped). For vehicles equipped with cabs, check windows, doors, seals, mounts,
etc. Inspect the hand-held fire extinguisher. Visually inspect canopy, or cab for
damage (as equipped).
9. Check hydraulic oil reservoir for leaks and proper operating level. If equipped,
inspect the electrically driven hydraulic power pack and all hosing and cables.
10. If equipped, check the air compressor’s oil level and the condition of the
compressor’s air intake filter. Fill and replace as required.
11. If equipped with a cable reel, check the cable reel torque unit’s oil level, fill as
required. Inspect the general condition of the cable reel. If equipped with water and
air supply hose reels, inspect the general condition of each hose reel.
12. Check oil/water level in water box, fill as required. Grease shotcrete pump at
manifold or fill auto lube pump (if equipped). Check all points are receiving grease. If
equipped, inspect the grease drum and grease hose reel.
13. Inspect general condition of accelerant and form oil tanks, hosing and hose reels, as
equipped. Inspect the pressure washer system and all engine end components.
14. Inspect general condition of shotcrete sprayer boom and mount, nozzle,
hosing/piping, and attachments. Lubricate.
Page 2 of 22 OM-SS2-O1
Number: OM-SS2-O1
Revision: Original
15. Ensure frame articulation lock is in the storage location.

16. Ensure that the MAIN BATTERY DISCONNECT switch is in the On position. Start the
engine and check all instrument gauges, engine protection alarm and warning lights,
horn, drive lights, work lights, any warning lights (if equipped), and back-up alarm.
Allow engine to idle and warm-up while monitoring gauges.
17. Perform brake tests as per unit label, test steering controls. Check engine air filter
indicator, check transmission oil level at operating temperature.
18. Ensure that the emergency steering system is functional (if equipped).
19. Test vehicle’s interlocks and control features important to safe vehicle operation.
20. Test all functions including boom and auxiliary controls, shotcrete pump controls,
accelerant controls, etc.
21. Inspect the main AC electrical panel and battery charger (if equipped).
A procedural explanation for each daily pre-operation check follows.
Number: OM-SS2-O1
Revision: Original
DAILY PRE-OPERATION MAINTENANCE PROCEDURES
If the Shotcrete Sprayer or any of its sub-systems are found to

be damaged or non-functional, tag the vehicle out-of-service
immediately and inform the appropriate personnel to correct
the problem. Failure to do so may result in serious injury or
property/equipment damage.
1. Walk around inspection, general condition of Shotcrete Sprayer. Look for

leaks, loose hardware, damage, etc.
Inspect the Shotcrete Sprayer’s general condition and remove any debris that has
collected on it. Be on the alert and look for any flammable materials such as
oil/grease/gas stained rags, or gloves, aerosol cans, etc. If any such items are
found, dispose these items as per local governmental or mine site policies.
Check for leaks, loose or missing fasteners, general damage, and condition of all
windows and the windshield (for cracks), hosing, tanks, and electrical harnesses.
Report any problem to the appropriate personnel.
Check area around the vehicle for any obstacles that might be damaged by, or may
cause damage to the vehicle when it is driven.
2. Check diesel fuel level, transmission oil pre-start level, automatic lube system
reservoir (if equipped). Fill as required. If no automatic lube system is present,
manually grease the unit at all grease stations and grease points.
The diesel fuel level is checked using the sight gauge located on the rear of the
diesel fuel tank. The tank is located on the passenger side of the vehicle, beside the
operator’s compartment. When looking at the sight gauge the fuel level can be seen
by viewing the minimum/maximum level marks. It is recommended to fill the fuel tank
at the beginning of each shift.
If the diesel fuel level is low, fill as required at the manual fill spout, or at the optional
fast fill port (if equipped). Refer to the recommended fluid stated in section
OM-SS-O5 titled Recommended Lubricants &Fluids. Inspect the ground below the
diesel fuel tank and any fuel lines connecting to the engine. No leaks or wetness
must be present. Correct as required. See Figure 2.
Ensure that the manual fill point cap and chain are present and not damaged.
Inspect the fill point for signs of any leaks.
Number: OM-SS2-O1
Revision: Original
If equipped with the fast fill system, inspect the fill point for signs of any leaks or
damage. Ensure that the protective cap and lanyard are present and not damaged
prior to using the fast fill system.
Transmission
Oil Dipstick Auto Lube
Reservoir
Transmission
Oil Fill Point Remote Fill
Grease Point
Diesel Fuel Manual
Diesel Fuel
Fill Point
Fast Fill
Chain Point
Diesel Fuel Lanyard

Maximum Level
Diesel Fuel
Diesel Fuel Tank
Minimum Level
Figure 2– Typical Diesel Fill Location
Check to ensure that there is sufficient oil in the transmission for startup. The
transmission oil level must be rechecked once the vehicle is running and warm.
Visually check the auto lube reservoir, if equipped. Fill as required using the
recommended fluid stated in section OM-SS-O5 titled Recommended Lubricants
&Fluids. Do not remove the lid to fill the reservoir. Use the remote fill grease point to
fill the reservoir so that no contamination enters into the automatic lube system. If no
auto lube system is present, manually grease at the manifolds and grease points
provided. Refer to section OM-SS-O5 titled Recommended Lubricants &Fluids.
Number: OM-SS2-O1
Revision: Original
3. Inspect tires, wheel assemblies and visually inspect wheel mounting bolts.
The Shotcrete Sprayer uses either pneumatic tires, or solid tires. Regardless of the
type, all tires, treads, and sidewalls must be in good condition with no visible
damage such as large pieces of tread missing.
Each wheel rim must be in good condition with no visible damage such as large
dents, or cracks. Mounting fasteners must be in place and properly tightened.
Only qualified personnel with proper tooling must repair
damaged tires and wheels.
The manufacturer’s recommended pressure must never be exceeded (applicable
only to pneumatic tires).
Over inflation of pneumatic tires could result in serious injury
or death. Follow all applicable mine specific rules and
regulations with regards to tire inflation and repair. See
applicable parts manual for proper inflation pressure.
4. Inspect engine belts, hoses, air intake, and exhaust system for damage.
Exhaust components may be HOT! Always use gloves when
checking exhaust.
The engine belts must be free of fraying, nicks, and cuts. Belts must be neither too
tight nor too loose (approximately ½ inch deflection in belt tension is
acceptable).Note that Mercedes engines have auto tensioned belts and if the belt is
loose, contact your maintenance department.
Ensure that the protective engine belt guarding is installed and not damaged.
Examine air filter hoses for leaks, and check all fittings, clamps, and ties carefully.
Ensure that the hoses are not resting on or touching shafts, couplings, heated
surfaces, any sharp edges or other hazardous areas.
Inspect all engine hoses, the air intake system and the exhaust system for damage.
Check exhaust shields and covers for damage and/or missing sections. Check that
the heat-insulating exhaust system material (if equipped) is present and not
damaged. Ensure that the exhaust system is pointing away from the boom control
panel.
Number: OM-SS2-O1
Revision: Original
5. Visually inspect all controls for damage, leaks, loose, or missing parts, etc.
Inspect the driver’s instrument panel (DIP), pedals, main control panel, process
control panel, rear hydraulic controls, remote pendant (if equipped), battery charger
and boom control panel and front hydraulic controls for damage, leaks, loose or
missing parts, loose doors, etc. If any control looks questionable, contact your
maintenance department for repair.
If equipped, inspect the condition of the remote pendant’s power cables for the
possibility of them being punctured, pinched, or kinked. If any of the cables look
questionable, contact your maintenance department for repair.
6. Check engine oil level, engine coolant level and coolant hoses. Fill as
required. Look for and correct leaks.
The engine oil dipstick location is on the operator side of the engine. If the oil is low,
add oil as required. Refer to the recommended fluid stated in section OM-SS-O5
titled Recommended Lubricants & Fluids. The oil fill location is at the top of the engine.
It is covered with a screw style cap. Also, if equipped, a fill spout may be installed
beside the engine oil dipstick. See Figure 3.
Coolant
Engine Oil Fill
Filling Point
Point Access Hole
(Top of shroud)
Sight Gauge
Engine Oil Fill Point Radiator

Expansion
Reservoir
Engine Oil Dipstick
Figure 3 – Typical Engine Oil and Coolant Check and Fill Points
The engine coolant level is checked by viewing the sight gauge. The sight gauge is
located on the radiator expansion reservoir on the operator side of the engine. If the
coolant level is low, add as required at the filling point located on the top of the
radiator expansion reservoir. Refer to the recommended fluid stated in section OM-
SS-O5 titled Recommended Lubricants & Fluids.
Number: OM-SS2-O1
Revision: Original
The engine coolant reservoir may be pressurized. Contact with

pressurized fluids may cause fluid penetration and burn
hazards. Failure to follow the inspection, maintenance and
service instructions may cause personal injury.
Examine coolant hoses for leaks, and check all fittings and clamps carefully. Make
sure that the hoses are not resting on or touching shafts, couplings, heated surfaces,
any sharp edges or other obviously hazardous areas. Inspect the frame and ground
below the engine’s radiator as well as any hoses connecting to the radiator. No
wetness on the hoses or leaks under the engine must be present. Correct as
required.
7. Visually inspect fire suppression system dry chemical tank, lines/hoses,

nozzles and palm actuators. Ensure actuation bottles are attached and secure.
Visually inspect the fire suppression system dry chemical tank for damage.
Inspect the fire suppression system hoses. Ensure that they are connected and in
good condition. Inspect for cracks and wear.
Check that the actuation bottles are present and attached securely. Check that the
palm actuators are installed and in good condition. Ensure that the safety pins and
seals are in place.
Check the fire suppression system nozzles to ensure that they are clean, sealed and
free of damage. For more information, refer to section OM-SS-V2 titled Machine
Safety Items.
8. Inspect operator’s compartment or cab for mud or objects that could jam
pedals or cause slips. Inspect the seat belt; grab handles, safety chains and
steps (as equipped). For vehicles equipped with cabs, check windows, doors,
seals, mounts, etc. Inspect the hand-held fire extinguisher. Visually inspect
canopy, or cab for damage (as equipped).
There must not be anything on the floor of the operator’s compartment that could
possibly restrict the travel of the brake or accelerator pedals, which could potentially
cause an accident. Ensure that the operator’s compartment or cab is clear of any
flammable materials, mud and debris.
The seat belt must be in good condition. Visually inspect the belt material, no fraying
or cuts in the belt material are allowed. Test the latching mechanism for proper
engagement and disengagement. The latching mechanism must function properly.
Check all grab handles and steps to enter/exit the operator’s compartment, or cab.
They must be in good condition, free from oil, dirt and damage. They must be
painted in accordance with site, or local policy.
Number: OM-SS2-O1
Revision: Original
The hand held fire extinguisher located just outside the operator’s compartment
must be fully charged and ready for use in case of an emergency. Some
extinguishers have a sight gauge located on the neck of the extinguisher, which
indicates its charge level, others use charge bottles that use red coloured pop-up
indicators after they are discharged. It is the operator’s responsibility to become
familiar with the fire safety systems present on their specific vehicle.
If the vehicle has a canopy or enclosed cab, visually inspect it for damage. Ensure
that the structure is secure and that the mounting bolts are present and tight. Check
the wipers (and all wiper accessories, if equipped), blower motor (if equipped) for
functionality. Ensure that all controls are functioning properly and that the windshield
washer reservoir is full (if equipped). Fill as required. Check all cab air filters and
replace as required.
Inspect the emergency exit windshield (if equipped) to ensure that the red
emergency exit handle and the seal that secures the windshield in place, is present
and secure. On the inside of the cab, ensure that the seat belt cutter is present and
not damaged. See Figure 4. Refer to the vehicle labeling with regards to the use of
the emergency exit procedure.
Red
Emergency Exit Emergency
Windshield Exit Handle
Red Emergency Exit

Handle Instructions Seal
Seat Belt
Cutter
Figure 4 – Typical Emergency Exit Windshield (if equipped)
Number: OM-SS2-O1
Revision: Original
9. Check hydraulic oil reservoir for leaks and proper operating level. If equipped,
inspect the electrically driven hydraulic power pack and all hosing and cables
Contact with pressurized fluids may cause fluid penetration
and burn hazards to the skin. High pressure fuel or oil spray
may cause a fire hazard. Failure to follow the inspection,
maintenance and service instructions may cause personal
injury, or death.
Always use gloves when handling hoses. Never handle
pressurized lines at any time.
Hydraulic oil level is checked using a sight gauge located on the hydraulic reservoir
(located on front right corner of the rear frame of the unit). When looking at the sight
gauge, the oil level can be seen by viewing minimum/maximum level marks.
If the hydraulic oil level is low, fill as required using the manual pump and crank.
Refer to the recommended fluid stated in section OM-SS-O5 titled Recommended
Lubricants & Fluids, or in the operator’s compartment or cab. See Figure 5. Inspect
the area around the hydraulic tank, hydraulic lines, cylinders, brake lines, etc. No
leaks or wetness must be present. Correct as required.
Hydraulic
Tank
Sight Gauge
Manual Pump
and Crank
Hydraulic Oil
Transfer Hose
Bulk
Hydraulic Oil
Drum
Figure 5 – Typical Manual Fill Crank
Number: OM-SS2-O1
Revision: Original
Inspect the condition of the hydraulic system pressure filters. There are two main
pressure filters located by the diesel fuel tank (not shown), and if equipped with the
power pack, one auxiliary pressure filter located in front of the hydraulic oil Tank
(shown below). Check them by viewing the clear bubble on the top of the filter
housing. As long as the indicator inside the clear bubble is a solid silver circle
outlined in red, the hydraulic filter is good.
Hydraulic
Return Filter Bypass
(Inside Tank) Indicator
Clear Bubble
(On Filter Cooling Fan
Housing)
Auxiliary
Hydraulic
Pressure Filter
(Inside Housing, if Electric
equipped) Motor
Protective
Structure
Hydraulic
Pumps
Figure 6 – Typical Hydraulic Filter Indicators and Power Pack
If equipped, inspect the hydraulic pumps and the electric motor that drives them.
Ensure that all components are clean and that there is nothing around it that could
possibly restrict the cooling fan from operating. See Figure 6.
Check all hoses and fittings going to and from the powerpack. There must not be
any damage, or leaks present. Check the area below the powerpack. No leaks or
wetness must be present.
Check the protective structure that protects the powerpack. Inspect for any signs of
damage, broken, or missing pieces. Report any damage to maintenance personnel
immediately.
Check the wiring to the electric motor for any signs of damage such as melted
wiring, cuts, nicks, or tears.
Number: OM-SS2-O1
Revision: Original
10. If equipped, check the air compressor’s oil level and the condition of the
compressor’s air intake filter. Fill and replace as required.
Check the compressor’s oil level using the sight glass located on the lower right side
of the housing (same side as the air pressure gauge) of the compressor body. If
there is oil present to the top of the sight glass, the level is good. If oil is required fill
as recommended in section OM-SS-O5 titled Recommended Lubricants & Fluids.
Inspect the condition of the compressor air intake filter. Replace as required.
11. If equipped with a cable reel, check the cable reel torque unit’s oil level, fill as
required. Inspect the general condition of the cable reel. If equipped with water
and air supply hose reels, inspect the general condition of each hose reel.
Swing the cable reel out and check the oil level in the cable reel’s torque unit using
the sight glass located on the side of the housing. If there is oil present to the top of
the sight glass, the level is good. See Figure 7. If oil is needed, remove the dipstick
and fill as required referencing section OM-SS-O5 titled Recommended Lubricants &
Fluids. When finished, replace the dipstick. The unit can also be inspected and
maintained according to the maintenance labels on the unit.
Cable Reel
Cable
Reel
(inside)
Dip Stick
Sight
Glass
and Drain
Torque
Unit
Figure 7 – Cable Reel and Torque Unit

Inspect the cable, connections, covers, attachments, etc. for damage, wear, loose or
missing parts. Ensure that the inside and outside of the drum does not have any dirt,
or debris on it that could possibly restrict it from rotating, or that could cause wear, or
damage.
Number: OM-SS2-O1
Revision: Original
If your vehicle is equipped with a water and/or air hose reel, be sure to inspect the
reels for functionality and the hoses for any signs of nicks, cuts and tears. Grease
the hose reels at all grease points. See Figure 8.
Air Hose
Water Hose Reel and
Reel and Air hose
Water Hose
Grease Fittings
Grease Fittings
Water Reel/Air
Reel Control
Valve
(If equipped)
Figure 8 – Typical Water and Air Hose Reel (if equipped)
Number: OM-SS2-O1
Revision: Original
12. Check oil/water level in water box, fill as required. Grease shotcrete pump at
manifold or fill auto lube pump (if equipped). Check all points are receiving
grease. If equipped, inspect the grease drum and grease hose reel.
Remove both covers from the water box and check the oil/water level. Top up as
needed. Refer to section OM-SS-O5 titled Recommended Lubricants & Fluids. Also
check for leaks from the shotcrete pump cylinders at this time (it may only be visible
if water is used). Reinstall covers using caution not to damage the position sensors
or their cables.
Check the shotcrete hopper for debris or hardened concrete. Check condition of
hopper door grating and ensure that there is no concrete build up around the swing
tube.
Grease the shotcrete pump though the grease manifold on the operator (left) side of
the hopper, or top up auto greaser reservoir. If your pump is manually lubricated also
grease the pump several times per shift as a minimum. If your pump is automatically
lubricated check that all lube points are receiving grease. Fill as required using the
recommended fluid stated in section OM-SS-O5 titled Recommended Lubricants &
Fluids. Your particular vehicle may be equipped with a bulk grease drum operated
by mine air supply accompanied by a grease hose reel and grease trigger nozzle
used to lubricate the vehicle. See below.
It is very important that the shotcrete pump is well lubricated to

prevent premature failure of the pump components.
When changing the bulk grease drum, ensure that cleanliness is observed. No water
or other contaminants must enter the drum. Check the bulk grease drum to ensure
that it contains a sufficient amount of grease. Replace grease drum as required.
Inspect grease hose reel, nozzle fittings and grease pump for leaks and/or damage.
If any leaks or damage are found, immediately contact the appropriate maintenance
personnel. Inspect all quick disconnect fittings to ensure that they are in good
condition.
At the air filter/regulator/lubricator (FRL) assembly, drain the water from the air filter
bowl by loosening the air filter drain at the bottom of the air filter bowl. Check the
general condition of the air filter assembly, attached hosing and air pressure gauge.
See Figure 9.
Number: OM-SS2-O1
Revision: Original
Check the lubricator oil level. This is done by viewing the oil level sight glass located
on the side of the lubricator bowl. If the oil level is low, fill as required following the
recommended fluid stated in section OM-SS-O5 titled Recommended Lubricants &
Fluids. The lubricator bowl is filled by removing the filler plug located on either side
of the drip rate sight glass. The lubricator oil drip rate can be seen by viewing the
drip rate sight glass on top of the lubricator during operation. The drip rate can be
adjusted by turning the lubricator adjustment knob clockwise, or counter-clockwise.
Air Pressure Lubricator

Gauge Adjustment Knob
Air Filter Drip Rate Sight

Glass
Sight Glass Filler Plug

(1 of 2)
Air Filter Drain

Oil Level Sight
Glass
Figure 9 – FRL Assembly
13. Inspect general condition of accelerant and form oil tanks, hosing and hose
reels, as equipped. Inspect the pressure washer system and all engine end
components.
Accelerant is a corrosive product. It can cause severe burns if
it contacts skin or other body parts. Read and Understand the
product Material Safety Data Sheet for the product you are
using. Always wear appropriate Personal Protective
Equipment when handling accelerant.
Visually inspect the accelerant tank for damage, leaks, cracks and missing parts.
Check the inside of the tank for excessive foreign material or crystallized accelerant.
Fill the accelerant tank with the projected amount of product required for the job.
Number: OM-SS2-O1
Revision: Original
Check the accelerant pump and associated hosing and piping for damage, wear,
leaks and crystallized accelerant. If required, contact the appropriate personnel for
repairs. Check the oil level in the accelerant pump (if equipped) by viewing the level
through the clear window at the front of the unit. See Figure 10. If oil is required, fill
as required at the oil fill point by using the recommended fluid as stated in section
OM-SS-O5 titled Recommended Lubricants & Fluids.
Accelerant
Pump
Accelerant Pump Oil

Fill Point
Accelerant Pump Oil

Level Check Point
(front of unit)
Figure 10 – Typical Accelerant Pump Oil Level Check Location
Visually inspect the form oil tank, pump, hosing, hose reel and wand for damage,
leaks, cracks, etc. Top up the form oil level if required. Inspect the pressure washer
pump, hosing, reel and wand for proper oil level, damage, leaks, etc. The oil level in
the pressure washer pump must be inside the red bullseye on the sight glass on the
base of the pump.
Inspect the pressure washer pump, water scaler pump (if equipped), hosing, reel
and wand for damage, leaks, etc. Inspect all hoses for damage such as cuts, nicks,
or pieces missing. Check all fittings and connection points for damage and possibly
loose fittings. See Figure 11.
Number: OM-SS2-O1
Revision: Original
Check all ball valve handles for functionality and to ensure that nothing is in the way
that could prevent them from opening and closing.
Pressure
Washer Pump
Water Scaler
Pump Water
(if equipped) Supply/Drain
Ball Valve
Handle
Figure 11 – Typical Pressure Washer and Form Oil Systems
14. Inspect general condition of shotcrete sprayer boom and mount, nozzle,
hosing/piping, and attachments. Lubricate.
Inspect the boom, all valves, cylinders, ride control system, nozzle, hosing, piping,
covers, attachments, etc. for damage, wear, leaks, loose or missing parts. Ensure
that the boom does not have any excessive buildup of material on it that could cause
wear or damage. Ensure that the nozzle and water scaler nozzles (if equipped) are
free from wear and that they are not plugged.
The working pressures and volumes of the shotcrete system
are high. Always make sure your hose clamps are adjusted
properly and have a safety pin or equivalent installed before
attempting to pump any material through the system. Failure
to check the clamp and install safety pins could result in
serious injury or death as well as equipment and property
damage.
Check each hose/pipe section to ensure that the safety pin is installed into the
adjustable quick-latch clamp. These safety pins prevent the clamp(s) from opening
during operation. Inspect the quick-latch clamps for signs of wear or damage. If any
wear or damage is found, do not attempt to operate the shotcrete sprayer system.
Report any problem to the appropriate personnel. For more information, refer to
section OM-SS-V2 titled Machine Safety Items.
Lubricate the rack and pinion and main connection pin. Refer to section OM-SS-O5
titled Recommended Lubricants & Fluids.
If any repairs are required contact the appropriate personnel.
Number: OM-SS2-O1
Revision: Original
Any maintenance work that is required in the boom area must

be done with the boom in the lowered position whenever
possible. If work is to be done under the boom in the “raised”
position, the boom must be properly secured or blocked into
position to prevent the boom from lowering.
15. Ensure frame articulation lock is in the storage location.

If installed, remove the articulation lock bar and securely place it in the storage
position located on the frame behind the articulation area. If the bar is already
stored, verify that it is secure.
Refer to section OM-SS-V2 titled Machine Safety Items.
16. Ensure that the MAIN BATTERY DISCONNECT switch is in the On position. Start the
engine and check all instrument gauges, engine protection alarm and warning
lights, horn, drive lights, work lights, any warning lights (if equipped), and
back-up alarm. Allow engine to idle and warm-up while monitoring gauges.
When starting the engine, ensure that the emergency/park brake
is engaged by pressing the EMERGENCY/PARK BRAKE button and the
TRANSMISSION DIRECTION selector switch is in the Neutral (N)
position. If either of these conditions is not met, the engine does
not crank.
With the engine running, and the Shotcrete Sprayer in DRIVE
mode, the steering controls are active. A pinch point exists at
the Shotcrete Sprayer’s articulation point. Ensure that the
articulation area is clear before starting the vehicle.
Number: OM-SS2-O1
Revision: Original
While the engine is running monitor all gauges, warning indicators and alarm
indicators. View the electronic display (Figure 12) to verify that the engine RPM, oil
pressure, coolant temperature and battery voltage are within their normal operating
ranges. For normal operating ranges, refer to section OM-UTV-O3-MERC titled
Carrier Operation.
Figure 12 – Typical Electronic Display

If any gauge is out of normal operating range or a warning indicator, or alarm indictor
is activated, shut down the vehicle and contact maintenance personnel immediately.
With the engine running and the emergency/park brake applied, activate the warning
light(s) (if equipped), drive lights, and work lights switches. Walk around the vehicle
to visually determine that each light is working.
With the engine running and the emergency/park brake applied, place the
TRANSMISSION DIRECTION selector switch into the Reverse (R) position. A loud
audible alarm must be immediately heard. On some vehicles, the deck drive lights
automatically turn ON as well when Reverse is selected. Put the TRANSMISSION
DIRECTION selector switch into the Neutral position and the audible alarm must stop
and if equipped, the deck drive lights turn OFF.
With the engine running, visually inspect the exhaust mounting, intake and exhaust
ducting and connections for leaks. Check for unusual noise or vibration. If the noise
or vibration is excessive, stop the engine and do not operate until the cause is
determined.
Ensure that all gauges and indicators are within normal working limits.
Use care, the exhaust system may be extremely hot!
When performing pre-operation inspections on a running

vehicle, do not place yourself in a position where any body
parts, or clothing could become caught in moving parts.
Number: OM-SS2-O1
Revision: Original
With the engine running, activate a hydraulic function and inspect the condition of
the hydraulic return filter inside the hydraulic tank. This is done by viewing the
bypass indicator on top of the hydraulic tank. As long as the needle is pointing
towards the green area, the filter inside the tank is good. See Figure 6.
17. Perform brake tests as per unit label, test steering controls. Check engine air
filter indicator, check transmission oil level at operating temperature.Perform
the operator’s daily brake test. Refer to section OM-UTV-O4 titled Brake Test
Procedure. If the vehicle fails any part of the brake test, tag the vehicle down
immediately and notify the appropriate personnel.
A pinch point exists at the Shotcrete Sprayer’s articulation.
Ensure that the articulation is clear before testing the steering.
With the engine running and the TRANSMISSION DIRECTION selector switch in the
Neutral position, test that the articulation responds properly to steer stick input. Do
not over steer the vehicle during this test unless the park brakes are released. The
wheels do not turn but drag.
With the engine running and the TRANSMISSION DIRECTION selector switch in the
Neutral position, inspect the air cleaner restriction indicator. If the air cleaner
restriction indicator is in the red area, notify the maintenance department or replace
the outer air filter element only.
With the engine running, the TRANSMISSION DIRECTION selector switch in the Neutral
position and the emergency/park brakes applied, inspect the transmission fluid level
using the transmission dipstick. The dipstick is located beside the toolbox above the
diesel fuel tank. The transmission fill point is located beneath the dipstick. See
Figure 2.
For an accurate reading, the transmission must be at the required operating
temperature.
If the transmission fluid is low, fill as required using the recommended fluid stated in
section OM-SS-O5 titled Recommended Lubricants & Fluids.
18. Ensure that the emergency steering system is functional (if equipped).
With the engine running, check the emergency steer accumulator pressure gauge,
located above the access panel to the transmission. Ensure that the accumulator is
charged to within operational parameters (2400 – 2900 psi).
19. Test vehicle’s interlocks and control features important to safe vehicle
operation.
Refer to section OM-SS-O2 titled Modes of Operation & Interlocks and section
OM-SS-V2 titled Machine Safety Items.
Number: OM-SS2-O1
Revision: Original
20. Test all functions including boom and auxiliary controls, shotcrete pump
controls, accelerant controls, etc.
If any problems, damage or wear is found during the pre-
operation inspection, notify maintenance personnel
immediately. Failure to repair problems, damage or wear may
result in equipment damage and/or personal injury.
When rewinding the hoses the nozzle / hose end must be
walked back to the unit. If allowed to rewind unattended,
personal injury or damage to equipment could occur.
Ensure the hose does not twist, kink or get caught during the
hose retract process. If any problems do occur, stop the hose
reel immediately and correct the issue.
With the vehicle running, check for the proper operation of all controls, including
boom functions both manual and remote, shotcrete process controls for the
shotcrete pump and accelerant pump, and all auxiliary functions such as the
outriggers and form oil pump.
Refer to section OM-SS2-V5 titled System Layout & Auxiliary Controls for proper
operation of the controls. If any function or control fails to work as intended or
designed, tag the vehicle down immediately and contact the appropriate personnel
for repair.
21. Inspect the main AC electrical panel and battery charger (if equipped).
Inspect the main AC electrical panel and battery charger’s general condition. All
instrument gauges, indicator lights and buttons must be free of damage. The panel
doors must be fastened closed.
High Voltage! Do not open electrical panels unless qualified to
do so.
Inspect the main AC electrical panel’s general condition. All instrument gauges,
indicator lights and buttons must be free of damage. All electrical enclosures must
be closed and sealed. If any electrical panel is not closed and sealed properly,
corrosion to the electrical panel components and wiring occurs. This eventually
leads to vehicle malfunction.
Check the filters on the bottom of the battery charger to ensure that they are clean
and not clogged.
Ensure that the vehicle is connected to the mine power supply. Turn the main AC
electrical panel’s MAIN AC POWER BREAKER switch and the vehicle’s MAIN BATTERY
DISCONNECT switch to the ON position.
Number: OM-SS2-O1
Revision: Original
At the main AC electrical panel, press and hold the GROUND FAULT TEST pushbutton.
AC power to the vehicle must be shut OFF (can be seen on the voltage meter on the
main AC electrical panel). Release the GROUND FAULT TEST pushbutton and reset
the main voltage. Start the powerpack. With the powerpack running, test the
EMERGENCY STOP button on the main AC electrical panel. When the EMERGENCY
STOP button is pushed, the powerpack must stop. With the powerpack stopped and
the EMERGENCY STOP button still engaged, attempt to restart the power-pack. The
powerpack must not restart.
With the diesel engine running, test the EMERGENCY STOP button on the main AC
electrical panel. When the EMERGENCY STOP button is pushed, the 24VDC control
system power is interrupted and the diesel engine shuts down. With the 24VDC
control system power interrupted and the EMERGENCY STOP button still engaged,
attempt to restart the diesel engine. The diesel engine must not start.
Testing of the remote transmitter and all EMERGENCY STOP buttons must be
completed as part of the radio transmitter and station functional testing.
Notes:

Phone: 1-866-856-3626
Title: MODES OF OPERATION & INTERLOCKS
Number: OM-SS-O2
Revision: B
Written By: JanPaul Brenner Revised By: JanPaul Brenner
Checked By: René Dubois Checked By: Craig Marchand
Approved By: Bill Tytaneck Approved By: Bruce Mackereth
MODES OF OPERATION
The Shotcrete Sprayer has two main modes of operation, DRIVE mode and AUXILIARY
mode.
• DRIVE mode is used to drive the vehicle. Steering, braking and cable reel
functions are available in this mode.
On some vehicles, when in DRIVE mode, the boom lift and boom
swing functions are used to manipulate the boom from the driver’s
instrument panel (DIP). This allows the driver to maneuver the
vehicle more effectively in tight areas. During tramming, it is
recommended that the boom be in the horizontal position.
• AUXILIARY mode is used to perform shotcrete spraying operations, or operate
auxiliary functions such as the main AC electrical panel functions, pressure
washer pump, outriggers and rear cable reel control.
Main mode selection is achieved by the following:
DRIVE Mode
• The EMERGENCY/PARK BRAKE switch is in the Applied (down) position.
• The TRANSMISSION DIRECTION selector switch is in the Neutral (N) position.
• Toggle the bottom of the DRIVE/AUXILIARY MODE switch.
AUXILIARY Mode
• The EMERGENCY/PARK BRAKE switch is in the Applied (down) position.
• The TRANSMISSION DIRECTION selector switch is in the Neutral (N) position.
• Toggle the top of the DRIVE/AUXILIARY MODE switch.
OM-SS-O2 Page 1 of 8
Number: OM-SS-O2
Revision: B
There are two sub-modes available while operating in AUXILIARY mode, MANUAL
mode and REMOTE mode.
• MANUAL mode: This sub-mode allows the operator to manually control
functions such as the outriggers, the boom from the control valves located in the
front control stand, form oil pump, pressure washer pump as well as start/stop
the shotcrete and accelerant pumps from the panels. No functions on the remote
pendant are available in this mode.
• REMOTE mode: This mode allows the operator to control boom functions from
the remote. In this mode many functions cannot be operated from their manual
controls. Other controls may also be locked out such as the ability to start the
shotcrete pump from the control panels. The shotcrete pump and accelerant
pump can be started and stopped from the remote in this mode. Refer to section
titled Shotcrete Sprayer Components for the operation of controls.
These sub-modes, if equipped, are selected using the REMOTE MODE/MANUAL MODE
switch located on the process control panel and/or the boom control panel.
Some vehicles use a MODE MANUAL/REMOTE selector switch on the
boom control panel only.
Page 2 of 8 OM-SS-O2
Number: OM-SS-O2
Revision: B
INTERLOCKS
The Shotcrete Sprayer has the following interlocks built into it. These interlocks are
designed to protect the operator and the equipment and therefore, there must never be
an attempt to defeat them.
Automatic Brake Application (ABA) Interlock - The vehicle’s braking system is
designed in such a way that the vehicle’s emergency/park brakes are applied in the
event of low hydraulic system accumulator pressure, low transmission pressure, or if
there is a loss of electrical power. Optionally, an engine oil pressure interlock for the
ABA may also be installed on your vehicle.
Drive/Auxiliary Mode Interlock – This interlock is used to disable all DRIVE mode
functions while operating the vehicle in AUXILIARY mode, or to disable all AUXILIARY
mode functions while operating the vehicle in DRIVE mode.
Manual/Remote Mode Interlock (if equipped) - This interlock is used to disable all
MANUAL mode functions while operating the vehicle in REMOTE mode or to disable all
REMOTE mode functions while operating the vehicle in MANUAL mode.
Engine Crank Interlock – To prevent unexpected machine movement when starting
the engine, the engine crank circuit is interlocked to the EMERGENCY/PARK BRAKE button
and TRANSMISSION DIRECTION selector switch. In order for the engine to crank, the
EMERGENCY/PARK BRAKE button must be in the Applied (fully down) position and the
TRANSMISSION DIRECTION selector switch must be in the Neutral (N) position. Once the
engine is running, the engine’s crank circuit is disabled. This prevents inadvertent
engagement of the engine’s starter which prevents damage to the engine and/or starter.
Engine Protection Interlock (Mercedes equipped) - The engine protection system
consists of three protection levels predetermined by the customer - indication only,
throttle limitation, or shutdown. The system can be programmed so that if a critical fault
occurs for one of the following parameters, the engine shuts down. For another
parameter, a warning only occurs. Refer to the vehicle labeling for the engine protection
system installed on your particular vehicle.
These parameters are as follows:
• High coolant temperature.
• Low coolant level.
• Low engine oil pressure.
• Indication Only – If a fault occurs and the vehicle’s engine protection system is
programmed for an indication only, the WARNING indicator light and/or ALARM
indicator light illuminate. The horn may sound as well depending on the seriousness
of the fault.
Number: OM-SS-O2
Revision: B
• Throttle Limitation – If a fault occurs and the vehicle’s engine protection system is
programmed for throttle limitation, the engine’s throttle is limited to a pre-
programmed setting. This occurs after the warning condition threshold is exceeded
for an extended period of time.
• Shutdown – If a fault occurs and the vehicle’s engine protection system is
programmed for shutdown, the W ARNING indicator light and/or ALARM indicator light
illuminates and the horn sounds. A shutdown timer starts counting down for a
predetermined length of time.
These times are:
• 30 seconds for low engine oil pressure.
• 60 seconds for high coolant temperature.
When 20 seconds are left on the timer, the W ARNING indicator light begins to
flash before the engine shuts down.
When 10 seconds are left on the timer, the ALARM indicator light begins to flash
and the horn sounds before the engine shuts down.
Transmission Neutralizer Interlock - When the vehicle is placed in AUXILIARY mode,
the transmission does not shift into Forward, Reverse, First, Second, or if equipped,
Third gear. This provides a safety mechanism preventing the vehicle from moving
unexpectedly in AUXILIARY mode.
Fast Idle Interlock – In order for the fast idle function to be used, the vehicle must be
placed into AUXILIARY mode.
Drive Lights Interlock (if equipped) – When the vehicle is placed into AUXILIARY
mode, the driving/tramming lights do not turn ON. Even when the light switches are ON
and the indicator lights within these switches are illuminated. This prevents extra load
on the 24V DC electrical system when plugged into mine power.
Cable Reel Last Wind Interlock (if equipped)
THE OPERATOR MUST ENSURE THAT THE TRAMMING
DIRECTION IS TOWARDS THE AC TRAILING CABLE. THE
OPERATOR MUST BE ABLE TO REEL IN SOME OF THE AC
TRAILING CABLE WHILE TRAMMING IN THIS DIRECTION
OTHERWISE DAMAGE TO THE AC TRAILING CABLE, THE
CABLE REEL, OR ELECTRICAL SUB-STATION COULD
OCCUR. THE OPERATOR MUST DRIVE SLOWLY AND
ENSURE THAT THE AC TRAILING CABLE IS NOT RUN OVER.
Depending upon customer requirements, the tramming direction may
be interlocked to the Reverse direction only.
Number: OM-SS-O2
Revision: B
To prevent damage to the cable reel, AC trailing cable and ground fault panel, the cable
reel is interlocked with the brake system and transmission directional control. This
interlock automatically applies the emergency/park brakes and prevents them from
releasing when a minimum amount of AC trailing cable is left on the cable reel.
When three or less wraps of trailing cable are left on the cable reel:
• the last wind interlock illuminates the CABLE REEL (LAST) W IND W ARNING indicator
light located on the driver’s instrument panel, or application junction box.
• an audible alarm sounds (if equipped).
When one layer of trailing cable is left on the cable reel:
• the last wind interlock illuminates the CABLE REEL (LAST) W IND ALARM indicator
light located on the driver’s instrument panel, or application junction box.
• the emergency/park brakes automatically apply.
To deactivate this interlock:
1. The DRIVE/AUXILIARY MODE switch located on the driver’s instrument panel must
be toggled to DRIVE.
2. The only direction that can be activated by using the TRANSMISSION DIRECTION
selector switch located on the driver’s instrument panel, is the direction that
allows the vehicle to be trammed towards the trailing cable.
3. The CABLE REEL (INTERLOCK) OVERRIDE switch located on the driver’s instrument
panel, or application junction box must be pressed and held.
4. Release the emergency/park brakes by using the EMERGENCY/PARK BRAKE switch
located on the driver’s instrument panel.
5. Slowly tram the vehicle while pressing the CABLE REEL IN switch located on the
driver’s instrument panel, or application junction box to wind enough trailing cable
onto the cable reel until this interlock is deactivated.
At any time the CABLE REEL (INTERLOCK) OVERRIDE switch is released
and the CABLE REEL (LAST) WIND ALARM indicator light is still
illuminated, the emergency/park brakes are automatically applied.
6. Release the CABLE REEL (INTERLOCK) OVERRIDE and CABLE REEL IN switches once
the CABLE REEL (LAST) WIND ALARM indicator light turns OFF.
Hydraulic Level/Temperature Interlock (if equipped) - To protect the vehicle from
either a low hydraulic oil level condition, or a high hydraulic oil temperature condition,
this interlock prevents the vehicle from operating on either diesel AUXILIARY mode or
optionally, electric power. When the conditions are corrected, the vehicle is able to
operate.
Number: OM-SS-O2
Revision: B
Hopper Grate Interlock - If the hopper grate latch pin is in the OPEN or OUT position,
all shotcrete pumping functions are stopped. If the hopper grate is opened (up), the
latch pin cannot be placed in the CLOSED, or IN position.
THE HOPPER GRATE INTERLOCK IS INTENDED AS A
MINIMAL SAFETY DEVICE TO PREVENT MACHINE
MOVEMENT IF THE HOPPER GRATE IS OPENED. DO NOT
DEPEND ON THE HOPPER GRATE INTERLOCK FOR
SERVICING INSIDE THE HOPPER OR THE PUMP. ALWAYS
LOCK AND TAG THE VEHICLE ACCORDING TO LOCAL
REGULATION AND SITE POLICY BEFORE PERFORMING
SERVICE WORK INSIDE THE HOPPER OR ON THE PUMP.
Accelerator Pump/Water Enable Interlock - While operating the vehicle manually, or

using the remote pendant (if equipped), this interlock prevents the accelerator pump
and water flow enable from being turned on at the same time.
Air Compressor Interlock (if equipped) - To protect the air compressor from a low
compressor oil level condition, a high compressor oil temperature condition, or a high air
compressor motor temperature, this interlock prevents the air compressor from
operating. When the conditions are corrected, the air compressor is able to operate.
Electrically Driven Hydraulic Power Pack Interlock (if equipped) - To protect the
power pack from either a low hydraulic oil level condition or a high hydraulic oil
temperature condition, this interlock prevents the power pack from operating. When the
conditions are corrected, the power pack is able to operate.
Voltage Trip Interlock (if equipped) – To protect the power pack, air compressor and
water pump motor from either a high or low voltage condition at the main AC electrical
panel, this interlock prevents the power pack, air compressor and water pump from
operating. When the conditions are corrected, the power pack, air compressor and
water pump are able to operate.
Water Scaler Pressure OK Interlock (if equipped) – This interlock is used to enable
the priming pump sequence for the water scaler pump. It also prevents the main electric
pump from operating if the water scaler pump outlet pressure is not sufficient.
Cab Door Open Water Scaler Pump Interlock (if equipped) – This interlock prevents
the water scaler pump from operating if a door on the enclosed cab is open.
Cab Door Open Shotcrete Pump Interlock (if equipped) – This interlock prevents the
shotcrete pump from operating if a door on the enclosed cab is open.
Water Scaler Motor ON Interlock (if equipped) – This interlock prevents the water
scaler motor from operating if the water level in the water tank is too low.
Number: OM-SS-O2
Revision: B
Fly Rock Guard Interlock (if equipped) – This interlock prevents the water scaler from
operating if the fly rock guard is not in its upright position.
Operator Present Water Scaler Interlock (if equipped) – This interlock prevents the
water scaler from operating if the operator is not present in the operator’s seat.
Operator Present Brake Interlock (if equipped) – This interlock prevents the
emergency/park brakes from releasing if the operator is not present in the operator’s
seat and if equipped, seat belt engaged. The emergency/park brakes also re-apply if the
operator leaves their seat.
Horn/Drive Lights Interlock (if equipped) – This allows the operator to toggle the
HORN ON switch to flash the drive lights to warn oncoming traffic both visually and
audibly simultaneously.
Outriggers Down Brake Interlock (if equipped) – The LEFT ENGINE OUTRIGGER and
RIGHT ENGINE OUTRIGGER switches on the driver’s instrument panel (DIP), or application
junction box (APP JB) each contain a red indicator light. They illuminate as the
outrigger(s) are lowered from the fully raised tramming position. If any one of the
indicator lights illuminate, the emergency/park brakes cannot be released. This interlock
prevents the operator from driving the vehicle with the outrigger(s) lowered, causing
possible damage to the outriggers, or the vehicle.
Outriggers Up Boom Enable Interlock (if equipped) – The BOOM ENABLE switch on
the driver’s instrument panel (DIP), or application junction box (APP JB) contains a
green indicator light. In AUXILIARY mode it illuminates when both of the engine end
outriggers are in the lowered position and on the ground. If either of the outriggers are
raised, the indicator turns OFF and the boom is disabled. In DRIVE mode it illuminates
when the BOOM ENABLE switch is pressed and held. This interlock prevents the operator
from operating the boom in AUXILIARY mode without the outriggers on the ground to
stabilize the vehicle.
Boom Extend/Retract in Drive Mode Interlock (if equipped) – This interlock allows
the boom to be extended and retracted in DRIVE mode only under the following
conditions:
• The BOOM ENABLE switch must be activated.
• The transmission must be in neutral.
• The emergency/park brakes applied.
Number: OM-SS-O2
Revision: B
Shotcrete Pump Blockage Interlock (if equipped) – This interlock prevents the
shotcrete pump from operating if the shotcrete pump detects a high pressure condition.
While paused, the shotcrete pump attempts to fix the problem by cycling in reverse a
couple of times.
Once a blockage is detected and completes its cycle:
a. Shut the shotcrete pump OFF.
b. Turn the shotcrete pump ON (at the process control panel) while
simultaneously pressing the SHOTCRETE PUMP PRESSURE TEST button.
c. Repeat Steps a and b once more if required.
d. If the problem persists, find and correct the blockage in the shotcrete hose
following proper mine procedure.
Heating/Air Conditioning Interlock (if equipped) – In order for the heating/AC blower
motors and windshield fan to operate, the vehicle’s engine oil pressure must remain at a
normal operating pressure. If the oil pressure drops below the threshold, the blower
motors and fan do not operate.
Auto Lance Interlock (if equipped) – This interlock prevents the auto lance option
from automatically starting if the AUTO LANCE SPEED switch on the boom control panel
(in AUXILIARY/MANUAL mode), or remote pendant (in AUXILIARY/REMOTE mode) is
not in the OFF position and one of the following occurs:
• Switching back and forth between AUXILIARY/MANUAL and AUXILIARY /
REMOTE modes.
• Switching back and forth between diesel and electrical power in either
AUXILIARY/MANUAL mode, or AUXILIARY/REMOTE mode.
BEFORE ACTIVATING THE AUTO LANCE OPTION, ENSURE
THAT ALL PERSONNEL ARE CLEAR OF THE AUTO LANCE
BOOM.
To activate the auto lance option after a mode, or operating power change, the AUTO
LANCE SPEED switch on the boom control panel, or remote pendant must be turned to
the OFF position and then to either the SLOW , or FAST position.

Phone: 1-866-856-3626
Title: CARRIER OPERATION
Number: OM-UTV-O3-MERC
Revision: D
Written By: JanPaul Brenner Revised By: Jeff Smith
Checked By: Joe Agombar Checked By: Craig Marchand
Approved By: Darren Bowins Approved By: René Dubois
STARTING PROCEDURE
This vehicle may be equipped with a cold weather package. If this is
the case, be sure to disconnect all mine powered heaters that maybe
equipped on your vehicle before tramming. For more information on
these devices, see the Engine Maintenance Bulletin.
The following procedure is a guide for mines that do not have a standard starting
procedure. FOLLOW MINE SPECIFIC RULES AT ALL TIMES.
1. Perform your daily pre-operational inspection as outlined in section titled Pre-
Operation Inspection.
2. Turn the MAIN BATTERY DISCONNECT switch to the ON position.
3. If equipped, turn the STARTER ISOLATOR switch to the ON position.
4. Verify that all EMERGENCY STOP buttons are reset (pulled out) (if equipped).
5. Ensure that the EMERGENCY/PARK BRAKE switch is in the Applied (down) position.
6. Ensure that the TRANSMISSION DIRECTION selector switch is in the Neutral (N)
position.
7. Ensure that the DRIVE/AUXILIARY MODE switch is in DRIVE mode.
ENSURE THAT THE VEHICLE’S ARTICULATION AREA
REMAINS CLEAR AT ALL TIMES. FAILURE TO COMPLY MAY
RESULT IN EQUIPMENT AND/OR PROPERTY DAMAGE,
SERIOUS INJURY, OR DEATH.
8. Turn the IGNITION switch to the ON position.
The following occurs:
• The horn sounds for approximately 5 seconds.
The HORN BYPASS switch can be pressed and held to silence the horn
during starting.
• The IGNITION ON indicator light illuminates.
• The ENGINE PROTECTION ALARM and W ARNING indicator lights illuminate for 5
seconds.
• Once the ENGINE PROTECTION ALARM indicator light goes out, the horn is
silenced.
OM-UTV-O3-MERC Page 1 of 22
Revision: D
IF THE ENGINE PROTECTION ALARM AND WARNING

INDICATOR LIGHTS REMAIN ILLUMINATED AFTER THE
INITIAL 5 SECONDS, DO NOT ATTEMPT TO START THE
ENGINE. CONTACT MAINTENANCE PERSONNEL.
• The BRAKE SYSTEM APPLIED and IMPENDING indicator lights illuminate. Once
transmission and brake accumulator pressure build to their normal operating
pressures, the BRAKE SYSTEM IMPENDING indicator light goes out. The BRAKE
SYSTEM APPLIED indicator light remains illuminated as the emergency/park
brakes are still applied at this point.
• The W AIT TO START Indicator light on the ENGINE START switch illuminates.
This indicates that the engine’s pre-heat system is active. Once the pre-heat
system is finished, the WAIT TO START Indicator light goes OUT.
IF THE WAIT TO START INDICATOR LIGHT BEGINS TO FLASH
AT ANY TIME, DO NOT ATTEMPT TO START THE ENGINE.
CONTACT MAINTENANCE PERSONNEL.
9. If your vehicle is equipped with a high altitude kit, you must hear the hydraulic tank
compressor run. Wait until the pressure gauge on top of the hydraulic tank shows at
least 5 PSI BEFORE cranking the engine. This prevents the hydraulic pump from
cavitating. See Figure 1.
IF YOU DO NOT LET PRESSURE BUILD IN THE HYDRAULIC
TANK BEFORE STARTING THE VEHICLE, SEVERE DAMAGE
TO THE HYDRAULIC PUMP AND OTHER COMPONENTS OF
THE UNIT OCCURS. A LOW HYDRAULIC TANK PRESSURE
DOES NOT PREVENT THE ENGINE FROM CRANKING.
Figure 1 - Hydraulic Tank Pressure Regulator and Gauge

10. If the engine is not started after several minutes of the IGNITION switch being turned
ON, sound the horn to warn personnel nearby that the engine is about to start.
Page 2 of 22 OM-UTV-O3-MERC
Revision: D
11. Once the W AIT TO START Indicator light on the ENGINE START switch goes OUT, push
and hold the ENGINE START switch. The engine’s starter engages.
WAIT UNTIL THE WAIT TO START INDICATOR LIGHT GOES
OUT BEFORE STARTING THE ENGINE.
12. If the engine does not start, wait one minute and try again.
DO NOT ENGAGE THE STARTER FOR MORE THAN TWENTY
SECONDS AT A TIME AND WAITING ONE MINUTE BETWEEN
ATTEMPTS TO PREVENT DAMAGE TO THE ENGINE’S
STARTER.
Some engine starters are equipped with overheat protection devices
that automatically prevent starter over cranking and overheating.
Regardless, it is still recommended that you follow the above
procedure to prevent damage to the engine’s starter.
13. If the engine does not start after the second attempt, notify the maintenance
department.
IF THE ENGINE PROTECTION ALARM AND WARNING
INDICATOR LIGHTS ILLUMINATE AFTER THE ENGINE IS
STARTED, SHUT THE ENGINE OFF AND CONTACT
MAINTENANCE PERSONNEL TO CORRECT THE PROBLEM.
FAILURE TO CORRECT THE PROBLEM MAY RESULT IN
SERIOUS DAMAGE TO THE VEHICLE.
IF THE TRANSMISSION AND BRAKE ACCUMULATOR
NORMAL OPERATING PRESSURES ARE REACHED, BUT THE
BRAKE SYSTEM IMPENDING INDICATOR LIGHT DOES NOT
GO OUT, SHUT THE ENGINE OFF AND CONTACT
IF THE HORN BEGINS TO SOUND AFTER THE ENGINE IS
STARTED, SHUT THE ENGINE OFF AND CONTACT
FAILURE TO CORRECT THE PROBLEM MAY RESULT IN
SERIOUS DAMAGE TO THE VEHICLE.
Revision: D
IF THE WAIT TO START INDICATOR LIGHT BEGINS TO FLASH

AFTER THE ENGINE IS STARTED, SHUT THE ENGINE OFF
AND TURN OFF THE MAIN BATTERY DISCONNECT SWITCH. A
FLASHING WAIT TO START INDICATOR LIGHT INDICATES A
MALFUNCTION OF THE ENGINE’S PRE-HEAT SYSTEM.
CONTACT MAINTENANCE PERSONNEL TO CORRECT THE
PROBLEM. FAILURE TO CORRECT THE PROBLEM MAY
RESULT IN SERIOUS DAMAGE TO THE VEHICLE.
14. Once the engine starts, release the ENGINE START switch.
15. Allow the engine to idle until the normal operating temperatures and pressures are
reached. Depending upon temperature and climate, this may take several minutes.
Verify the values by referring to the Normal Operating Ranges section below.
16. Continue your daily pre-operational inspection as outlined in section titled Pre-
Operation Inspection.
Cold starting aids are required for starting the engine at
temperatures below -12°C. Contact maintenance personnel if the
engine must be started at temperatures below -12°C (Refer to the
applicable engine manual for acceptable starting aids and
procedures).
Revision: D
DRIVING THE VEHICLE

Once all gauges are checked and are within normal operating ranges, (see Normal
Operating Ranges listed below), and the vehicle is checked for any possible leaks that
may be present with the vehicle running, and if required the leaks are repaired, the
vehicle is ready to operate. If you have not operated this vehicle before, select an open
area where you can safely operate the vehicle to become familiar with the vehicles
operation.
ONLY OPERATE THE VEHICLE IF PROPERLY TRAINED, OR
UNDER THE SUPERVISION OF A QUALIFIED TRAINER.
Before operating the vehicle, review the operator’s manual section
titled Modes of Operation & Interlocks for any possible interlocks
implemented on your vehicle.
If your vehicle is equipped with the Brake/Neutral Interlock, the
Emergency/Park Brake will be automatically applied if the vehicle is
left in Neutral (with the Emergency/Park Brake off) for longer than a
specified time period. The specified time period depends on machine
configuration but is typically 4 seconds. This interlock will apply the
Emergency/Park Brake while the vehicle is stationary or moving.
1. Ensure that all auxiliary systems, such as the deck, boom or outriggers are returned
to their tramming positions.
2. If wheel chocks are installed, remove them and store them in their proper storage
location.
3. Select DRIVE mode.
4. Apply the service brakes by pressing the service brake foot pedal and holding.
5. Check to ensure that the area is clear of personnel and obstacles.
6. Place the TRANSMISSION DIRECTION and TRANSMISSION GEAR selector switches to the
desired direction and gear.
7. Release the emergency/park brake by pulling the EMERGENCY/PARK BRAKE button up
to the reset position.
For the required conditions for releasing the brakes, refer to the
section titled Modes of Operation and Interlocks of your applicable
It may be necessary to hold the EMERGENCY/PARK BRAKE button in the
Reset position for a few seconds depending on the current brake
accumulator charge pressure. This is normal and does not
necessarily need to be done all the time.
8. Sound the horn to alert anyone nearby that the vehicle is about to move.
Revision: D
ENSURE THE VEHICLE’S ARTICULATION AREA REMAINS

CLEAR AT ALL TIMES. FAILURE TO COMPLY MAY RESULT IN
EQUIPMENT AND/OR PROPERTY DAMAGE, SERIOUS INJURY,
OR DEATH.
9. Release the service brake pedal, test steering and slowly move the vehicle by
pressing down on the accelerator pedal.
WHEN TRAVELING DOWN A RAMP, SELECT THE GEAR THAT
BEST MAINTAINS CONTROL AND STEERING RESPONSE.
REFER TO THE MAXIMUM SPEEDS LABEL LOCATED IN THE
OPERATOR’S COMPARTMENT AND ALWAYS FOLLOW SITE
SPEED POLICIES.
Revision: D
TORQUE CONVERTER LOCK

TYPES OF OPERATION/WHEN TO USE LOCK UP
Up Ramp (Incline) - Lock up application can be effective when the vehicle is loaded
and traveling on an incline, although the lock up operating range is narrower than for
level, or downgrade runs. Used in this application, lockup maximizes power transfer
from the engine to the wheels to provide maximum tramming speed.
Level Run – Lock up can be used in all gears so long as speeds do not become
excessive and the operator can control vehicle speed in a safe manner. Maximum
converter cooling and engine fuel savings is realized by using lock up properly on level
runs.
Down Ramp (Decline) – Using converter lock up on a decline allows maximum
retarding effect through the engine and mechanical drive train. Using the converter to
act as the retarder creates heat in the transmission/converter and does not provide the
level of retarding effect that the lock up system provides. Using lock up reduces heat
build-up in the converter; using the converter as a retarder generates heat.
WHILE TRAMMING DOWN STEEP RAMPS WHILE USING LOCK
UP, VEHICLE SPEED ACCELERATES DUE TO THE ROLLING
MASS. THEREBY TRANSMITTING POWER FROM THE
WHEELS, THROUGH THE DRIVE TRAIN AND TO THE ENGINE.
THIS SITUATION CAN CAUSE THE ENGINE TO “OVER-
SPEED” BEYOND ITS GOVERNED RPM AND MAY RESULT IN
SEVERE ENGINE DAMAGE, OR FAILURE.
EASING OFF THE THROTTLE, ENABLING THE EXHAUST
BRAKE AND APPLYING THE SERVICE BRAKE SHOULD BE
USED TO HELP SLOW THE ENGINE AND PREVENT OVER
SPEEDING.
Breakout Operation – DO NOT USE LOCK UP. Breakout operation requires maximum
torque provided by the converter. Severe shock loading to the drive train components
may occur if lock up is used during breakout operations.
Starting out of the Hole, or Stopping – DO NOT USE LOCK UP. Initial start-up and
travel of a vehicle (loaded or not) requires maximum torque provided by the converter.
Severe shock loading to the drive train components may occur if lock up is used during
breakout operations.
Revision: D
GENERAL RULES FOR OPERATING LOCK UP

Rule #1 – Lock up should be engaged whenever it is possible to do so on level runs,
down ramps, or up ramps either loaded, or empty.
The Exhaust Brake system can be activated along with lock up in
order to maximize powertrain retardation and therefore ground
speed control.
Rule #2 – Lock up must be disengaged:
• Before coming to a complete stop.
• While shifting gears when vehicle is moving (lock up disengages automatically
when gear selector switch is shifted to another gear and must be manually re-
engaged).
• When the incline is so steep that the engine loses RPM while lock up is engaged
(refer to the label on firewall for the minimum lock up engaged RPM value).
Your vehicle may be equipped with an automatic torque converter
lock up disengagement feature which disengages the torque
converter lock up when the vehicle’s engine drops below a set RPM.
OPERATING TECHNIQUES FOR LOCK UP
Traveling on Level Runs:
a. Ease off foot throttle.
b. Press up on the TORQUE CONVERTER LOCK UP switch to engage the lock up.
c. Press down on the foot throttle pedal again. Vehicle speed should increase over
what converter drive speed was. The operator may keep the foot throttle at 100%
but the fuel pump governor delivers only the fuel necessary to move the vehicle.
d. Converter lock up MUST be released before bringing the vehicle to a complete stop.
Disengage lock up when the engine RPM drops below the recommended operating
RPM (refer to the label on firewall for the minimum lock up engaged RPM value).
e. Converter lock up is automatically disengaged when shifting gears. The operator
MUST manually re-engage the torque converter lock up after shifting.
Revision: D
Traveling on Down Ramps (Loaded):

a. As the vehicle approaches the ramp, select the suitable gear. The steeper the ramp,
the lower the gear selected. Steep ramps normally require that 1st gear be used.
b. Engage lock up as explained previously BEFORE starting down ramp.
c. As the vehicle starts down ramp, ease off the foot throttle pedal. Allow engine
retardation to slow the vehicle to a controlled speed without having to use the
service brakes. The Exhaust Brake system may also be enabled to improve power
retardation and help slow the vehicle.
SOME DOWN RAMPS MAY BE TOO STEEP FOR THE ENGINE
TO PROVIDE ENOUGH RETARDATION TO KEEP THE VEHICLE
UNDER CONTROLLED SPEED FOR A GIVEN GEAR. IN THIS
CASE, THE VEHICLE WILL GAIN SPEED, CAUSING THE
ENGINE TO OVER-SPEED ABOVE A MAXIMUM RPM. YOU
MUST APPLY THE SERVICE BRAKES TO SLOW VEHICLE,
THEN SHIFT TO A LOWER GEAR IF POSSIBLE AND AGAIN
LOCK UP THE CONVERTER.
d. To stop the vehicle, let off the foot throttle pedal and start applying the service
brakes and at the same time, disengage lock up when the engine RPM drops below
the recommended operating RPM (refer to the label on firewall for the minimum lock
up engaged RPM value). Leave lock up in released position until the load is dumped
and vehicle is ready to start back up the ramp.
Traveling on Down Ramp (Empty):
The technique is the same for that used for traveling down ramp loaded as noted
previously, except higher gears may be used where the haulage allows faster speeds.
Revision: D
Traveling on Up Ramp (Loaded):

a. Select desired gear and accelerate to governed engine speed.
b. Let off foot throttle pedal slightly and engage lock up. Vehicle should immediately
gain speed when throttle is depressed again. If the vehicle does not gain speed and
engine RPM drops, you MUST disengage lock up when the engine RPM drops
below the recommended operating RPM (refer to the label on firewall for the
minimum lock up engaged RPM value).
ALWAYS refer to the label on firewall for the minimum lock up
engaged RPM value. Ensure that the engine RPM is greater than the
recommended operating RPM when lock up operation is desired.
Traveling on Up Ramp (Empty):
a. The technique is the same for that used for traveling up ramp loaded as noted
above, but higher gears may be used.
ALWAYS refer to the label on firewall for the minimum lock up
engaged RPM value. Ensure that the engine RPM is greater then the
recommended operating RPM when lock up operation is desired.
Revision: D
AUTOMATIC TORQUE CONVERTER LOCK-UP OPTION

This option is similar to the previous setup above with the addition of a few components
in order to simplify operations, better monitor equipment to suit conditions and improve
overall efficiency.
The system provides automatic torque converter lock-up and disengagement based on
the requirements of the transmission. This eliminates the need for the operator to re-
engage the lock-up switch after each gear or direction change and provides a smoother
transition for both the operator and the machine.
This allows the operator to concentrate on safety, road conditions, steering and braking
rather than when to engage and disengage the torque converter lock-up.
This system relies on input from the engine, transmission, throttle position, ground
speed and gear/direction switches to determine when the torque converter should be
locked-up.
SYSTEM COMPONENTS
Transmission Controller Panel - Used to house the transmission controller. This panel
also has an override switch on the side to provide the operator a way to move the
machine, in both forward or reverse direction, in 1st gear only, in case of a controller
failure (Figure 2).
Figure 2 - Transmission Controller Panel
Revision: D
Transmission Controller Override Switch - The transmission controller override switch is

used in the case of a transmission controller failure in order to move the machine out of
harm’s way or to a maintenance area. The switch is located on the left side of the panel
and has three (3) positions. Turning the switch counterclockwise turns the Override
function OFF. Turning the switch Clockwise turns the Override function ON. The switch
indicator (green) will illuminate as the override function enables.
To use the Transmission Controller Override function the operator must:

1. Place the Transmission in Neutral (N) using the direction selector switch.
2. Apply the Brakes using the emergency/park brake switch.
3. Turn the Transmission Controller Override selector switch clockwise (CW) to ON.
4. Shift the Transmission Direction selector switch to Forward or Reverse.
5. Release the brakes.
When the Override is activated the transmission is limited to first (1st)

gear only in either direction.
To re-enable the transmission controller the operator must turn the Transmission
Controller Override selector switch counterclockwise (CCW) to OFF.
Cutting the power to the machine will also disable the Override function
and will need to be re-enabled after start up if desired.
Transmission Controller Display Panel - The transmission controller display panel is

mounted on the top of the Driver’s Instrument Panel (DIP) and is used to provide
information to the Operator about transmission gear, ground speed, direction/gear
selector switch position, diagnostic data and active and/or inactive error codes.
It has one (1) Mode (M) button to access the different functions and modes and a two
(2) digit LED display. Two (2) LED indicator lights are used to indicate diagnostic modes
(yellow “D” LED) and active errors (red “F” LED). Finally an amber warning light is used
to warn the operator of an over speed condition or when a downshift or direction
change, engagement or re-engagement cannot be granted (Figure 3).
Revision: D
Figure 3 - Transmission Digital Display

Mode (M) button - The M button on the display is used to toggle between the various
display screens and can also be used to toggle between the different display modes:
• Normal Display Mode – Activated during start up as default by not pressing the
Mode (M) button during initial startup. Provides the operator with standard
operating information. Once in Normal display mode pressing the Mode (M)
button will toggle between the following display screens: Gear Position (GP),
Vehicle Speed in km/hr (SP), Vehicle Speed in mph (rS) & Shift Lever Position
(SL).
• Diagnostic Display Mode – Activated during start up by pressing the Mode (M)
button during initial start-up of the controller. Provides the operator with a number
of diagnostic screens to help troubleshoot errors. Once in Diagnostic display
mode pressing the Mode (M) button will toggle between the following display
screens: Turbine Speed (tS), Engine Speed (ES), Speed Ration (Sr), Output
Speed (oS), Battery Supply Voltage (bA), Digital Input Test (di/it) & Throttle Pedal
Position (tP). (See MB-ELE2815 for more information on Digital Input Test.)
• Error Display Mode – Activated at any time by pressing the Mode (M) button for
more than 2 seconds. Provides the operator with various error codes which can
help troubleshoot the machine during a fault. Once in Error display mode
pressing the Mode (M) button will toggle between the following display screens:
Active Faults (AF) & Inactive Faults (iF). (See MB-ELE2816 for more information
on error codes.)
Revision: D
Driver’s Instrument Panel (DIP) - The Driver’s Instrument Panel houses the Torque
Converter Lock-up switch which is used to turn the automatic torque converter lock-up
ON or OFF. The rocker style switch is found at the bottom left row of switches. Push
the top of the switch to turn the automatic torque converter lock-up feature ON as
indicated by the light on the upper section of the switch. The indicator light at the bottom
of the switch indicates when the torque converter is actually locked-up. Toggle the
bottom of the switch to turn the torque converter lock-up feature OFF (Figure 4).
Figure 4 - Driver’s Instrument Panel Torque Converter Lock-Up Switch
Revision: D
OPERATING TECHNIQUES FOR LOCK UP
GENERAL RULE FOR OPERATING LOCK UP

Lock up should be engaged whenever it is possible to do so when on level runs, down
ramps, or up ramps either loaded, or empty. It is recommended that the Torque
Converter Lock-Up Switch stay in the ON (Up) position to allow automatic Torque
Converter Lock-Up control at all times, allowing the transmission controller to determine
when lock-up should be engaged and disengaged. Only if it is critical that the torque
converter stays disengaged should the Torque Converter Lock-Up switch be toggled to
the OFF (Down) position.
The Exhaust Brake system can be activated along with lock up in

order to maximize powertrain retardation and therefore ground
speed control.
WHILE TRAMMING DOWN STEEP RAMPS WHILE USING LOCK

UP, VEHICLE SPEED ACCELERATES DUE TO THE ROLLING
MASS. THEREBY TRANSMITTING POWER FROM THE
WHEELS, THROUGH THE DRIVE TRAIN AND TO THE ENGINE.
THIS SITUATION CAN CAUSE THE ENGINE TO “OVER-
SPEED” BEYOND ITS GOVERNED RPM AND MAY RESULT IN
SEVERE ENGINE DAMAGE, OR FAILURE.
EASING OFF THE THROTTLE, ENABLING THE EXHAUST

BRAKE AND APPLYING THE SERVICE BRAKE SHOULD BE
USED TO HELP SLOW THE ENGINE AND PREVENT OVER
SPEEDING.
OPERATING PROCEDURE
1. Place the TORQUE CONVERTER LOCK-UP SWITCH on the DIP in the ON
position. This will enable the Automatic Lock-Up feature and illuminate the upper
indicator light on the switch and can be left in the ON position unless the operator
requires the Lock-Up feature to be disabled.
2. The bottom indicator light on the Torque Converter Lock-Up Switch on the DIP will
illuminate when the torque converter is physically locked-up.
3 Place the TORQUE CONVERTER LOCK-UP SWITCH on the DIP in the OFF
position to disable the Automatic Lock-Up feature.
For detailed maintenance information of the transmission Controller System, refer to

MB-ELE2819.
Revision: D
NORMAL OPERATING RANGES

Mercedes 904 with Clark T32000 Transmission
Brake Accumulator Pressure .................... 1850psi - 2300psi (127 – 158 Bar)
Engine Speed ............................................. 900 - 2200 rpm
Voltage (DC)................................................ 22V - 28V
Engine Oil Pressure ................................... 7psi min. - 80psi max (0.5 – 5.5 Bar)
Engine Coolant Temperature .................... 200° - 210°F (93° - 99°C)
Transmission Fluid Pressure .................... 240 - 300psi (16.5 – 20.7 Bar)
Transmission Fluid Temperature.............. 180° - 200°F (82.2° - 93.3°C)

Engine Speed ............................................. 900 - 2200 rpm
Voltage (DC)................................................ 22V - 28V
Engine Oil Pressure ................................... 7psi min. - 80psi max (0.5 – 5.5 Bar)

Engine Speed ............................................. 700 - 2200 rpm
Voltage (DC)................................................ 22V - 28V
Engine Oil Pressure ................................... 45psi min. - 80psi max (3 – 5.5 Bar)
Revision: D
PARKING & SHUTDOWN

This vehicle may be equipped with a cold weather package. If this is
the case, be sure to connect all mine powered heaters that maybe
equipped on your vehicle aftershutting it down.
If your vehicle is equipped with the Brake/Neutral Interlock, the

Emergency/Park Brake will be automatically applied if the vehicle is
left in Neutral (with the Emergency/Park Brake off) for longer than a
specified time period. The specified time period depends on machine
configuration but is typically 4 seconds. This interlock will apply the
Emergency/Park Brake while the vehicle is stationary or moving.
The following procedure is a guide for mines that do not have a standard parking and
shutdown procedure.
FOLLOW MINE SPECIFIC RULES AND REGULATIONS AT ALL TIMES.
Wheel chocking requirements and parking location rules are specified by the mine and
must be followed by the operator.
WHEN PARKING ON A GRADE, ARTICULATE THE VEHICLE

SO THAT IT FACES A WALL, OR SIMILAR STRUCTURE.
When parking the vehicle, park away from traffic areas or in its
designated area.
To park and shutdown the vehicle:

1. Apply the service brake pedal until the vehicle comes to a complete stop.
2. Press the EMERGENCY/PARK BRAKE button to enable the emergency/park brakes.
3. Place the TRANSMISSION DIRECTION selector switch into the Neutral position.
4. Release the service brake pedal.
5. If the vehicle is equipped with outriggers, lower them until they are in contact with
the ground and taking on the weight of the vehicle. If not, place wheel chocks on
both sides of one wheel, or in accordance with mine regulations. If parking the
vehicle on a ramp or slope, place both wheel chocks on the downward side of two
separate tires, or in accordance with local and mine policies.
6. Allow the engine to idle for two minutes.
7. Turn the engine IGNITION switch to the OFF position.
8. Turn the MAIN BATTERY DISCONNECT switch to the OFF position when parking for
extended periods of time, or when leaving the vehicle unattended.
Revision: D
It may be necessary to leave the parking light ON (if equipped) to

warn other operators nearby that the vehicle is parked and
unattended.
9. Walk around the vehicle to check for any fuel, oil and coolant leaks, broken hoses or
any other visible damage. If any repairs are needed, inform the appropriate
Revision: D
LOCKING AND TAGGING VEHICLE OUT OF SERVICE

IN SOME CASES IT MAY BE NECESSARY TO LEAVE A
DISABLED VEHICLE ON A ROADWAY. WARNING DEVICES
MUST BE PLACED AT LEAST 200 FEET IN FRONT OF AND
BEHIND THE VEHICLE TO WARN APPROACHING TRAFFIC.
REFER TO YOUR LOCAL AND SITE POLICIES.
The following procedure is a guide for mines that do not have a standard locking and
tagging out procedure.
FOLLOW MINE SPECIFIC RULES AND REGULATIONS AT ALL TIMES!
To lock and tag out the vehicle:
1. Follow standard parking procedures.
2. Turn off the MAIN BATTERY DISCONNECT switch.
3. Lock-out the MAIN BATTERY DISCONNECT switch using the lock-out bracket provided.
4. Place one Out of Service tag on the MAIN BATTERY DISCONNECT switch.
5. Place one Out of Service tag on the steering control.
6. Identify on the tags:
a. Vehicle number.
b. Suspected problem.
c. Name of person who is tagging vehicle.
d. Date.
7. Notify the maintenance department.
Revision: D
TOWING THE VEHICLE

THE FOLLOWING PROCEDURE MUST ONLY BE PERFORMED
BY TRAINED AND QUALIFIED MAINTENANCE PERSONNEL.
FAILURE TO COMPLY MAY RESULT IN SERIOUS DAMAGE TO
THE VEHICLE AND/OR DEATH TO PERSONNEL.
Always follow all mine site and/or governmental rules and

regulations regarding vehicle towing.
The following procedure can be used to prepare the vehicle for towing in the event that
it is required. Refer also to the Brake Release Instructions For Towing label found inside
the operator’s compartment.
To prepare the vehicle for towing:
1. Open the brake manifold compartment access door.
2. Remove the hydraulic hose labeled TK05 or TK45 from the port labeled T or TK on
the brake manifold. See Figure 5.
Hydraulic
Hose
(TK05)
Figure 5 – Typical Brake Manifold
3. Connect a hydraulic hand pump to port T or TK on the brake manifold.

4. Apply between 300 and 500 psi max. pressure to release the driveline/park brakes.
5. Tow the vehicle as required.
6. When finished, disconnect the hand pump from the port on the brake manifold.
7. Install the hydraulic hose onto its port on the brake manifold.
8. Close the brake manifold compartment access door.
Revision: D
Notes:
Revision: D
Notes:

Phone: 1-866-856-3626
Title: BRAKE TEST PROCEDURE
Number: OM-UTV-O4
Revision: H
Checked By: Checked By: Donna Umlah
Approved By: Steve Czerny Approved By: Bruce Mackereth
BRAKE TEST PROCEDURE

IF THE VEHICLE MOVES DURING ANY BRAKE TEST SHUT IT
DOWN, DECOMMISSION IT IMMEDIATELY FOLLOWING MINE
SPECIFIC LOCKOUT AND TAG-OUT PROCEDURES. INFORM
THE APPROPRIATE PERSONNEL TO CORRECT THE
PROBLEM. FAILURE TO CORRECT THE PROBLEM MAY
RESULT IN EQUIPMENT AND/OR PROPERTY DAMAGE,
SERIOUS INJURY, OR DEATH.
As a minimum, a brake test must be carried out on the vehicle at the beginning of each
shift. Mine requirements may require more frequent brake tests.
A complete brake test consists of testing ALL braking systems on

the vehicle.
For an explanation of the operator’s compartment layout, refer to section titled
Operator’s Compartment Layout of this Operator’s Manual.
Start the vehicle following the startup procedure explained in section titled Carrier
Operation of this Operator’s Manual. Follow the instructions as outlined by the Brake Test
label located in the operator’s compartment. See example of a typical Brake Test label
shown in Figure 1.
Ensure that you follow the specific brake test label instructions on
your particular vehicle.
OM-UTV-O4 Page 1 of 4
Number: OM-UTV-O4
Revision: H
SERVICE BRAKE TEST

1. APPLY SERVICE BRAKES
2. RELEASE EMERGENCY/PARK BRAKES
3. PLACE TRANSMISSION IN 2ND GEAR FORWARD
4. INCREASE ENGINE SPEED TO FULL THROTTLE
5. UNIT SHOULD NOT MOVE
EMERGENCY/PARK BRAKE TEST
1. APPLY EMERGENCY/PARK BRAKES
2. PLACE TRANSMISSION IN 2ND GEAR FORWARD
3. ENSURE SERVICE BRAKES ARE RELEASED
4. INCREASE ENGINE SPEED TO FULL THROTTLE
5. UNIT SHOULD NOT MOVE
Figure 1 - Example of a Typical Brake Test Label
SERVICE BRAKE TEST
IF THE VEHICLE MOVES, SHUT IT DOWN AND

DECOMMISSION IT IMMEDIATELY. INFORM THE
APPROPRIATE PERSONNEL TO CORRECT THE PROBLEM.
FAILURE TO COMPLY MAY RESULT IN EQUIPMENT AND/OR
PROPERTY DAMAGE, SERIOUS INJURY OR DEATH.
1. Apply the service brakes by firmly pressing down on the service brake pedal.
2. Release the emergency/park brake by pulling the EMERGENCY/PARK BRAKE button up
to the Reset position.
3. Place the TRANSMISSION DIRECTION selector switch into the Forward position.
4. Place the TRANSMISSION GEAR selector switch to 2nd gear.
5. Gently press down on the accelerator pedal to raise the engine RPM to the RPM
stated on the Brake Test label.
6. The vehicle must not move.
7. Release the accelerator pedal.
8. Apply the emergency/park brakes by pressing the EMERGENCY/PARK BRAKE button.
10. Release the service brake pedal.
11. If the vehicle did not move then carry on to next test.
Page 2 of 4 OM-UTV-O4
Number: OM-UTV-O4
Revision: H
EMERGENCY/PARK BRAKE TEST
IF THE VEHICLE MOVES, SHUT IT DOWN AND

DECOMMISSION IT IMMEDIATELY. INFORM THE
APPROPRIATE PERSONNEL TO CORRECT THE PROBLEM.
FAILURE TO COMPLY MAY RESULT IN EQUIPMENT AND/OR
PROPERTY DAMAGE, SERIOUS INJURY OR DEATH.
1. Apply the emergency/park brakes by pressing the EMERGENCY/PARK BRAKE button.
2. Apply the service brakes by firmly pressing down on the service brake pedal.
3. Place the TRANSMISSION DIRECTION selector switch into the Forward position.
4. Place the TRANSMISSION GEAR selector switch to 2nd gear.
5. Release the service brakes.
6. Gently press down on the accelerator pedal to raise the engine RPM to the RPM
stated on the Brake Test label.
7. The vehicle must not move.
8. Release the accelerator pedal.
10. If the vehicle did not move, proceed with the inspection or operation of the vehicle as
necessary.
OM-UTV-O4 Page 3 of 4
Number: OM-UTV-O4
Revision: H
Notes:

Phone: 1-866-856-3626
Page 4 of 4 OM-UTV-O4
Title: RECOMMENDED LUBRICANTS & FLUIDS
Number: OM-SS-O5
Revision: Original
RECOMMENDED LUBRICANTS AND FLUIDS

As customer requirements change, certain components listed in the
table below may not be applicable to your particular vehicle.
It is the operator’s responsibility to become familiar with their
particular vehicle and its options.
MacLean
Location Lubricant Capacity
Part #
Multi-purpose Molybdenum Grease
Grease 1015699 N/A
EP2
Hydraulic System Mineral Oil (Tellus 46) Harmony or 190 L
1012269
(SS3) equivalent (AW46) 50 US Gallons
Hydraulic System Mineral Oil (Tellus 46) Harmony or 180 L
1012269
(SS2) equivalent (AW46) 48 US Gallons
160 L
Fuel (SS3) #2 Diesel Fuel N/A
42 US Gallons
178 L
Fuel (SS2) #2 Diesel Fuel N/A
47 US Gallons
Engine Coolant CAT Extended Life Coolant or 1061577 56 L
(Mercedes 904/906) equivalent Pre-Mixed 50/50 CAT-101-2844 15 US Gallons
(Deutz 2012 L04 T3) equivalent Pre-Mixed 50/50 CAT-101-2844 15 US Gallons
(Deutz 2012 L06 T3) equivalent Pre-Mixed 50/50 CAT-101-2844 14 US Gallons
(Caterpillar C6.6) equivalent Pre-Mixed 50/50 CAT-101-2844 10.5 US Gallons
Engine Oil CH-4 Caterpillar Diesel Engine Oil or 1061863 15 L
(Mercedes 904) equivalent (SAE 15W40) CAT-155-6199 4 US Gallons
(Mercedes 906) equivalent (SAE 15W40) CAT-155-6199 5.8 US Gallons
(Deutz 2012 L04 T3) equivalent (SAE 15W40) CAT-155-6199 3.7 US Gallons
(Deutz 2012 L06 T3) equivalent (SAE 15W40) CAT-155-6199 5.3 US Gallons
Number: OM-SS-O5
Revision: Original
MacLean
Location Lubricant Capacity
Part #
(Caterpillar C6.6) equivalent (SAE 15W40) CAT-155-6199 4 US Gallons
Transmission Oil ESSOTRANS 30 Transmission Oil or 25 L
1037011
(Clark 32000) equivalent (SAE 30) 6.5 US Gallons
TDTO/TO-4 CAT Transmission Oil
Transmission Oil 34 L
and Drive Train Oil or equivalent CAT-9X-6466
(Caterpillar 535C) 9 US Gallons
(SAE 30)
TDTO/TO-4 CAT Transmission Oil
1060738 800 ml
Driveline Brake (SS3) and Drive Train Oil or equivalent
CAT-9X-6466 27 US oz
(SAE 30)
Axle – New Holland HYDRAUL 56 (ESSO) Drive Train Oil 28 L
1005160
(per axle) or equivalent (SAE 30) 7 US Gallons
Axle–Caterpillar 36 L
CAT OIL, SAE 30TO -4 CAT-9X-6466
(per axle) 9.5 US Gallons
Axle - Dana 113
Oil, Synthetic SAE 75W90 (API GL5- 16.3 L
Central Housing 1121050
MIL 2105-B), or equivalent 4.3 US Gallons
(per axle)
Axle - Dana 113 Left & Oil, Synthetic SAE 75W90 (API GL5- 2.6 L (each)
1121050
Right Hub (per axle) MIL 2105-B), or equivalent 88 US oz
Axle - Dana 114
Oil, Synthetic SAE 75W90 (API GL5- 18 L
Central Housing 1121050
MIL 2105-B), or equivalent 4.8 US Gallons
(per axle)
Axle - Dana 114 Left & Oil, Synthetic SAE 75W90 (API GL5- 4.7 L (each)
1121050
Right Hub (per axle) MIL 2105-B), or equivalent 1.2 US Gallons
Cable Reel Torque
Esso GX 85W-90 N/A As Required
Unit
Air Compressor
CompAir – Synthetic CS5000XLP 1098158 As Required
(SS3)
Air Compressor
Mattei M135 #8000F2 1107256 As Required
(SS3 and SS2)
Water Scaler Pump –
Pratissoli MW40D1-1800 9L
100HP 1123429
Shell Tellus #C220 SAE 85W-90 2.4 US Gallons
(SS3)
Lubricator Oil Air Lubricant Oil #ATL-1 1091687 As Required
Peristaltic Accelerant
Allentown #28010 1101302 As Required
Pump
Title: RECOMMENDED LUBRICANTS& FLUIDS
Number: OM-SS3-O5-MERC
Revision: Original
*Consult MacLean Engineering’s Service Department for Cold

Weather Fluid Recommendations.
In applications above freezing water can be used. However, this gives the shortest life
of the piston cups in the pump.
Below freezing either oil, or a 50/50 water/glycol mix must be used. Any oil can be used,
including strained used oil. It is recommended that good quality oil be used for this
application as it doubles the life of the piston cups compared to using straight water.If
desired, soluble oil mixed with water can also be used. Any oils specifically designed for
machining or cutting operations must not be used.
Number: OM-SS-O5
Revision: Original
Notes:

Phone: 1-866-856-3626
Title: LUBRICATION CHART
Revision: Original
OM-SS2-O6-MERC Page 1 of 2
Title: LUBRICATION CHART
Revision: Original
Notes:

Phone: 1-866-856-3626
Page 2 of 2 OM-SS2-O6-MERC
Title: SHOTCRETE SPRAYER OPERATIONS
Number: OM-SS2-O7
Revision: Original
Checked By: René Dubois/Craig Checked By:
Marchand Approved By:
Approved By: Bill Tytaneck
GENERAL SAFETY AND OPERATIONAL INSTRUCTIONS

This section of the operator’s manual outlines the cable reel, electrically driven
hydraulic power pack and air compressor operations.
ALWAYS FOLLOW MINE SPECIFIC RULES AND REGULATIONS
AT ALL TIMES!
Failure to adhere to the recommendations and warnings of
this manual and the vehicle labeling could lead to equipment
damage, personal injury, or death.
There is a risk of injury when handling cement/concrete
products and curing agents. Always follow manufacturer,
mine site and government regulations in regards to
cement/concrete and curing agent handling.
Always read and understand all labels before operating the
Shotcrete Sprayer.
It is the responsibility of the operator / mechanic to become
familiar with the requirements of all applicable mine and
government regulations and standards and the
recommendations in the safe use of the Shotcrete Sprayer and
the products carried in or on the equipment.
• Before operating the Shotcrete Sprayer a good understanding of the operation and
safety measures must be acquired. Only a fully trained and qualified person must
operate the Shotcrete Sprayer.
• Perform a proper Pre-Operational inspection of your vehiclebefore using it. Refer to
OM-SS2-O1 titled Pre-Operation Inspection.
• Ensure that all controls are functioning as designed and expected.
• Operate the equipment only when you are physically fit and well, and not under the
influence of alcohol or drugs.
• When setting up the vehicle to spray, ensure that the work area is in good order,
hosing and cabling is laid out well and the vehicle is in good operating condition.
Set the vehicle up so it is stable and as close to level as the job allows.
Number: OM-SS2-O7
Revision: Original
• Before spraying, coat the hopper and pump area in form oil or another release
agent.
• Before spraying, coat the boom and nozzle assemblies in form oil or another
release agent.
• Read and understand the MSDS for the accelerant and other related products you
are using for spraying. Always wear appropriate personal protective equipment
(PPE) for your task.
• Make sure you properly slick the shotcrete pumping system with water prior to
spraying.
Number: OM-SS2-O7
Revision: Original
CABLE REEL OPERATION (IF EQUIPPED)

When the third last wrap of the AC trailing cable on the cable
reel is reached, an amber warning indicator light and audible
alarm sounds. When the last wrap of AC trailing cable on the
cable reel is reached, a red alarm indicator illuminates, the
audible alarm is maintained and the vehicle’s emergency/park
brakes automatically apply. Caution must be taken when
tramming while connected to mine power supply.
A possible pinch point exists at the cable reel assembly.
When the vehicle is running, do not reach into, or around the
cable reel assembly. Possible injury to personnel may occur.
Do not leave the switch in the ASSIST OUT position once you
spooled out the required length of AC trailing cable. The AC
trailing cable could spool out unnecessarily if left in the
ASSIST OUT position.
Electrically
Driven Hydraulic Main AC
Power Pack Electrical Panel
Cable Reel
Deck Mounted
Cable Reel
Selector Switch
Figure 1 – Typical Cable Reel and Components
Cable Reel - The cable reel stores the AC trailing cable when not in use.
Deck Mounted Cable Reel Selector Switch - This three position selector switch
allows the cable reel to take up any excess AC trailing cable or to hydraulically assist in
dispensing the AC trailing cable. The vehicle must be in AUXILIARY mode to be able
to use this selector switch.
The following function allows the operator to unwind, or wind the AC trailing cable onto
the cable reel.
Number: OM-SS2-O7
Revision: Original
To operate the cable reel using the deck mounted CABLE REEL selector switch:
1. Position the deck end of the vehicle close to the mine’s high voltage power supply
plug, or panel.
2. With the vehicle’s diesel engine running, place the vehicle into AUXILIARY mode.
3. Using the CABLE REEL selector switch, turn the switch to ASSIST OUT.
If the AC trailing cable is fully spooled from the cable reel, the
CABLE REEL LAST WIND WARNING/ALARM indicator lights illuminate,
an audible alarm sounds and the vehicle’s emergency/park
brakes apply when the vehicle is placed back into DRIVE mode.
4. When the required amount of AC trailing cable is spooled from the cable reel, turn
the CABLE REEL selector switch to OFF to stop the cable reel.
5. Using a cable anchor, securely fasten the AC trailing cable to an anchor point on
the wall so that it is restrained from pulling on the plug, or the mine electrical panel
when driving to the work site. Always follow mine site policy when connecting
the AC trailing cable.
6. Tram the vehicle to the work area.
7. Park the vehicle and turn off the diesel engine.
8. Walk back towards the plug and ensure that the AC trailing cable is placed to the
side of the drift. If necessary, hang the AC trailing cable from the wall out of water
and away from vehicle traffic. Always follow mine specific procedures when
handling the AC trailing cable.
Number: OM-SS2-O7
Revision: Original
9. Connect the AC trailing cable to a suitablepower source and turn the power ON at
the power source as per mine site policy.
Once the high voltage AC trailing cable is plugged into the
mine’s power supply, and the mine’s power supply is ON, the
AC trailing cable is LIVE. TO PREVENT POSSIBLE SERIOUS
INJURY OR DEATH, NEVER HANDLE A LIVE CABLE.
10. Enable power to the main AC electrical panel by following the steps outlined in the
section below titled Power Pack Operation.
Be aware of potential hazards and when necessary take
action to remove, or correct such hazards, or inform the
appropriate personnel as per mine standards and regulations.
11. POST SIGNS AND MARKERS - Once the vehicle has trammed to the work area,
place proper signs and markers in accordance with mine specific regulations. An
example is: DANGER High Voltage AC Trailing Cable.
12. INSPECT THE WORK AREA FOR HAZARDS -Visually inspect the work area for
potential hazards that could pose a danger when tramming the vehicle into the work
area, and hazards that could pose a danger while working in the area. Examples of
such hazards are:
• Large pieces of rock in the roadway, or an uneven road bed.
• Air and water pipes/hoses.
• Equipment, tools and supplies on the ground.
• Ventilation tubing.
• Un-detonated explosives.
• Bolts and screen protruding from the walls and back.
13. When finished with mine power supply, disable power to the main AC electrical
panel by following the steps outlined in the section below titled Power Pack
Operation.
14. At the mine power source, turn the power source OFF as per mine site policy
15. Disconnect the AC trailing cable from the mine power supply and all anchors, etc.
Always follow mine specific procedures when handling the AC trailing cable.
16. While in AUXILIARY mode and using the deck mounted CABLE REEL selector
switch, turn and hold the switch to REEL IN until the AC trailing cable is fully spooled
back onto the cable reel.
17. Release the deck mounted CABLE REEL selector switch and it automatically returns
to the OFF position.
Number: OM-SS2-O7
Revision: Original
The following function allows the operator to either spool a required amount of AC
trailing cable onto the cable reel, or spool the entire AC trailing cable onto the cable
reel from the operator’s compartment.
To operate the cable reel from the application junction box (wind in only):
1. The vehicle can be in DRIVE, or AUXILIARY mode to operate the CABLE REEL IN
switch.
2. Toggle and hold the top of the CABLE REEL IN switch until the required amount of AC
trailing cable is spooled back onto the cable reel.
Spooling the AC trailing cable back onto the cable reel using the
CABLE REEL IN switch is typically done with the vehicle in DRIVE
mode and driving in the Reversedirection.
3. Release the CABLE REEL IN switch and the cable reel automatically turns OFF.
To override the last wind alarm:
Once the last wind alarm is present in DRIVE mode, the vehicle
can only be overridden and driven in the direction of the cable
reel until the alarm condition is cleared.
1. Toggle and hold the top of the CABLE REEL OVERRIDE switch.
2. Press the EMERGENCY/PARK BRAKE button.
3. Pull and release the EMERGENCY/PARK BRAKE button to reset it.
4. Toggle and hold the top of the CABLE REEL IN switch while driving the vehicle in the
direction of the cable reel until the alarm stops.
5. Release the CABLE REEL OVERRIDE switch and the CABLE REEL IN switch. The cable
reel automatically turns OFF.
Number: OM-SS2-O7
Revision: Original
POWER PACK OPERATION (IF EQUIPPED)

Shotcrete Sprayers equipped with an electric/hydraulic powerpack are capable of
operating on diesel or electric. Electric is the preferred power source when spraying
shotcrete because it provides more hydraulic flow and the air compressor is operable.
Diesel provides a lower hydraulic flow, but the operator experiences only slightly less
performance than that of the electric spraying. The main difference is that when
spraying on diesel, an outside air source capable of supplying at least 300 CFM of air
at 40-50 PSI is required.
In order for the operator to begin any spraying operations, the vehicle must be placed
in AUXILIARY mode. The Shotcrete Sprayer has only one mode switch located on the
driver’s instrument panel (DIP). For details refer to OM-SS-O2 titled Modes of Operation
& Interlocks.
To start the electrical power pack:
1. Place the vehicle into AUXILIARY mode. If the vehicle is already connected to mine
power supply, proceed to Step3.
2. Spool the AC trailing cable out from the cable reel and connect it to an appropriate
mine AC power source. Refer to the previous section titled Cable Reel Operation.
3. At the main AC electrical panel, place the MAIN POWER DISCONNECT switch into the
ON position.
4. Once the unit is plugged into a compatible GFI panel and the MAIN AC POWER
BREAKER switch is turned ON, press and hold the MAIN POWER RESET button until
the green 120VAC RECEPTACLE ON indicator light illuminates, then release.
If AC power does not initiate, check all EMERGENCY STOP buttons.
Also, verify plug connections and AC trailing cable for damage.
5. Press the green POWER PACK START push button to enable power to the electrical
power pack motor.
6. The green POWER PACK RUN indicator light illuminates.
If the hydraulic pump does not start:
Check that the 120VAC RECEPTACLE ON indicator light on the main AC electrical panel
is illuminated. If it is not, follow Steps 1 through 6 to start the electric power pack.
Number: OM-SS2-O7
Revision: Original
If any of the following conditions occur, notify maintenance immediately:

• The VOLTAGE MONITOR UNDER/OVER indicator lights on the main AC electrical
panel are illuminated.
• The HYDRAULIC OIL TEMPERATURE/LEVEL W ARNING indicator lights on the main
AC electrical panel are illuminated.
• The hydraulic oil level in the hydraulic tank is below the minimum oil level on the
hydraulic tank sight gauges (with vehicle on level ground).
• The hydraulic oil temperature in the hydraulic tank is above the normal operating
temperature as noted on the hydraulic tank sight gauge thermometer. For
normal operating ranges, refer to section titled Carrier Operation.
7. Once the electrical power pack is activated, any auxiliary function on the vehicle
can be used.
When using the remote pendant (if equipped), all manual
hydraulic control valve functions are disabled.
8. If using the remote pendant, refer to the remote pendant section in this manual.
To stop the electrical power pack:
1. Once finished with the electrical power pack, press the red POWER PACK STOP push
button to disable power to the electrical power pack motor.
2. The green POWER PACK RUN indicator light goes OUT.
3. Place the MAIN POWER DISCONNECT switch into the OFF position.
4. Disconnect the AC trailing cable from the mine power supply.
5. Spool the AC trailing cable onto the cable reel. Refer to the previous section titled
Cable Reel Operation.
Number: OM-SS2-O7
Revision: Original
AIR COMPRESSOR OPERATION (IF EQUIPPED)

To start the air compressor:
1. If mine power supply has not been connected it will need to be. Refer to the Steps
found in the Cable Reel Operation section earlier in this manual.
2. Press the green AIR COMP. START push button (located on either the main AC
electrical panel, or boom control panel) to enable power to the air compressor
motor.
3. The green AIR COMP. RUN indicator lightsilluminate.
To stop the air compressor:
1. Once finished with the air compressor, press the red AIR COMP. STOP push button to
disable power to the air compressor motor.
2. The green AIR COMP. RUN indicator lights flash and then go OUT.
The air compressor cannot be restarted while the AIR COMP RUN
indicator lightsareflashing.
If the air compressor does not start and if any of the following conditions occur, notify
maintenance immediately:
• The VOLTAGE MONITOR UNDER/OVER indicator lights on the main AC electrical
panel are illuminated.
• The air compressor motor temperature is above the normal operating
temperature.
• The hydraulic oil level in the air compressor is belowthe minimum oil level.
• The hydraulic oil temperature in the air compressoris above the normal
operating temperature.
• Air pressure still contained in the system after a shutdown sequence.
3. If mine power supplyis connected and no longer required, it must be disconnected.
Refer to the Steps found in the Cable Reel Operation section earlier in this manual.
Number: OM-SS2-O7
Revision: Original
AIR,WATER AND ACCELERANT SYSTEMSOPERATION

The Shotcrete Sprayer is equipped with air and water systems to support the shotcrete
spraying process. Air is required to spray shotcrete on the work surface and water is
required for work surface washing as well as line slicking and vehicle cleaning.
The Shotcrete Sprayer has one onboard compressor to supply compressed air when
running on mine power supply, or if needed, mine air can be connected to the vehicle
instead. A supply of water from the mine water system must be connected to the
vehicle as the Shotcrete Sprayer does not have an onboard water source.
The accelerant dosing system is also grouped with air and water systems for the
purpose of this manual because it is directly connected to both systems on the boom.
Please note that a description of the accelerant pump ON/OFF and speed control is
provided under shotcrete process controls found in section OM-SS2-V5 titled System
Layout & Auxiliary Controls. Compressor electrical controls are also described earlier in
this section.
Mine Services and Inlets
Depending upon vehicle configuration, the layout of the mine
supply inlets may change.
Mine Water
Inlet and Mine Air
Valve Inlet
Water Box Fill

Valve
Compressed
Air Outlet
Accelerant Point and
Transfer inlet Valve
Point and
Valve
Figure 2– Typical Mine Services and Inlets
Mine Water Inlet – This quarter-turn inlet ball valve can be adapted to fit the couplings
in use at any site. When mine water is connected and the valve is in the Open position,
water from this inlet is used for the high pressure washer pump, washing the work
surface with the spray nozzle (water scaler pump if equipped), rear wash wand, filling
the shotcrete pump water box, slicking and flushing the accelerator and shotcrete hose
lines.
Number: OM-SS2-O7
Revision: Original
Mine Air Inlet – This inlet can be adapted to fit the couplings in use at any site.
Compressed air from the mine air system is connected here to provide a source of
compressed air for spraying operations when using diesel power for spraying
operations.This inlet requires and air source capable of delivering a minimum of 300
CFM at 50-60 PSI. An air source selector valve (not shown) is located in front of the
operator’s side rear fender.
Water Box Fill Valve – This quarter-turn valve is used to fill the shotcrete pump water
box with water when the vehicle is connected to mine water.
Accelerant Transfer Inlet Point – This point and valve allow the transfer of accelerant
from a Transmixer transport tank. Connect the transfer hose from the Transmixer to
this point and open the valve. (Handle is in line with the valve body whenin the Open
position.)
Compressed Air Outlet Point – This point provides compressed air to a Transmixer to
operate its auxiliary powerpack, or optional air powered accelerant pump. This point
provides compressed air if the Shotcrete Sprayer is running on its onboard air
compressor or from mine air.
Water system and strainer drain valve
Mine Water
Mine Water
Supply To
Supply
Water/Accelerant
Selector Valve
Mine Water Water

Supply To Strainer
Pressure Washer Drain Valve
Mine Water
Supply To Water
Scaler
Figure 3 – Typical Water System andStrainer Drain Valve
Number: OM-SS2-O7
Revision: Original
Mine Water Supply to Front of Vehicle – As soon as the mine water supply is
connected and the mine water inlet valve is turned to the On position, water is
immediately available for the components at the front of the vehicle that require it. They
are the water/accelerant selector valve that controls the flow of water, or accelerant to
the spray nozzle, the water scaler pump (if equipped) and the high pressure washer
pump.
Water Strainer Drain Valve –This valve drains the strainer of residual water in the
system when the mine water supply is turned to the Off position. Open this valve to
flush out the strainer onto the ground. When the valve handle is perpendicular to the
valve body it is in the Closed position (shown). When the valve handle is in line with the
valve body it is in the Open position.
Air and Water/Accelerant Control System
1
2
Figure 4 - Typical Air, Water/Accelerant Control Valves

1. Air Flow Control Valve – This is a quarter-turn ball valve that controls the flow of
air to the nozzle for spraying operations. Adjust this valve as required to get the
proper spray pattern and compaction of material on the work surface. This valve is
also used to control air flow to the nozzle when washing the work surface.When the
valve handle is perpendicular to the valve body it is in the Closed position (shown).
When the handle is in line with the valve body it is in the Open position. Optionally a
pressure gauge can be installed on the outlet fitting of this valve to indicate spraying
air pressure.
Number: OM-SS2-O7
Revision: Original
2. Water/Accelerant Selector Valve

Before turning the selector valve to activate the water supply
to the nozzle, the accelerant tank outlet valve must be turned
to the Off position. Failure to do so places the accelerant
system into a pressure relief state.
This valve is a quarter-turn three way selector ball valve. Use this valve to select
either water,or accelerant to the nozzle. When the handle is perpendicular to the
valve body (shown), accelerant is selected to flow to the nozzle. When the handle is
in line with the valve body, water is selected to flow to the nozzle.
Accelerant Pump and Valves
There are two mounting configurations available for the Shotcrete Sprayer. Both
configurations are shown inFigure5.
1
2
4
3
1 3
2
1
2
Figure 5 - Typical Accelerant Pump Valves
1. Flush Water Inlet Valve - This is a quarter-turn ON/OFF ball valve. This valve
controls the inlet flow of water from the mine water inlet to the inlet side of the
accelerant pump. When the valve handle is perpendicular to the valve body is it in
the Closed position (shown). When the handle is in line with the valve body it is in
the Open position. During spraying operations, this valve must be in the
Closedposition. This valve is only in the Open position to flush the accelerant
system when cleaning up at the end of the job.
2. Accelerant System Relief Outlet Valve – This valve is used to direct the
accelerant flow to the ground when pressure inside the hose exceeds the set limit.
Number: OM-SS2-O7
Revision: Original
3. Accelerant Tank Outlet Valve

When operating the accelerant pump ensure that either the
accelerant tank outlet valve or the water flushing valve is
open. This ensures that the pump is able to draw a liquid and
discharge it. To avoid excessive wear, or damage to the
pumping hose, do not run the pump in a relief condition (i.e.
flushing the relief valve) for more than a few seconds.
This valve controls the outlet flow of accelerant product from the accelerant tank to
the accelerant pump. This valve is a quarter-turn ball valve. When the valve handle
is in-line with the valve body the valve is in the Open position (shown closed). When
it is perpendicular to the valve body it is in the Closed position. This valve must be
in the Open position for spraying operations and in the Closed position for flushing
operations.
4. Accelerant Pump Outlet Valve – This valve controls the outlet flow of accelerant
from the accelerant pump to the nozzle. When the valve handle is in-line with the
valve body (shown), the valve is open. When it is perpendicular to the valve body it
is closed. This valve must be open for spraying operations. This valve must be
closed in order to flush the accelerant system relief outlet valve. This valve can also
be opened when flushing the system with water to flush out the line from the pump
to the nozzle.
Number: OM-SS2-O7
Revision: Original
Form Oil and Pump Valves
Figure 6 – Typical Form Oil Pump Valves

1. Form Oil Strainer Drain Valve – This valve is used to drain excess form oil from
the form oil pump via a Y-strainer. This valve is a quarter-turn ball valve. When the
valve handle is in-line with the valve body the valve is in the Open position. When it
is perpendicular to the valve body it is in the Closedposition (shown). This valve
must be in the Closed position for form oil spraying operations and in the Open
position for draining the excess form oil in the form oil pump.
2. Form Oil Tank Outlet Valve – This valve controls the outlet flow of form oil from
the form oil tank to the form oil pump. This valve is a quarter-turn ball valve. When
the valve handle is in-line with the valve body the valve is in the Open position.
When it is perpendicular to the valve body it is in the Closed position (shown). This
valve must be in the Open position for spraying operations and in the Closed
position to stop the form oil flow from the form oil tank.
Number: OM-SS2-O7
Revision: Original
WATER/AIR HOSE REEL OPERATION (IF EQUIPPED)

The water hose and air hose on their corresponding reel are manually spooled out and
then typically spring retracted. Optionally, the hose rewind process may be
hydraulically controlled. Both are described below.
To connect to mine water/air supply:
1. Manually pull out the required amount of hose from its hose reel.
2. Connect it to the corresponding mine supply source as per mine site policy.
3. Turn ON the mine supply source.
Air Hose and Hose

Water Hose and Reel
Hose Reel
Rear Auxiliary
Control Valve
Figure 7 – Water and Air Hose Reels

To disconnect the mine water/air supply and retract the hose:
1. Turn OFF the mine supply source.
2. Disconnect the mine supply source as per mine site policy.
3. If equipped with a manual spring rewind, pull on the hose to activate the return
spring and guide hose onto reel. If equipped with the hydraulic rewind option,
activate the WATER REEL/AIR REEL valve handle at the rear auxiliary control valve to
retract each hose onto its corresponding hose reel.
The functionality for this valve is as follows:
• Push the valve handle to retract the water hose onto the water hose reel.
• Pull the valve handle to retract the air hose onto the air hose reel.
Number: OM-SS2-O7
Revision: Original
USING THE GREASING SYSTEM (IF EQUIPPED)
Always follow all applicable mine site and government

regulations in regards to the handling and dispensing of
lubricants.
The following procedure is to be used as a guide for mines that do not have a standard
procedure for dispensing grease from the vehicle.
Always use gloves when handling hoses.
To dispense grease:
1. Ensure that the area around the vehicle is clear and well ventilated.
2. Follow the Parking & Shutdown procedure found in sectiontitled Carrier Operation.
3. Connect to mine air supply.
4. Ensure that the grease points around the vehicle to be lubricated are clean.
5. Remove the grease gun from its storage position.
6. Manually unwind enough grease hose so that all grease points on the vehicle can
be reached.
7. Start the grease pump by turning the grease pump ball valve handle perpendicular
to the ball valve housing.
8. Grease the vehicle as required.
9. Walk the grease gun and grease hose back to the grease transfer hose reel.
10. Retract the grease hose onto the grease transfer hose reel.
Do not allow the grease hose to retract unattended. Personal
injury or damage to equipment could occur.
Ensure that the grease hose does not twist, kink or get caught
during the retracting process. If any problems do occur, stop
the grease transfer hose reel immediately by pulling the
grease hose back out and correcting the issue.
11. Stop the grease pump by turning the grease pump ball valve handle until it is in line
with the ball valve housing.
Number: OM-SS2-O7
Revision: Original
CHANGING THE BULK GREASE DRUM (IF EQUIPPED)

Always follow all applicable mine site and government
regulations in regards to the handling and dispensing of grease.
The following procedure is to be used as a guide for mines that do not have a standard
procedure for transferring grease from the vehicle.
Handle Lifting
Point and
Grease Pump & Safety Chain
Lid Assembly
Safety Warning
Label
Quick
Disconnect
Grease Hose Tie Down Bolt
Fittings (1 of 2)
Bulk Grease
Drum
Figure 8 – Typical Bulk Grease Drum Assembly
Number: OM-SS2-O7
Revision: Original
To change the grease drum:

1. Follow the Parking & Shutdown procedure found in section titled Carrier Operation.
2. Ensure that the grease line pressure release ball valve located behind the air
filter/regulator/lubricator (FRL) assembly is in the pressure released position (the
ball valve handle is in line with the grease line pressure release ball valve body).
3. Adhere to all warnings found on the safety warning label located on the grease
pump housing. See Figure 9.
Figure 9 – Typical Safety Warning Label

4. Disconnect the quick-disconnect grease hose fittings from the fittings on the grease
pump.
5. If equipped, remove the grease drum heater from the grease drum.
Number: OM-SS2-O7
Revision: Original
6. Loosen the wing nut on each tie-down bolt enough that the tie-down bolt clears the
tie-down brackets on the lid assembly.
Before attempting to loosen the wing-nut, lift and hold the
locking pin out of its corresponding slot on the tie-down bolt.
See Figure 10.
Wing-Nut
Locking Pin
(in slot)
Tie-Down Bolt
Figure 10 – Typical Locking Pin

7. Move the tie-down bolts away from the lid assembly.
8. Using a suitable lifting device, attach it to the handle on top of the grease pump and
attach the provided safety chain to secure.
Do not lift grease drum without assistance.
9. Carefully remove the grease pump and lid assembly from the grease drum.
10. Remove the empty grease drum from the grease drum mounting plate.
11. Using a suitable lifting device, place a full grease drum into the grease drum
mounting plate.
12. Remove the lid from the grease drum.
13. Install the grease pump and lid assembly onto the grease drum.
14. Remove the safety chain from the lifting device.
15. Remove the lifting device from the handle on top of the grease pump.
16. Position the lid assembly such that the tie-down brackets on the lid assembly line
up with the tie-down bolts. See Figure 8.
17. Position the tie-down bolts onto the lid assembly.
Number: OM-SS2-O7
Revision: Original
18. Tighten the wing-nuts until the grease pump/drum is secured into the grease drum
mounting plate.
19. Ensure that the locking pin on each wing-nut falls into its corresponding slot on
each tie-down bolt. See Figure 10.
20. Connect the quick-disconnect grease hose fittings onto the fittings on the grease
pump and ensure that they are properly installed.
21. If equipped, install the grease drum heater onto the grease drum.
Number: OM-SS2-O7
Revision: Original
REMOTE PENDANT OPERATION
Figure 11 – Pendant Functionality
Number: OM-SS2-O7
Revision: Original
Connecting the Remote Pendant

When operating multiple functions, the speed at which the
devices are operating is reduced.
To connect the remote pendant to the remote receiver:
1. At the boom control panel, place the vehicle into MANUAL mode.
2. Ensure that all toggle switches on the remote pendant are in their Neutral (centre)
or Off (down) positions and that the BOOM DISABLE button is pushed down.
If the remote pendant is wireless, proceed to Step 6.
3. Plug in the battery end of the tethered cable to the remote pendant.
4. Remove the protective caps from the ends of the remote pendant’s tethered cable
and remote receiver’s mating connector.
5. Connect the remote pendant’s tethered cable connector to the remote receiver’s
mating connector.
6. Place the vehicle into AUXILIARY REMOTE mode.
7. Turn the PENDANT KEY SWITCH to the On position.
8. Place the BOOM DISABLE button in the Operating position. The POWER /
COMMUNICATIONS INDICATOR light simultaneously illuminates and quickly flashes.
If the POWER/COMMUNICATIONS INDICATOR light does not start
flashing, ensure the remote receiver’s power cable is connected.
If it is not, connect it and then turn the IGNITION switch OFF then
ON. This must be done to re-connect power to the remote
receiver.
9. With the remote pendant in hand, press the COMMUNICATION LINK/HORN button to
initiate a communication link between the remote pendant and the remote receiver.
If any toggle switch is not in their Neutral (centre) position when
the COMMUNICATION LINK button is pressed, a communication link
cannot be established.
10. The remote pendant is now ready for use.
Number: OM-SS2-O7
Revision: Original
To disconnect the remote pendant from the remote receiver:

1. On the remote pendant, push the BOOM DISABLE button down and turn off the
PENDANT KEY SWITCH. Power to the remote pendant is disabled.
2. Place the vehicle into AUXILIARY/MANUAL mode.
If the remote pendant’s tethered cable is used, continue with the following steps:
3. Disconnect the remote pendant’s tethered cable connector from the remote
receiver’s mating connector.
4. Install the protective caps to the ends onto of the remote pendant’s tethered cable
and remote receiver’s mating connector.
Notes:

Phone: 1-866-856-3626
Title: WATER SCALER OPERATION
Number: OM-SS2-O8
Revision: Original
Approved By: Darren Bowins Approved By:
GENERAL SAFETY AND OPERATIONAL INSTRUCTIONS

Failure to adhere to the recommendations and warnings of this
manual and the machine labeling could lead to equipment
damage, personal injury or death.
Always ensure that the engine end outriggers are lowered
before boom operation.
Always read and understand all labels before operating the
Shotcrete Sprayer and attached options.
ALWAYS FOLLOW MINE SPECIFIC RULES AND REGULATIONS
AT ALL TIMES!
• Before operating the shotcrete sprayer, a good understanding of the operation and
safety measures must be acquired. Only a fully trained and qualified person must
operate the Shotcrete Sprayer.
• Perform a proper pre-operational inspection of your vehicle before using it. See
section OM-SS2-O1 titled Pre-Operation Inspection for details.
• Be sure that all controls are functioning as designed and expected.
• Operate the equipment only when you are physically fit and well, and not under the
influence of alcohol or drugs.
• Thoroughly inspect all high pressure hosing and fittings before use.
It is the responsibility of the operator / mechanic to become
familiar with the requirements of all applicable mine and
government regulations and standards and the recommendations
in the safe use of the Shotcrete Sprayer and the products carried
in or on the equipment.
Number: OM-SS2-O8
Revision: Original
System Overview
The jets of water that the Water Scaler produces are extremely
dangerous! They are capable of cutting soft materials
including the human body. Always operate from the specified
protected area (operators compartment) with the doors closed.
Never operate while personal are within harm’s way.
The water scaler option on the Shotcrete Sprayer utilizes a high pressure, low volume
piston pump to push water through a group of nozzles mounted on the shotcrete nozzle
oscillating mount located at the working end of the boom.
Water is forced through the nozzles at high pressure. This creates a high velocity water
jet that is used to prepare the surface for ground support by removing loose rock and
debris from the walls, back and face of a heading prior to installing ground support.
Water Scaler Option Components

Pay special attention to all Safety information in this section.
This option produces very high pressures during operation.
These pressures can be immediately fatal to nearby personnel.
The water scaler system is capable of producing hydraulic
pressures in excess of 6600 PSI! NEVER TOUCH, OR STAND
NEAR ANY OF THE SYSTEM COMPONENTS DURING
OPERATION. NEVER STAND NEAR THE SPRAY NOZZLES
WHEN THE VEHICLE IS OPERATING!
This section of the Operator’s Manual presents all of the information related to the
operation of the high pressure, low volume water scaler option for the Shotcrete
Sprayer.
Number: OM-SS2-O8
Revision: Original
Scaler Pump and Control Valve

The system consists of a hydraulically driven high-pressure washer pump, several
control valves, high pressure hosing and several small nozzles mounted on the boom.
An application junction box (APP JB) inside the operator’s compartment contains a
switch to enable the water scaler pump functions. Some vehicles may also contain a
connector inside the operator’s compartment to provide a place to plug in the remote
pendant.
Scaler Pump Outlet

Pressure Gauge
Scaler
Pump
Outlet
Valve
Scaler
Pump
Scaler Pump
Hydraulic Control
Valve
Scaler
Hydraulic Flow Pump
Control Valve
Figure 1 - Typical Scaler Pump and Control Valve Layout
Number: OM-SS2-O8
Revision: Original
Component Description
The water scaler option on the Shotcrete Sprayer has very few components to operate.
A description of all components shown in Figure 1 is as follows:
Scaler Pump – This is a hydraulically driven high-pressure water pump. It is capable of
moving water at pressures in excess of 6600 PSI. When this pump is operating it
shakes from side to side on rubber mounts. This is normal. This pump can run dry for
short periods of time in order to flush water out. Non-potable water can also be used as
long as the strainer for both the high pressure washer pump and scaler is in place and
is 80-mesh or smaller.
Scaler Pump Outlet Valve – This is a high-pressure ball valve used to block flow from
the pump to the nozzles. This valve is closed to prevent water from passing through the
scaler pump during shotcrete spraying operations.
Outlet Pressure Gauge – This gauge shows the operator the line pressure that the
scaler is currently operating at. The normal operating range is around 3000 PSI but may
vary depending on conditions and application.
Scaler Pump Hydraulic Control Valve – This valve turns the scaler pump ON and
OFF. It is a two-position solenoid cartridge valve operated from the scaler control
junction box in the cab.
Hydraulic Flow Control Valve – This variable flow control valve controls the volume of
oil going to the scaler pump. Adjusting this valve varies the output volume and water jet
pressures.
Number: OM-SS2-O8
Revision: Original
Remote Pendant and APP JB
Water Scaler
Enable Switch
Remote
Pendant
Figure 2 – Typical Remote Pendant and APP JB
Number: OM-SS2-O8
Revision: Original
A description of all components shown in Figure 2 is as follows:
Remote Pendant – This is the same remote pendant used for normal spraying
operations. A complete description of the pendant is found in the Operator’s Manual
section OM-SS2-V5 titled System Layout & Auxiliary Controls.
Water Scaler Enable Switch – This is a three position momentary switch used to start
and stop the water scaler pump. Toggle the top of the switch to start the water scaler
pump. Toggle the bottom of the switch to stop the water scaler pump. Releasing the
switch returns it to center. This switch only enables the water scaler pump when the
vehicle is in REMOTE mode and the operator is sitting in the seat. As soon as the
operator leaves the seat, the water scaler pump is immediately disabled.
Number: OM-SS2-O8
Revision: Original
Water Scaler Nozzle Assembly
Water Scaler
Nozzle Head
Assembly
Interchangeable
Nozzles
Spray Head and

Actuator
Assemblies
Figure 3 – Water Scaler Nozzle Assembly
The jets of water that the water scaler produces are extremely
dangerous! They are capable of cutting soft materials
including the human body. Always operate from the specified
protected area (operators compartment) with the doors closed.
Never operate while personal are within harms way.
Components shown in Figure 3 are described as follows:
Spray Head Actuators – The water scaler nozzles mount directly to the same
assembly that the spray nozzle is. This gives the scaler exactly the same range of
motion that the shotcrete nozzle has.
Water Scaler Nozzle Head Assembly – This spray head holds the scaler nozzles and
acts as a manifold for them.
Interchangeable Nozzles – The scaler head contains up to three replaceable nozzles.
Each nozzle can be replaced independently. This also allows for different types of
nozzles to be used and can even allow for different types of nozzles to be used at the
same time for the best performance depending on conditions.
Number: OM-SS2-O8
Revision: Original
Using the Water Scaler Option

Because of the danger of flying rock and other debris, the area
in which the Shotcrete Sprayer is setup to scale must be roped
off and signed “DO NOT ENTER - Scaling in Progress” to keep
unauthorized personnel out of the work zone.
Use of the water scaler option is similar to that of spraying shotcrete however the actual
water scaler is more like using a very large pressure washer. To setup the scaler, refer
to the procedure below.
Setup the Scaler:
1. Connect a mine water source to the mine water inlet point on the rear of the vehicle.
The source must be able to provide about 15 gallons per minute of water. DO NOT
CONNECT THE REMOTE PENDANT YET. See Operator’s Manual section OM-
SS2-V5 titled System Layout & Auxiliary Controls for details.
2. Ensure that the remote pendant’s serial cable is disconnected from the pendant and
receiver. Store the serial cable as necessary.
3. Connect the remote pendant serial permanently routed cable coming from inside the
operator’s compartment onto the remote receiver.
4. Place the remote pendant in the operator’s compartment and connect the serial
cable that was just connected from Step 3. coming from the remote receiver
5. If not already turned on, turn ON all power to the vehicle and start the power pack or
engine.
6. Place the vehicle in AUXILIARY mode and REMOTE mode.
7. Using the remote pendant, test all boom functions.
8. Exit the cab and ensure that the mine water supply to the vehicle is turned ON.
9. Ensure that the scaler nozzles are pointed in a safe direction and the boom is fully
extended.
10. Open the scaler pump outlet valve (valve handle is in line with valve body).
11. Ensure that water is flowing out of the nozzles before starting the water scaler pump.
12. Once water flows out of the nozzles and you determine that the nozzles are pointed
in a safe direction, enter the cab.
13. While sitting in the operator’s seat, toggle the top of the W ATER SCALER ENABLE
switch on the APP JB to start the water scaler pump.
The operator must be sitting in the operator’s seat at all times
during the water scaling process. If not, the water scaler does not
function.
Number: OM-SS2-O8
Revision: Original
14. If required, pump flow/pressure/jet velocity can be adjusted using the hydraulic flow
control valve. Turn the flow control valve to adjust flow as desired.
15. Once the system is setup, shut it OFF and prepare to scale.
Using the Scaler
Once the scaler is setup, tested and ready to work, you may begin scaling with it. You
must operate the scaler from inside the cab.
As you scale, debris is falling down and flying away from the
work surface. No personnel must be near the area when
scaling unless they are seated in the cab with all of the doors
and windows shut. The area in which the Shotcrete Sprayer is
working must be roped-off to prevent access while scaling.
Falling rock and debris can damage the nozzles, actuators and
boom. Scale in a manner that avoids having falling debris
strike any of these parts.
1. Ensure that the power pack, or engine is running and that the vehicle is in
AUXILIARY mode and REMOTE mode. Enter the cab and close the door and
windows. Ensure that the fly-rock guard is not damaged and is in place.
2. Position the boom where you wish to begin scaling with the nozzles about 3-4 feet
away from the work surface.
3. While sitting in the operator’s seat, toggle the top of the W ATER SCALER ENABLE
switch on the APP JB to start the water scaler pump.
The operator must be sitting in the operator’s seat at all times
during the water scaling process. If not, the water scaler does not
function.
4. Adjust the angle of the nozzles in relation to the work surface and turn the nozzle
oscillation ON. See Operator’s Manual section OM-SS2-V5 titled System Layout &
Auxiliary Controls for details.
5. Scale as needed until ground is good.
6. When finished, disable the water scaler pump.
7. Close the scaler pump outlet valve. (Valve handle is perpendicular to the valve
body.)
Number: OM-SS2-O8
Revision: Original
Stowing the Scaler

Once scaling is complete, you must perform the following to keep the scaler system in
good operating condition. For each temperature condition, follow the specific steps then
follow the steps for both conditions.
In warm conditions, where the ambient temperature remains a minimum of 5°C / 41°F
and the scaler is used regularly, no special actions is required to stow the scaler.
1. Aim the nozzles in a safe direction and stop the scaler pump.
2. Exit the cab and proceed directly to the scaler pump outlet valve. Close the valve
(shown closed in Figure 1).
In cold conditions, where the ambient temperature drops below 5°C / 41°F or the
scaler is not used for some time, follow the steps below. These steps must also be
followed immediately after scaling when the vehicle is spraying shotcrete in cold
conditions.
1. Aim the nozzles in a safe direction and stop the scaler pump.
2. Exit the cab and go to the rear of the vehicle. Shut OFF the water inlet to the vehicle.
3. Shut off mine water to the vehicle, depressurize the line and then disconnect it.
4. Connect mine air to the vehicle’s water inlet, or a jumper hose between the vehicle’s
air outlet and water inlet.
5. Open all water outlets on the vehicle and turn ON compressed air to the water
circuit. Use only enough air volume to clear all water out of the water circuits.
6. Ensure that all water is blown out of the scaler pump and rest of the system.
7. Shut OFF air, depressurize lines and remove hoses.
8. If desired, pour about 1 liter/quart of engine or RV antifreeze into system and blow
through system with air. (This helps prevent corrosion and prevent any remaining
water from damaging components.)
Depending on the configuration of your vehicle and options
ordered, you may be able to isolate different parts of your water
system during use. Consult section OM-SS2-V5 titled System Layout
& Auxiliary Controls for information on your options. If you have
questions about which options are installed on your vehicle, you
may contact MacLean Engineering and Marketing Co., for
clarification.
Number: OM-SS2-O8
Revision: Original
Basic Troubleshooting
The following table lists several common problems with their possible solutions that
could be encountered when using the Water Scaler option on a Shotcrete Sprayer.
Problem Possible Cause(s) Possible Remedy
No water at the scaling • Water not connected to unit, or • Check Supply. Make sure all
nozzles Supply not turned on. valves are open.
• Open Pump Outlet Valve fully.
• Pump Outlet Valve not open.
• Clean out/Replace Nozzles
• Nozzles Plugged • Clean out or replace water
• Water Strainer Plugged strainer cartridge.
Scaler pump will not • Hydraulic Supply not adequate. • Check flow control valve for
turn on or runs slowly position and adjust.
• Unit not in Auxiliary or Remote
Modes • Ensure power pack or engine is
running.
• Operator not present in the
operator’s seat. • Make sure unit is in Auxiliary
Mode and Remote Mode.
Water/Oil is leaking • Pump Seals are worn out. • Overhaul Pump.
from bottom of Scaler
Pump. (More than 10 drops
per minute)
Output Pressure is low • Water inlet volume too low. • Connect to supply with a
minimum of 15 GPM of flow.
• Pump Flow Control is set to low.
• Adjust Hydraulic Flow Control
• Pump unloader set too low or is
Valve.
malfunctioning
• Adjust/Troubleshoot Pump
Unloader as needed.
Number: OM-SS2-O8
Revision: Original
Notes:

Phone: 1-866-856-3626
Title: Operator Training Topics and Checklist
Number: OM-SS3-T1
Revision: Original
Written By: Chris Wismer Revised By:
Checked By: Lynn Mitchell Checked By:
Approved By: Rick Ketter Approved By:
TRAINING TOPICS
NO PERSONS OTHER THAN THE TRAINER AND THE TRAINEE(S)
SHALL BE IN CLOSE PROXIMITY TO THE UNIT DURING
OPERATION.
MEM SS3 Shotcrete Sprayer Operator Training shall include, but may not be limited to
the following topics:
1. General Safety
2. Operating Safety
3. Servicing Safety
4. Fire Prevention Safety
Review all relevant safety topics for the unit. For this unit, materials handling safety
should also be discussed as shotcrete and accelerant are corrosive products.
5. Machine Configuration
6. Machine Safety Items
7. Operator and Passenger Compartments
8. Driver’s Instrument Panel & Controls
9. Shotcrete Pump and Related Controls
10. Boom and Related Controls
Review operator’s manual sections and discuss all points as outlined in manual.
Familiarize operator with the machine’s configuration. Review all points with operator on
the unit to ensure he/she understands and can identify all safety points discussed in the
Safety Items section. Identify possible pinch points and safety hazards. Review the
location and function of all operator controls and gauges and displays. Review any
relevant safety issues pertaining to the unit’s configuration and controls.
11. Pre-Operation Inspection
Review the operator’s manual section and discuss all points as outlined in the manual.
Review all points with the operator on the unit and demonstrate a proper pre-op
inspection. Highlight safety points and importance of daily Machine Pre-Operational
Inspection, Maintenance, and Controls Testing.
OM-SS3-T1 Page 1 of 8
Number: OM-SS3-T1
Revision: Original
12. Modes of Operation & Interlocks

Review operator’s manual sections and discuss all points as outlined in the manual.
Familiarize the operator with the Machine’s Drive and Auxiliary modes and
Manual/Remote sub-modes. Familiarize the operator with the unit’s Interlocks by
reviewing all points on machine and demonstrate systems so he/she understands and
can identify all Interlocks and their function.
13. Carrier Operation
Review operator’s manual sections and discuss all points as outlined in the manual.
Familiarize the operator with Carrier Operations. Review all points with the operator on
the unit and demonstrate systems so he/she understands and can identify all
components pertaining to operating the Carrier. The operator should be comfortable
with starting, driving, parking and shutdown, and tagging the vehicle “Out of Service”.
14. Brake Test Procedure
Review Operator’s Manual section and discuss all points as outlined in the manual.
Review and demonstrate the Brake Test Procedure. Highlight the importance of
performing Brake Tests in accordance with company policy, as well as local law and
during Pre-Operation Inspection.
15. Recommended Fluids and Lubricants.
Identify Oil and Lube specification label in driver’s dash area (or as installed) of the unit.
Discuss importance of using correct fluids and lubricants as well as maintaining proper
levels and reducing contamination.
16. Lubrication Chart
Review the operator’s manual sections. Review all fluid specifications and all fluid fill
points on the unit. Review lubrication frequency and familiarize operator with all
lubrication points. Emphasize the importance of checking fluids daily and greasing unit
at all prescribed intervals.
17. Boom and Outriggers
Review operator’s manual section and discuss all points as outlined in the manual.
Familiarize the operator with all boom functions, outrigger controls and safety features.
Review boom capacities/reach distances and general maintenance. Demonstrate the
boom controls, outrigger controls and ensure the operator is comfortable with all control
functions. Ensure the operator is comfortable using the remote control pendant. The
operator should be comfortable with preparing the unit for operation, operating the
boom, and stowing the boom.
Page 2 of 8 OM-SS3-T1
Number: OM-SS3-T1
Revision: Original
18. Setting Up the Unit to Spray

Review procedure for setting up the unit to spray. This must include:
• Workplace Inspection and Ventilation Check prior to setup (adherence to mine
standards)
• Positioning the unit properly for spraying.
• Connection of power, water and compressed air.
• Filling the accelerant system.
• Deploying the Boom and installing the nozzle.
• Coating unit with form oil.
• Slicking the shotcrete delivery system.
• Lubricating the shotcrete delivery system(pump)
• Testing and inspecting the shotcrete delivery system.
• Valve positioning for spraying operations.
• Ensuring a good layout of all service cables and hoses for access to the pump
hopper
19. Spraying with the Unit
Review the proper methods for washing/scaling with the unit. Ensure the operator is
familiar with how to use the machine for scaling (if equipped) and for washing the work
surface prior to spraying shotcrete. This must include valve positions.
Review how to properly connect a Maclean Engineering MEM-TM3 Transmixer to the
unit if used. This will include compressed air and accelerant transfer connections and
methods.
Review proper method for spraying shotcrete. This must include boom movement
techniques, pump (shotcrete and accelerant) rate adjustments and air pressure
adjustments. It must also include techniques for dumping into the hopper,
maintaining/monitoring shotcrete flow, and recognizing/managing potential/common
problems.
Review and practice procedures such as stopping the machine due to line plugs,
unplugging lines and emergency emptying of the unit due to a breakdown.
Number: OM-SS3-T1
Revision: Original
20. Cleaning the Unit

Review and practice proper methods for cleaning the machine when spraying is
complete. These items must include:
• Emptying and cleaning the shotcrete pump and delivery lines
• Flushing the Accelerant Injection System
• Washing down the unit.
• Post operation lubrication.
21. Job Teardown
Review methods for packing the unit up when the job is finished. This includes:
• Stowing the boom and attached hosing
• Disconnecting and stowing cables, hosing, remote, etc.
• Properly lifting and locking the pump and outriggers for transport.
22. General Review
Review any items of safety or operation that the operator is not clear on.
23. Operator’s Test
Have trainee(s) complete operator’s test OM-SS3-T2
Number: OM-SS3-T1
Revision: Original
Training must include the documentation of all topics covered. The trainer and the
trainee(s) must sign-off for each topic covered and the time spent in training.
A training checklist is provided on the following page in which this information should be
recorded.
Notes regarding the trainee’s previous operating experience should be made (General
previous experience – number of years & type equipment, has the trainee operated
MacLean Utility Vehicles or had partial training in the past?)
Any deviations or additions to the training agenda should be recorded either on the
checklist sheet or in a Service Report Summary (record training related SRS #’s in the
table following the checklist).
All information must be copied to MacLean Engineering’s Technical Service
department.
Certification will only be issued once checklist has been completed and signed off by
trainee and trainer.
No trainee shall be certified unless the MacLean trainer is satisfied that the individual
can safely and competently operate the piece of equipment.
Number: OM-SS3-T1
Revision: Original
OPERATOR CHECKLIST
MINE SITE: MINE UNIT #:
TRAINER: DATE:
TRAINEE Print: EMPLOYEE #:
Signature:
COMPLETED
SECTION TOPIC NOTES / COMMENTS
Initial
OM-UTV-S1 General Safety
OM-UTV-S2 Operating Safety
OM-UTV-S3 Servicing Safety
OM-UTV-S4 Fire Prevention Safety
OM-SS3-V1 Machine Configuration
OM-SS-V2 Machine Safety Items
Operator & Passenger
OM-SS3-V3
Compartments
Driver’s Instrument Panel &

OM-SS3-V4-MERC
Controls
OM-SS3-O1-MERC Pre-Operation Inspection

OM-SS-O2 Modes of Operation & Interlocks
OM-SS3-O3-MERC Carrier Operation
OM-UTV-O4 Brake Test Procedure
Recommended Lubricants and
OM-SS-O5-MERC
Fluids
OM-SS3-O6-MERC MEM-SS3 Lubrication Chart
OM-SS3-O7 Shotcrete Sprayer Components
Total # of Training Hours =__________

Test Score = __________
Number: OM-SS3-T1
Revision: Original
TRAINING RECORDS
PREVIOUS EXPERIENCE:
Record the trainee’s previous operating experience below (general experience - # years
& type equipment, has the trainee operated MacLean Utility Vehicles or received partial
training in the past?)
SRS REFERENCES:
Record the #’s of any Service Report Summaries relating to the training of the operator.
Number: OM-SS3-T1
Revision: Original
NOTES:

Phone: 1-866-856-3626
Title: MEM-SS3 Shotcrete Sprayer Operator Training Test
Number: OM-SS3-T2
Revision: Original
Written By: Chris Wismer Revised By:
Checked By: Lynn Mitchell Checked By:
Approved By: Rick Ketter Approved By:
MEM-SS3 Shotcrete Sprayer Operator Training Test
Please fill in the sections below:
Company: Date:
Mine Site: Contact:
Instructor: Machine:
Trainee: SRS #: (office use only)
Read the questions carefully. For questions requiring a written answer, you may keep
your answer short but complete. For multiple choice questions circle the corresponding
letter for the answer that is most correct. For True/False questions, circle your answer.
1) Name the locations of the three (3) fire suppression palm actuators and how
to activate them if the need arose.
a) _______________________________________________________________
b) _______________________________________________________________
c) _______________________________________________________________
2) Name two (2) mechanical safety devices on the MEM-SS3 Shotcrete Sprayer.
a) _______________________________________________________________
b) _______________________________________________________________
Title: MEM-SL3 Shotcrete Sprayer Operator Training Test
Number: OM-SS3-T2
Revision: Original
3) There are 4 Emergency Stop buttons on the MEM-SS3 Shotcrete Sprayer.

Name their locations and their functions.
a) ________________________________________________________________
b) ________________________________________________________________
c) _______________________________________________________
d) ________________________________________________________________
4) When should an Operator’s Brake Test be performed? (circle one)
a) Whenever you feel like it.
b) At the beginning of your shift
c) Before you enter a ramp
d) Both b and c
5) Name any two safety Interlocks found on the SS3 Shotcrete Sprayer.
a) ________________________________________________________________
b) ________________________________________________________________
6) If the MEM-SS3 Shotcrete Sprayer fails the daily brake test, what must be
done?
________________________________________________________________
________________________________________________________________
Number: OM-SS3-T2
Revision: Original
7) The Pump Hoist Position Sensor circuit is used as an: (circle one)
a) Interlock
b) Indicator/warning
c) Both
8) What are the ventilation requirements for the SS3 Shotcrete Sprayer, and
where can this information be found on the machine?
_______________________________________________________________
_______________________________________________________________
9) Before performing any checks or maintenance in the midship area of the unit,
what must you do first?
_______________________________________________________________
_______________________________________________________________
10) Number the steps in order to change unit over from Drive Mode to Auxiliary
Mode.
a) ( ) Place transmission in Neutral
b) ( ) Bring unit to complete Stop
c) ( ) Apply Park Brakes.
d) ( ) Place Mode switch in Auxiliary
11) When driving the unit on a ramp what is the best practice? (circle one)
a) Place unit in 1st gear, turn on the engine brake and run the engine at max RPM.
b) Place unit in a gear suitable for your ramp, drive to conditions and use
supplemental (engine) braking as needed.
c) Pick a gear, point it where you want to go and hope for the best.
Number: OM-SS3-T2
Revision: Original
12) In point form, briefly describe how to park a disabled unit on the ramp.
________________________________________________________________
________________________________________________________________
________________________________________________________________
________________________________________________________________
________________________________________________________________
13) What is a safe distance between vehicles when travelling the ramp?
a) 30 feet
b) 100 feet
c) If the machine ahead is too slow help them out.
d) Follow local regulations and site policies.
14) If the SS3 Shotcrete Sprayer breaks down while spraying, approximately how
long do you have to move the shotcrete before it begins to set in the system?
a) 10-15 minutes
b) 3-3.5 hours
c) 30-45 minutes
d) Take all the time you need.
15) What is the first thing you must do before operating the machine?
a) Change date on yesterday’s pre-op slip.
b) Kick the tires, pick up the wheel chocks, start engine and go.
c) Perform a complete Pre-op, perform a complete walk around inspection and

perform the prescribed Daily Brake Test.
d) Turn on the Master Switch.
Number: OM-SS3-T2
Revision: Original
16) When handling shotcrete accelerant or the accelerant transfer system on the
SS3 Shotcrete Sprayer you should:
a) Wear all required PPE and be careful.
b) Treat it like it’s water.
c) Get your partner to do it.
d) You must be qualified to handle accelerant.
17) When mounting and dismounting the SS3 Shotcrete Sprayer, you should
always:
a) Use the provided steps, ladders and handles/hand rails.
b) Jump on or off the unit to speed up your job.
c) Use 3 or 4 point contact as required.
d) Both A and C
18) What is the minimum interval for washing your SS3 Shotcrete Sprayer?
a) Daily (every shift)
b) Weekly
c) Monthly
d) That’s the cross-shift’s job.
19) When should form oil be applied to the unit?
a) Weekly
b) Monthly
c) At the beginning of each shift and as needed through the shift.
d) Form oil is optional, just don’t splash the shotcrete.
Number: OM-SS3-T2
Revision: Original
20) When working inside of the pump hopper you should:
a) Trust the grate interlock switch to keep the unit from running.
b) Shut down the unit, and apply locks and tags as per site or local regulation.
c) Never work inside the hopper.
d) Leave the unit running and have someone guard the controls while you work in
the hopper.
21) If your skin comes in contact with shotcrete what should you do?
a) Let it cure and peel it off later.
b) Wash it off right away with clean water and soap (if available).
c) Have partner pressure wash you off.
d) Wash it off in the shower at the end of the shift.
22) In point form, list the steps required to safely connect the unit to mine power.
__________________________________________________________________
__________________________________________________________________
__________________________________________________________________
__________________________________________________________________
__________________________________________________________________
__________________________________________________________________
__________________________________________________________________
__________________________________________________________________
23) When operating in Auxiliary Mode, Remote Sub-mode, the shotcrete pump
can only be stopped and started from the Remote Control Pendant.
TRUE FALSE
Number: OM-SS3-T2
Revision: Original
24) The Shotcrete Process Control Panel and the Shotcrete Boom Control Panel
contain some identical controls that can be used at the same time.
TRUE FALSE
25) Before shotcrete is placed into the hopper, what must be done to prepare the
system to prevent blockage of the shotcrete hoses, nozzle, pump, etc.
a) Fill hopper with water and pump through until it comes out of the nozzle. Allow it
to sit in the lines for 5 minutes.
b) Nothing, dump in shotcrete and start spraying.
c) Fill hopper with water and a slicking agent, mix for several minutes using reverse
mode of the pump on a low speed. Pump mixture through system and let it sit in
the hoses for at least 5 minutes.
d) Either A or C
26) Why is the proper amount of air pressure required at the nozzle for spraying
operations?
a) For air entrainment in the shotcrete for greater strength.
b) To spray the shotcrete further so you can reach into tight spots behind pipes and
cables.
c) For proper shotcrete compaction on the work surface.
d) For a wider spray pattern to shorten the time it takes complete a job.
27) When cleaning the unit after completing a job, which component is it
necessary to clean thoroughly?
a) Hopper and Pump assembly
b) Shotcrete Delivery Pipes and Hoses
c) Injection Ring and Nozzle
d) Any covers, shields or components that have shotcrete on them.
e) All of the above.
Number: OM-SS3-T2
Revision: Original
28) If one or both compressors shutdown unexpectedly, the operator should:
a) Continue to spray with low or no air pressure.
b) Stop spraying operations immediately, call an electrician and wait.
c) Stop spraying, shut off the shotcrete/accelerator pumps and try to restart the
compressor(s) at least one minute after they have shutdown.
d) Continue spraying at reduced pump output until your partner gets the
compressor(s) running.
29) When tramming the unit short distances (less than 500 meters) it is
acceptable to not use the boom support stand.
TRUE FALSE
30) As a best practice for care of the Accelerant System, you should:
a) Completely flush the accelerant system out with water after every job is
complete.
b) Flush the accelerant system out at the end of the shift.
c) Leave the accelerant system filled with accelerant at all times.
d) Mix the accelerant with water so it “self flushes” the system at all times.
31) The shotcrete pump must be greased:
a) At the beginning of the shift.
b) With a power greaser
c) Never, it is self lubricated.
d) Remixer bearings at the beginning of the shift, Swing tube bearings about once
per hour.
Number: OM-SS3-T2
Revision: Original
32) Briefly describe the importance of having all the holes in the injection ring
open.
__________________________________________________________________
__________________________________________________________________
__________________________________________________________________
__________________________________________________________________
__________________________________________________________________
33) If a plug occurs in the shotcrete delivery hoses, the first thing you must do is:
a) Decrease air pressure.

b) Wait 10 more seconds to see if blockage will clear by itself.
c) Beat hose with hammer to clear blockage.
d) Stop the shotcrete pump.
34) When should the air compressor intake filter be checked?
a) Weekly
b) During a scheduled maintenance.
c) Daily / Beginning of the shift
d) Both b and c
e) Only when there is low air flow from the compressors.
35) The “Water Box” of the shotcrete pump lubricates the pump piston seals.
You should only fill it with:
a) Special shotcrete pump oil
b) Almost any clean, free-flowing lubricant including water will do.
c) Water.
d) Water-Glycol mix.
Number: OM-SS3-T2
Revision: Original
36) When connecting or disconnecting the remote control:
a) Shut down the unit and turn off the Master Switch
b) You can do it if the machine is running.
c) You must have an electrician do it for you.
d) You must have a mechanic do it for you.
NOTES: You may use this space for extra room when answering questions if you
require.

Phone: 1-866-856-3626

SS2-017 - Shotcrete Sprayer - Operator Manual - v001 - r0

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Mining Division

FOR INFORMATION OR ASSISTANCE

The proprietary information contained in this document is the property of

Module # Rev Date Topic

Revision: Original Revision Date: 21-DEC-2018 By: VMR

FOLLOW MINE SPECIFIC RULES AT ALL TIMES!

• Use recommended safety devices and personal protective equipment, i.e.

• Follow the recommended daily inspection procedure outlined in this manual as

• NEVER operate a machine that has been tagged “Out of Service”.

Always notify operator when approaching the utility vehicle!

If any questions or problems arise, please contact Maclean Engineering Technical

ALWAYS NOTIFY THE MACHINE OPERATOR WHEN

If any questions or problems arise, please contact MacLean Engineering Technical

• Follow the mine site’s lock-out and tag-out procedures.

If any questions or problems arise, please contact MacLean Engineering Technical

FIRE PREVENTION SAFETY

When working in a confined environment, it is impossible to prevent combustive dust

If any questions or problems arise, please contact Maclean Engineering Technical

SS2 SHOTCRETE SPRAYER OVERVIEW

Figure 1 – Typical Operator’s Side Layout

The layout of the passenger’s side of the vehicle is shown in Figure 2.

The layout of the rear of the vehicle is shown in Figure 3.

Figure 3 – Typical Rear View Layout

The layout of the front of the vehicle is shown in Figure 4.

Shotcrete, Air and

Pressure Washer and

Figure 5 – Typical Front Support Platform

Figure 6 – Typical Articulation and Envelope

Refer to the Ventilation Requirements label located on the

If any questions or problems arise, please contact MacLean Engineering Technical

MACHINE SAFETY ITEMS

Figure 1 – Typical Portable Fire Extinguisher Location

Fire Suppression Fire Suppression

Figure 2 – Typical Fire Suppression System Layout

If your vehicle is equipped with a power pack, and your fire

Figure 3 – Front Passenger Side Fire Suppression Manual Palm Actuator

Rear Fender Passenger Side Fire

If the fire suppression system is activated, the pressure switch

Figure 5 – Typical Nozzle Locations (MEM-SS2 Shown)

Each customer has their own requirements for fire suppression.

Figure 6 – Typical Articulation Lock Bar

Figure 7 – Typical Articulation Lock Bar Storage Location

EMERGENCY/PARK BRAKE BUTTON

Figure 8 – Typical Emergency/Park Brake Button & Ignition Switch

MAIN BATTERYDISCONNECT SWITCH (Master Switch)

Figure 9 – Typical Main Battery Disconnect Switch & Lockout

EMERGENCY STOP BUTTONS

Figure 10 – Typical Operator’s Compartment Location

A second is located on the boom control panel as shown in Figure 11.

Figure 11 – Typical Boom Control Panel Location

Figure 12 – Typical Main AC Electrical Panel and Remote Pendant Location

SHOTCRETE PUMP TILT LOCK (IF EQUIPPED)

Figure 13 – MEM-SS3 Pump Lock- Up/Down Position

Figure 14 – MEM-SS2 Pump Lock - (shown in the down, unlocked position)

SHOTCRETE PUMP POSITION SENSOR

Figure 15 – Typical Hopper Lowered Indicator Light Location

Figure 16 – Pump Interlock Sensor Location

HOPPER GRATE SAFETY DEVICES

Figure 17 – Grate Pin Locked Figure 18 – Grate Pin Unlocked

Figure 19 – Grate Safety Chain

SHOTCRETE HOSE CLAMP SAFETY PINS

Figure 20 – Shotcrete Hose Clamp and Safety Pin

HYDRAULIC AND WATER SYSTEMS SAFETY