Atlas Copco Exploration Products

Pumpac Grout Pump

PUMPAC®
PUMPAC BASIC
Safety and Operating Instructions

© 2014 Atlas Copco Craelius AB | No. 6991 0903 01p | 2014-08-13

 Safety and operating instructions

Contents
Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Safety signal words . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Personal precautions and qualifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Hoisting and transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Storage, repair, maintenance and disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Personal protective equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Drugs, alcohol or medication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Safety area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Hoisting and transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Operation, precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Maintenance, precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9

Signs and stickers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Prohibition signs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
Warning signs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
Slip risk. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Moving parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Regulatory signs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
General regulatory signs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Information signs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Other signs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Rig data plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Patent protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Genuine parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Design and function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
Main parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
PUMPAC® . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Injection valve (hydraulic control panel) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
PUMPAC BASIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Danger zones . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Safe zones . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Safety devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Emergency stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Hoisting and transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

© 2014 Atlas Copco Craelius AB | 2014-08-13 3

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Safety and operating instructions

Hoisting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
PUMPAC® . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Safety check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
Emergency stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Preparation before start. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
Electric supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Water supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Grouting system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Before start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
Electrical cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Hydraulic control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Grout-line outlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Grouting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
After grouting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Service schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
Valve overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
Cylinder overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
Mounting tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
Replacing the pressure gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
Replacing the rubber hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
Refilling of glycerine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
Service. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
Service Kits for grout cylinder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Service Kits for piston rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Service Kits for valves standard and optional . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Service Kits for hydraulic control panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
Hydraulic schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
Lubricant recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Troubleshooting chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30

Disposal and environmental instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Oil and Grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

4 © 2014 Atlas Copco Craelius AB | 2014-08-13

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 Safety and operating instructions

Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Electrical components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Chemicals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Dust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Metals (steel, aluminum, etc.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Plastics and rubber. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Pressure vessel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Material Safety Data Sheets (MSDS/SDS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Optional equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Valve seat HD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32

Technical specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
PUMPAC®/PUMPAC BASIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
Valve system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Grout cylinder ø 80mm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Capacity graph PUMPAC 80B22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Grout cylinder ø 110 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Capacity graph PUMPAC 110B22 110B15, 110B8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Grout cylinder ø 150 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Capacity graph PUMPAC 150B22, 150B15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Hose couplings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
PUMPAC® . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
PUMPAC BASIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
Sound power level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
Sound pressure level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35

© 2014 Atlas Copco Craelius AB | 2014-08-13 5

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Safety and operating instructions

Introduction
These instructions are intended for operators of the Atlas Copco equipment. The aim of the
instructions is to provide you with knowledge of how to use the equipment in an efficient
and safe way. These instructions also give you advice and tell you how to perform regular
maintenance on the equipment. It does not replace thorough training of operator, it is a
complement. For further information concerning service measures, please contact your
nearest Atlas Copco representative.
Always read these instructions carefully and make sure that you understand all of them
before starting for the first time.

The owner of the equipment is granted the permission to take copies of this publication
solely for internal use. It is recommended, however, to order additional copies from Atlas
Copco representative in order to benefit from the latest revision. Atlas Copco Craelius AB
reserves the right to make changes in its products in order to improve design or performance
characteristics without notice. The information in this publication is assumed to be accurate at
the time of publication, but is subject to changes in order to remedy detected deficiencies or
to follow changes in the product.
Any user of this publication is requested to inform Atlas Copco Craelius AB about deficiencies
found, particularly in matters concerning product safety.

© 2014 Atlas Copco Craelius AB | 2014-08-11

Introduction
 Safety and operating instructions

Safety instructions  are aware of all the relevant national safety

instructions and accident prevention instructions
To reduce risk of serious injury or death to yourself or
others, read these safety instructions before operating  and have read and understood the Safety and
the machine. Post these safety instructions at work operating instructions.
locations, provide copies to employees, and make
sure that everyone reads the safety instructions before Operation
operating or servicing the machine. Comply with all
safety regulations. Operation of the equipment may only be undertaken
by qualified operators. Operators are qualified if they:
All possible hazards cannot be covered here, but we
highlight some of the most important. For additional  have undergone theoretical and practical training
safety information consult: on the equipment in conformity with the national
directives,
 Other documents and information packed with this
machine.  are aware of all the relevant national safety
instructions and accident prevention instructions
 Appropriate standards as referred to in the EC
Declaration of Conformity, if provided.  and have read and understood the Safety and
operating instructions.

Safety signal words Personal protective equipment

WARNING Entanglement hazard
The safety signal words Danger, Warning and Caution Loose fitting clothing and jewelry can get caught in
have the following meanings: the moving parts of the machinery and cause serious
injury or death.

DANGER Indicates a hazardous situation ►Do not wear jewelry and loose fitting clothes.
which, if not avoided, will result Always use approved protective equipment. Operators
in death or serious injury. and all other persons in the working area must wear
protective equipment, including at a minimum:
WARNING Indicates a hazardous situation  Protective helmet
which, if not avoided, could
result in death or serious injury.  Hearing protection in accordance with occupational
health and safety regulation
CAUTION Indicates a hazardous situation  Impact resistant eye protection with side protection
which, if not avoided, could  Respiratory protection when appropriate
result in minor or moderate
injury.  Protective gloves

Personal precautions and  Proper protective boots

qualifications Drugs, alcohol or medication

Only qualified and trained persons may operate or WARNING Drugs, alcohol or medication
maintain the equipment. Always use your common Drugs, alcohol or medication may impair your
sense and good judgement. judgment and powers of concentration. Poor reactions
and incorrect assessments can lead to severe
Hoisting and transport accidents or death.
Hoisting and transport of the equipment may only be ►Never use the machine when you are tired or under
undertaken by persons who: the influence of drugs, alcohol or medication.
 are authorized to operate a crane or fork-lift truck in ►Prevent other people from using the machine if
conformity with the applicable national directives, they are under the influence of drugs, alcohol or
medication.
 are aware of all the relevant national safety
instructions and accident prevention instructions
 and have read and understood the safety and
hoisting and transport chapters of this manual.

Storage, repair, maintenance and disposal

Storage, repair, maintenance and disposal of the
equipment may only be undertaken by persons who:

© 2014 Atlas Copco Craelius AB | 2014-08-11 7

02 Safety Instructions Grouting Ed.2
Safety and operating instructions

Safety area WARNING Dust hazard

When drilling with compressed air, the rock cuttings
WARNING Falling objects can cause serious are carried out of the bore in the form of small cuttings,
injury or death and dust, which can cause serious injury.
During operation, falling objects from great heights can Some dusts, fumes or other airborne material created
cause bodily injury and extensive damage. during use of the machine may contain chemicals
►Close off the working area. known to the State of California to cause cancer
and birth defects or other reproductive harm. Some
►Before starting always make sure no unauthorized
examples of such chemicals are:
persons are within the working area of the drill rig in
use.  Crystalline silica, cement and other masonry
products.
►Immediately stop operation when persons are
present in the danger area.  Arsenic and chromium from chemically-treated
rubber.
 Lead from lead-based paints.
Hoisting and transport ►To reduce your exposure to these chemicals, work in
WARNING Heavy equipment can cause serious a well-ventilated area and work with approved safety
injury equipment, such as dust masks that are specially
designed to filter out microscopic particles.
►Use a sling dimensioned for the load it will carry.
►Use a dust collector, or spray water with a water/
►Use only straps that are intact and intended for the
foam pump.
load in question.
WARNING Unexpected movement can cause
►Never use a damaged rope/sling.
serious injury
►Fasten straps in lifting eyes when present. If control levers and switches are not set to neutral
►Always lift at the center of gravity. position, starting the machine can lead to unexpected
movements and can therefore cause injury.
►Always make sure that nobody is under or anywhere
near a suspended load or within the swing radius of ►Set control levers and switches to neutral positions
the rope/sling. prior to starting up.

►Observe great care when strapping and lifting heavy WARNING Noise hazard
objects. High sound levels may cause permanent hearing loss.
NOTICE Sling can damage components ►Use hearing protection in accordance with
►When lifting, make sure that the sling will not occupational health and safety regulations.
damage the hydraulic hoses, mechanical WARNING Emergency situation
components etc.
An emergency situation can occur due to material
failure or incorrect handling.

Operation, precautions ►Stop the operation by pushing the emergency stop

button or if available pull the trip wire.
WARNING Hydraulic oil at high pressure ►Check proper function of the rig safety equipment at
Thin jets of hydraulic oil under high pressure can least once beginning of each shift.
penetrate the skin and cause permanent damage. WARNING Gas line pressurized, Explosion
►Immediately consult a doctor if hydraulic oil has hazard
penetrated the skin. If the equipment comes in contact with gas lines and
►Never use your fingers to check for hydraulic fluid explosives, an explosion could occur. Explosions will
leaks. lead to severe injuries or death.

►Keep your face away from any possible leaks. ►Never operate the machine in any explosive
environment.
►Never use the machine near flammable materials,
fumes or dust.

8 © 2014 Atlas Copco Craelius AB | 2014-08-11

02 Safety Instructions Grouting Ed.2
 Safety and operating instructions

►Make sure that there are no undetected sources of ►Always use original parts and accessories approved
gas or explosives. by Atlas Copco.
►When working in areas where gas lines are buried, WARNING Heavy machine can cause serious
make sure that your equipment is placed on the injury
windward side. ►During service and maintenance work, all
►Shut down all combustion engines, like hydraulic components that may be brought into motion or fall
power pack, generators etc. must be supported or tied secure.

►Leave the machine immediately. WARNING Thermal cracks may arise when
welding
►Warn people to evacuate the area.
►Do not do any welding on the equipment without
►Contact emergency personnel. consulting Atlas Copco.
►Contact the gas company to shut the gas off. WARNING Hot engine parts can cause burn
►Stay out of the area until the gas company declares ►Make sure the engine is turned off before all
the area to be safe. maintenance work and before refueling
►Be careful when draining hot oil and fluids
►Do not handle flammable fluids in the vicinity of hot
Maintenance, precautions surfaces, sparks or naked flames
WARNING Hydraulic oil WARNING Electric shock
Spilled hydraulic oil can cause burns, accidents by ►Do not touch live electrical lines
slippery conditions and will also harm the environment.
►Only authorized electricians may carry out work on
►Take care of all spilled oil and handle it according to the electrical system.
your safety and environment regulations.
►Only qualified electricians should perform any
►Never dismantle the hydraulic components when the electrical troubleshooting or maintenance. Remove
hydraulic oil is hot. all watches and rings that could contact live electric
circuits.
WARNING Hydraulic system under high
pressure ►Make sure all power to the system has been cut
Maintenance and repair on the machine and the before carrying out any maintenance work.
hydraulic equipment under pressure can lead to ►All electric cabinets should remain locked when not
severe injuries. Connections can loosen suddenly, under direct control of qualified electrician.
parts can suddenly move and hydraulic oil can be
ejected. ►Do not use the cabinets as a toolbox or spare
parts storage container. The inherent vibration and
►Depressurize the hydraulic system before magnetism associated with transformer and motor
performing maintenance on the hydraulic starters can cause inadvertent contact of foreign
equipment. objects with live circuits.
►Never replace high pressure hoses with hoses of ►Some electrical components may have power when
lower quality than the original or with hoses that the main circuit breaker is open, verify that power is
have removable couplings disconnected before servicing.
Pressure settings are always performed on a ►Do not tamper with safety interlock circuits, safety
pressurized system. guards or other safety devices, except as required
►Always exercise the greatest caution. during normal maintenance and troubleshooting.

►Pressure settings must only be performed by trained ►Confirm that all safety devices and circuits are
personnel. replaced and functioning before operation is
resumed.
WARNING Rotating parts can cause serious
injury and damage
►Always turn off the engine before performing any
maintenance or service on the equipment.
WARNING Machine modification
Any machine modification may result in bodily injuries
to yourself or others.
►Always contact your Atlas Copco Customer Center
before you modify the machine.

© 2014 Atlas Copco Craelius AB | 2014-08-11 9

02 Safety Instructions Grouting Ed.2
Safety and operating instructions

Signs and stickers Moving parts

The equipment is fitted with signs and stickers
containing important information about personal safety
and maintenance.
The signs and stickers shall always be easy to read.
Some of the following signs may be used on your
grouting equipment. Part numbers displayed on these
signs are designated to the plates only.

Prohibition signs

Moving parts can cause injuries.

♦ Keep out of the machine’s working area when it is in
♦ No admittance operation.

♦ No admittance for unauthorized personnel.

♦ Violation can cause personal injury. Regulatory signs

General regulatory signs

8915 0020 84

♦ Never put anything inside the CEMAG/CEMIX while

the engine is running.
♦ Violation can cause personal injury. ♦ The foot protection symbol means that you have to
wear boots.
♦ The eye, ear and head protections symbol means
Warning signs that you have to wear a hard hat, eye and ear
protection.
Slip risk ♦ The hand protection symbol means that you have to
wear hand protection.
♦ The instruction book symbol means that you have
to read the Safety and Operating instructions before
the equipment is used for the first time.

Slippery surface can cause injuries.

♦ Be careful when moving around on the rig.
♦ Do not run on the rig.

10 © 2014 Atlas Copco Craelius AB | 2014-08-13

03 Signs and stickers Unigrout Ed.2
 Safety and operating instructions

Information signs

Hydraulic oil drain

Other signs
Fire extinguisher

Rig data plate

See the Technical specifications section for further
information.

Atlas Copco Craelius

MÄRSTA - SWEDEN

A
Name
Hoisting/lifting point Type
Serial No.
Diesel power kW
B Rated voltage V Hz C
Electric power kW
I.P.
Gross weight kg D
3716 5522 00 Made in Sweden 201
AIB 100000282_00

A. Machine type
B. Serial number
C. The warning symbol together with the book symbol
means that the user must read the safety and operating
Hydraulic oil pressure instructions before the machine is used for the first time.
D. The CE symbol means that the machine is CE-approved.
See the CE Declaration of Conformity which is delivered
with the machine for more information.

Patent protection

Hydraulic oil level and temperature

Hydraulic oil filter

This product is protected by one or several world wide

patents.

© 2014 Atlas Copco Craelius AB | 2014-08-13 11

03 Signs and stickers Unigrout Ed.2
Safety and operating instructions

Genuine parts Cement Additive

3716 5565 83 3716 5565 81

Filling Emptying

3716 5565 87 3716 5565 54

Lower level limit Manually

3716 5565 84 3716 5565 86

Number 1 Number 2

1
3716 5565 78
2
3716 5565 79

For best performance make sure to always use

genuine Atlas Copco spare parts.

Before starting,
oil must be filled
according to lubricant
recommendations in the
Maintenance section
On Off

3716 5565 32 3716 5565 33

On/Off Water flow

3716 5565 31

3716 5565 27

3716 5565 35
Rotation 3716 5565 36
Rotation
Clockwise Counter-
clockwise

Grout flow Grout pressure

G
G
3716 5565 53 3716 5565 37

Rotation speed System pressure

regulation

3716 5565 06 3716 5565 01

Mixer Agitator

3716 5565 51 3716 5565 50

Hydraulic flow Vibrator

3716 5565 52 3716 5565 82

12 © 2014 Atlas Copco Craelius AB | 2014-08-13

03 Signs and stickers Unigrout Ed.2
 Safety and operating instructions

Overview Main parts

To reduce the risk of serious injury or death to yourself
or others, read the Safety instructions section found on
the previous pages of this manual before operating the PUMPAC®
equipment.

Design and function G

The PUMPAC® is a double-acting piston pump,

capable of pumping most grout mixes used in F
combination with sealing and reinforcement work in E
rock and overburden formations. D
H
C
 Medium pressure, high flow, cylinder diameter 150
mm. B

A
 High pressure, medium flow, cylinder diameter 110
mm.
 Heavy duty, extra high pressure, low flow, cylinder
A. Skid frame
diameter 80 mm
B. Quick release male connetion, inlet
The pump consist of hydraulic oil tank, hydraulic piston C. Electric motor
pump driven by an electric motor. A double-acting D. Pump cylinder
hydraulic cylinder with an integrated switch-over valve E. Ball valves
connected to a double-acting pump cylinder with F. Pressure meter
valves. G. Injection valve (hydraulic control panel)
The hydraulic system consist of hydraulic oil tank, H. Level indicator with low level switch
hydraulic piston pump driven by an electric motor. A
double-acting hydraulic cylinder with an integrated
switch-over valve. An oil-cooler connected to a fresh
water intake and the piston rod flushing.
M
The entire unit is mounted on a rigid skidframe,
provided with fork lift slots. Grout flow and grout
pressure are set by hydraulic control valves on the
valve block L
K
Pumpac basic O J

PUMPAC BASIC is the actual pump unit of the I

PUMPAC® and it is meant to be powered by an P
N
external hydraulic power unit.

Intended use
The pump system PUMPAC is intended for grout,
drilling fluid, mud, paint and pulp
I. Hydraulic pump
Unintended use J. Hydraulic return oil filter
Any use going beyond this shall be considered K. Hydraulic pump drive
”Unintended use”. The manufacturer is then not liable L. Water/Oil cooler
for damage occuring as a result; such use shall be at M. Electrical cabinet
the owner’s risk. Proper use also includes observing N. Slots for fork lift
information in operation-, service-, and maintenance O. Water connection (water/oil cooler and piston rod
books as stipulated by the manufacturer. flushing)
P. Hydraulic oil tank

© 2014 Atlas Copco Craelius AB | 2014-08-13 13

04 Overview Pumpac Ed.3
Safety and operating instructions

Injection valve (hydraulic control panel) Danger zones

A
A
C

A A

B D

m ft
A 1 3
During normal operation it is advised to always use
personal protective equipment within the danger zone.
A. High pressure setting valve
B. High and low pressure valve Safe zones
C. Grout flow setting valve
The area outside the danger zones are to be
D. Low pressure setting valve
considered as safe zones.

PUMPAC BASIC Safety devices

Emergency stop
C D
PUMPAC®
B

A. Stand
B. Pump cylinder
AIB 100000266_00

C. Ball valves
D. Hydraulic drive
The emergency stop button (A) is located on the front
side of the electrical cabitet.

1 2

AIB 100000357_01

The emergency stop button is activated by pressing

it (1). To reset an emergency stop button turn it
clockwise untill it pops out to normal position.

14 © 2014 Atlas Copco Craelius AB | 2014-08-13

04 Overview Pumpac Ed.3
 Safety and operating instructions

Hoisting and transport

WARNING Heavy equipment can cause serious
injury
►Use a sling dimensioned for the load it is intended to
carry.
►Use only straps that are whole and intended for the
load in question.
►Never use a damaged rope/sling.
►Fasten straps in lifting eyes when present.
►Always lift at the centre of gravity.
►Always make sure that nobody is under or anywhere
near a suspended load or within the swing radius of
the rope/sling.
►Observe great care when strapping and lifting heavy
objects.
NOTICE Sling can damage components
►When lifting, make sure that the sling will not
damage the hydraulic hoses, mechanical
components etc.

Hoisting

PUMPAC®

The PUMPAC® is mounted on a skid that has two

lifting slots for forklift (A).

© 2014 Atlas Copco Craelius AB | 2014-04-09 15

05 Hoisting and Transport Pumpac Ed.1
Safety and operating instructions

Operation Preparation before start

DANGER electric shock
Touching live electrical wires will cause serious injury Electric supply
or death.
In case of emergency:
►Never touch live and damaged electrical wires.
1. Press the emergency stop button
WARNING Running engine
2. Reset the emergency stop button by turning it
If the equipment is left unattended with the engine
clockwise.
running serious damage and injury can occur.
►Never leave the equipment unattended with the
A D
engine running.
WARNING Unexpected movement can cause I
O
serious injury
C E
If control levers and switches are not set to neutral
position, start of the machine can lead to unexpected
movements and can therefore cause injury.

01
8_
►Set control levers and switches to the neutral

02
00
00
10
positions prior to starting up.

AIB
B

WARNING Hydraulic oil at high pressure A. Electrical cabinet

Thin jets of hydraulic oil under high pressure can B. Main switch
penetrate the skin and cause permanent damage.
C. Start button(I) / Stop button(0)
►Immediately consult a doctor if hydraulic oil has
D. Signal lamp
penetrated the skin.
E. Emergency stop button
►Never use your fingers to check for hydraulic fluid
leaks. Standard electrical motor is designed for 400 V, 50 Hz.
(For other voltage or freq. contact your AC dealer).
►Keep your face away from any possible leaks.
1. Check all electric connections.
2. Check the direction of the rotation on the motor
Safety check when starting (phases can be changed without
warning on site). See arrow on the flange
There are safety devices built into the system for your between the motor and the hydraulic pump.
personal safety. Before each shift commences, an
extra and thorough safety check shall be carried out
on the equipment.
♦ Check the safety devices at least once every shift to
ensure that they are in full working order, so that you
know that they will be operational the moment you
need them.
♦ If you are unsure of the equipment's reliability, do
not put it into operation. Direction of rotation for the motor
3. In case of wrong direction, two phases must be
Emergency stop changed by an electrician.
♦ Check that the emergency stop stops the engine
by pressing the emergency stop button while the Water supply
engine is running.
Hydraulic oil cooler and piston rod flushing.
♦ Reset the emergency stop after use.

A. Connection for the fresh water source

16 © 2014 Atlas Copco Craelius AB | 2014-08-13

06 Operation Pumpac Ed.2
 Safety and operating instructions

♦ Connect the fresh water to the water connection A. Filter indicator

that supplies the water/oil cooler and piston rod B. Filter insert, cartridge (under the cap)
flushing (A) to a fresh water source. 3-6 liters / min.
is sufficient for continuous operation. Maximum Grouting system
pressure is 4 bar.
Grouting equipment
Hydraulic system L
♦ The hydraulic system is supplied without hydraulic
D
fluid. H
F
C G
B
Hydraulic oil level and temperature
A
A I

K
E H
B J

A. Measuring meter from Water tank

B. Mixer
C. Agitator
D. Return hose
A. Oil level indicator with low level switch E. Ball valve, outlet
B. Oil temperature gauge F. Ball valve, return circulation.
4. Before starting, the tank should be filled to at
G. Grout pump
least half level of the indicator (A).
H. Suction hose
♦ Recommended oil temperature for operation is 50°
to 70° C. I. Delivery hose
J. Grout recorder
♦ The tank can be drained via a bottom drainage plug.
K. Ball valve
Filter L. Packer

Hydraulic filter and indicator 1. Connect a suction hose between the agitator
and pump inlet.
The filter cartridge filtration efficiency is 0,010 mm. The
indicator (A) turns to red during operation when the 2. Connect a shut-off valve and a pressure hose
filter cartridge needs replacing. When replacing the of correct rating between the pump outlet and
cartridge, carefully clean the filter housing. packer (or back to the agitator for circulation).
3. Check that the whole grouting system is ready
for operation – hoses, packers, grout mix
e.t.c. A by-pass kit for pump recirculation is
A recommended.

Before start
1. Check that PUMPAC suction and delivery lines
are connected and open for operation.
B 2. Check hydraulic fluid level in hydraulic tank.
3. Open water flow through the water / oil cooler.
Adjust to 3-6 liters / minute. Max. 4 bar.
4. Open water flushing to the piston rod.

© 2014 Atlas Copco Craelius AB | 2014-08-13 17

06 Operation Pumpac Ed.2
Safety and operating instructions

Start 9. Adjust the flow valve to nearly closed by rotating

it clockwise.
10. Turn Hi-Lo pressure lever (D) to the requested
Electrical cabinet pressure range.

A D 11. Turn the requested pressure setting valve to a

low pressure.
I 12. Let the pump make a few strokes to get rid of air.
O
E 13. Close pump outlet and bypass valve on the
C
injection line.
14. Adjust hydraulic pressure setting valve until
requested max. grout pressure is set on the
gauge (B)
01
8_
02
00
00
10
B

B
AI

Grout-line outlet
A. Electrical cabinet
B. Main switch B

C. Start button(I) / Stop button(0)

D. Control lamp
E. Emergency stop button
A
1. Check that the emergency stop is not activated.
2. Turn on the main switch.

Hydraulic control unit A. Grout-line, outlet

♦ The pressure gauge (E) only shows the pressure in B. Pressure gauge (grout)
the hydraulic system.

Grouting
A C
E ♦ The grout flow should not be allowed to stop for
more than a few minutes. In case of trouble, let it
circulate back to the agitator until the problem is
solved.
1. Open pump outlet and start injecting.
2. Adjust pump flow with the flow setting valve.
3. Check hydraulic oil temperature. Should be 50°
to 70° C. Adjust cooling water accordingly.
D B
4. Check water flushing on the piston rod.
A. High pressure setting valve
B. Low pressure setting valve Piston rod water flushing
C. Flow setting valve
D. Hi-Low pressure valve
E. Hydraulic pressure gauge
3. Turn Hi-Lo pressure (D) valve to neutral.
4. Start the electric motor by pressing the green
button
5. Check direction of rotation
6. Check the hydraulic filter indicator. If indicating
red in low ambient temperature, check again
when oil is warmer.
7. Check that the emergency stop stops the motor.
8. Start the electric motor again.
18 © 2014 Atlas Copco Craelius AB | 2014-08-13
06 Operation Pumpac Ed.2
 Safety and operating instructions

After grouting
DANGER Electric shock
Spraying water on the electrical motor and cabinet can
cause serious injury and death.
►Never spray water on electrical equipment.
►Be careful when cleaning electrical equipment.
The following steps should be carried out after every
work shift. This is vital to ensure that the equipment
stays in optimal working condition. For instructions on
disassembly se "Valve overhaul" on page 22.
1. Clean the pump and hoses after completion of
grouting or when there is an extended break in
grouting operations.
2. Connect a spray gun to a side outlet of the pump
and clean the outside of the equipment.
3. Switch off by pressing the stop button and
turning the main switch to "OFF" after flushing.
4. Press the emergency stop button before leaving
the pump

A D

I
O
C E
01
8_
02
00
00
10
B

B
AI

A. Electrical cabinet
B. Main switch
C. Start button(I) / Stop button(0)
D. Signal lamp
E. Emergency stop button

© 2014 Atlas Copco Craelius AB | 2014-08-13 19

06 Operation Pumpac Ed.2
Safety and operating instructions

Maintenance
DANGER electric shock
Touching live electrical wires will cause serious injury or death.
►Never touch live and damaged electrical wires.
WARNING Hydraulic system under high pressure
Maintenance and repair on the machine and hydraulic equipment under pressure can lead to severe injuries.
Connections can loosen suddenly, parts can suddenly move and hydraulic oil can be ejected.
►Depressurize the hydraulic system before performing maintenance on the hydraulic equipment.
►Never replace high pressure hoses with hoses of lower quality than the original or with hoses that have
removable couplings
►Immediately consult a doctor if hydraulic oil has penetrated the skin.
►Never use your fingers to check for hydraulic fluid leaks.
►Keep your face away from any possible leaks.

2
1

5
4

9
6

20 © 2014 Atlas Copco Craelius AB | 2014-08-13

07 Maintenance Pumpac Ed.3
 Safety and operating instructions

Service schedule

• = Check/Inspect/Clean = Change/Replace/Overhaul

Ref. Description Daily Weekly Monthly Yearly Remark Service

Kits
1 Grease nipple for the Keep rod lubricated. Use
injecting piston rod
• universal grease.
2 Check all hoses & Check for wear & leakage
couplings
• replace when neccessary.
3 Hydraulic oil tank Check oil level. Change oil
• and filter* every year or every
1000 hours.
4 Tank breather Clean with paraffin.
•
5 Hydraulic oil filter Check indicator, during
• operation. If red, change
filter* and oil.
6 Pressure gauge Check with reference gauge.
•
7 Valves, for the Clean and check for wear.
injectionline • Replace if worn.
8 Cylinder, injectionline Clean and check for wear.
• Replace if worn.
9 Wash & clean After each shift/job circulate
equipment
• water through pump until
water is clean Wash off the
equipment.
* Hydraulic filter cartridge part no. 3716 5985 01
For wear and service parts, See spare parts list 6991 5101 62b.

© 2014 Atlas Copco Craelius AB | 2014-08-13 21

07 Maintenance Pumpac Ed.3
Safety and operating instructions

Valve overhaul
♦ The following steps should be taken every week or
when necessary.

H G

5. Grease threads, grooves, piston ends, o-rings

A. Nut and seals before reassembling.
B. Pressure meter
6. Inspect, clean and replace worn parts. High
1. Loosen nut (A) and remove the pressure meter
pressure means increased risk of wear (leading
(B)
to erosion) on valve seats.
Rear end, cylinder cover
Valve seats (A) with o-rings (B)
D C
C B

2. Loosen nuts (C) to free and raise the upper

manifold and outlet valves (D).
3. Remove the outlet valves (E,F)

Outlet valves

B
F
E
AIB-100000740_01

4. Loosen nuts (G) to free the lower manifold and

remove the inlet valves (H).

Inlet valves

22 © 2014 Atlas Copco Craelius AB | 2014-08-13

07 Maintenance Pumpac Ed.3
 Safety and operating instructions

Cylinder overhaul 7. Locate the piston rod joint connection (A) and
piston rod separation tool (B).
1. Remove the valves as described in the section
A
Valve overhaul.
2. Reassemble the two valves (outlet and inlet) to
the front cylinder cover.
3. To secure that the grout cylinder and the
injection line will stay in place while removing the
rear cylinder cover, slightly tighten the nuts over
the front cylinder cover and let the outlet and
inlet valve remain in position (F).

AIB-100000741_00
Rear cylinder head B

8. Remove the bolts from the joint reinforcement

and separate the flange from the locking sleeve.

4. Losen the nuts that holds the rear cylinder cover

(A).

AIB-100000742_00
Rear end cylinder cover
9. Place the supplied tool on the rod as illustrated.
The groove on the tool must face the locking
sleeve.
A

5. Swing out the linkscrews with nuts (E). Turn

the extractor nut clockwise to push the cylinder
cover free from the cylinder (F)
6. Pull out the rear cylinder cover and inspect the
AIB-100000743_00

cylinder covers and cavity for hardened cement

particles, remove if necessary (E). 10. Run the hydraulics until the locking sleeve
separates.
Rear cylinder cover

C
AIB-100000744_00

© 2014 Atlas Copco Craelius AB | 2014-08-13 23

07 Maintenance Pumpac Ed.3
Safety and operating instructions

11. Remove the split cotters . 21. Inspect the grout cylinder outer seals to see if
there are any worn seals or o-rings that need to
be replaced.

Grout cylinder 150 mm

AIB-100000745_00
12. Separate the piston rods.

Grout cylinder 110 mm

AIB-100000746_00

13. Exchange parts even if they are only slightly

worn. Erosion begins as soon as a way is
opened through the sealing system.
14. Loosen the bushing screws.
15. The bushing screws (A) can be removed and
inserted in the threaded holes in the flange for
extraction of the bushing. 22. Pull out the piston and piston rod from the
cylinder.
Bushing
23. Inspect the grout cylinder for wear or surface
scrathes.These could cause leakage and
decrease the effect of the pump.
24. Inspect the piston seals for wear and damage.
If worn disassemble the piston and replace the
seals.

A Mounting tools
A. Screw
16. Inspect and clean these surfaces: The piston Mounting tools for the injection line
rod, seals and o-rings. Spanner 46 mm
17. Replace if necessary.
Piston seal mounting tool for 110 mm and 150 mm
18. Pull out the cylinder with piston and piston rod. grout cylinder,
19. Exchange parts even if they are only slightly 3716 6499 00 för 110 mm grout cylinder.
worn. Erosion begins as soon as a way is
opened through the sealing system. 3716 6500 00 för 150 mm grout cylinder.

20. Clean o-ring grooves, rod ends and other sealing

surfaces carefully before reassembling. Note
that hardening cement can build very thin almost
invisible layers.

24 © 2014 Atlas Copco Craelius AB | 2014-08-13

07 Maintenance Pumpac Ed.3
 Safety and operating instructions

Replacing the pressure gauge Replacing the rubber hose

Caution Pressure I J
Installing the wrong pressure gauge can break it. K
G
►Make sure the pressure gauge is rated for the F
H
pressure provided by the cylinder it is intended to be D
E
used with
L
Pressure meter components
C

I J A B
K
G
F
H 1. Remove the pressure gauge (L), nipple (E) and
E D
air nipple (I)

L
2. Undo bolts (C).
C 3. Retract end covers (B).

A
4. Remove damaged rubber hose (H).
B
5. Insert new rubber hose.
A. Housing
B. End cover 6. The hose should extend 6 mm outside of the
C. Cap screw outer tube on both sides.
D. Seal washer
E. Nipple
F. Manometer nipple
G. Gasket
H. Hose
I. Air nipple
J. Set screw
K. Bearing ball
L. Pressure gauge
7. Mount end covers (B).
1. Undo the nipple (F) beneath the pressure gauge 8. Tighten bolts (C), carefully, both sides at the
(L) and then lift off the gauge same time to avoid forcing the hose out of
position.
2. Turn the new gauge (L) upside down.
9. Refilling of glycerine. See the section refilling of
3. Pump glycerine into the gauge until it indicates
glycerine for further information.
approx. 5 bar. Wait for air to escape. Repeat until
all air has escaped.
4. Keep gauge upside down.
5. Release vent screw (J) a few turns.
6. Check that the hole in the vent screw is open.
7. Top up nipple (F) with glycerine.
8. Install the gauge (L) at nipple (F).
9. Check gasket (G).
10. Let the excessive glycerine escape through the
vent screw (J) until no pressure remains.
11. Close the vent screw (J).

© 2014 Atlas Copco Craelius AB | 2014-08-13 25

07 Maintenance Pumpac Ed.3
Safety and operating instructions

Refilling of glycerine Service

I J Service Kits for grout cylinder
K
G Overhaul kit, grout cylinder 110 mm.
H
F
D
Seal kit, grout cylinder 110 mm.
E
Overhaul kit, grout cylinder 150 mm.
L
C Seal kit, grout cylinder 150 mm.

A B Service Kits for piston rod

1. Remove the pressure gauge (L) and the air Overhaul Kit, Piston rod bushing.
nipple (I). Seal Kit, Piston rod.
2. Take out the vent screw (J) and the bearing ball Overhaul Kit, hydraulic pump drive.
(K) from the air nipple.
Seal Kit, hydraulic pump drive
3. Check that the pressure gauge is full of
glycerine. See separate instruction. Overhaul Kit, Pressure meter
4. Keep the pressure gauge with the connection
upwards. Service Kits for valves standard and optional
Ball valve “B”
5. Keep the transmitter unit in horizontal position
with the gauge and air nipple openings upwards. Overhaul Kit, Ball valve “B”
6. Fill glycerin through the gauge opening (F) until it Seal Kit, Ball valve and Heavy duty, “B”, “HD”.
overflows in the air nipple opening. Ball valve. Heavy duty “HD”
7. Move the transmitter unit slightly, to be sure that Overhaul Kit, Ball valve. Heavy duty “HD”
no air is trapped inside.
Seal Kit, Ball valve and Heavy duty, “B”, “HD”.
8. Install the air nipple (I).
Disc valve “DV”.
9. Mount the ball (K).
Overhaul Kit, Disc valve “DV”.
10. Check that the hole in the vent screw (J) is open.
Seal Kit, Disc valve “DV”.
11. Mount the vent screw (J) but do not tighten.
12. Fill glycerine up to the top of nipple (F). Service Kits for hydraulic control panel
13. Check gasket (8) and install the pressure gauge Hydraulic control panel.
again. Let the excessive glycerine slowly escape
through the vent screw (J) until no pressure
remains.
14. Close the vent screw (J).

26 © 2014 Atlas Copco Craelius AB | 2014-08-13

07 Maintenance Pumpac Ed.3
 Safety and operating instructions

Hydraulic system
The hydraulic system main components consists of a HYDRAULIC DRIVE (1) which consist of a hydraulic cylinder
with a hydraulic operated directional valve (1A) integrated in the rear cylinder cover. This valve is controlled by an
electric operated pilot directional valve which in turn is actuated by two Inductive Transducers ( S1 and S2 ) , one
at each end of the piston-stroke.
An HYDRAULIC CONTROL UNIT (2) with start and stop functions of the HPPD pump unit. Flow (2E) and pressure
controls (2B,2C) for independent setting of flow and pressure. Choice of setting two different pressure levels for
easy operation when for example Tube-Manchett-Grouting is carried out.
By presetting the hydraulic pressure, which is related to the injection pressure, the pump will automatically stop
when the preset pressure value is reached. If the pressure lowered the pump will start again.
All manual valve cartridges can be replaced by optional electrical operated valve cartridges for remote control or
other external controls of the PUMPAC. With this feature can one or all functions be remote controlled. Contact AC
for suggestions.
Two HYDRAULIC PUMPS (3) , the main pump (3A) is an axial pressure compensated piston pump feeding the
HPPD. The flow and pressure can be set independently and adjusted during operation. Swhiching between two
preset pressure levels is also possible during operation by turning lever (2G).
The second pump (3B), of gear type, circulate the hydraulic oil through the water-oil cooler and back to the
hydraulic tank and the tank mounted return filter. This feature also allows possibility to connect an optional
hydraulic agitator, CEMAG, to the system.
A pressure relief valve (4) set to 210 bar controls the maximum pressure in the gear pump (3) circuit.
The frame mounted HYDRAULIC TANK (5) is provided with a Filler Cap with breater (5A), a Return Filter (5B), a
Drain Plug (5C) and a Level and Temp Gauge (5D). The Temp Gauge also contains a low lewel swhich connected
to the electric motor starter box which allows the electric motor to automatically stop if the hydraulic oil level is to
low. This feature will prevent damage to the hydraulic components if leakage occurs or if a hose breakes.
A WATER-OIL COOLER (5E) is flexibly mounted on the mounting base plate and connected to a water intake with
two On/Of ball valves, one for the water/oil cooler and the other one to the piston rod water flushing device. A flow
of 3-6 l/min is sufficient for the cooling.

© 2014 Atlas Copco Craelius AB | 2014-08-13 27

07 Maintenance Pumpac Ed.3
Safety and operating instructions

Hydraulic schedule

1. Hydraulic piston pump drive

A. Directional valve
B. Pilot valve
C. Pressure reducing valve
4 3 2. Hydraulic control unit
A. Differential sensing valve
5 B. Pressure relief valve
C. Pressure relief valve
D. Cavity (for electric operated
flow control valve)
E. Needle valve
F. 2 position 2-way valve
G. On/Off 3-way directional valve
H. Orifice 0.8 mm
I. Orifice 0.8 mm
3. Hydraulic pumps
A. Axial piston pump
B. Gear pump
4. Pressure relief valve
5. Hydraulic tank
A. Filler cap with breather
B. Return filter
C. Drain plug
D. Level and temp. gauge
E. Water/oil cooler.

28 © 2014 Atlas Copco Craelius AB | 2014-08-13

07 Maintenance Pumpac Ed.3
 Safety and operating instructions

Lubricant recommendations
Lubricant Recommendation
Hydraulic oil Use mineral-based hydraulic oil with good anti-wear, rust (oxidation) and foam inhibiting
properties, as well as effective air and water separation abilities. The viscosity grade should
correspond to the ambient temperature and ISO 3448, as follows:

Ambient temp. °C (°F) Viscosity grade Viscosity index

+25 to +40 (77 to 104) ISO VG 68 Min.95
0 to +25 (32 to 77) ISO VG 46 Min. 95
-30 to 0 (-22 to +32) ISO VG 32 Min. 95
Examples of oil grades in the temperature range 0 to + 25°C
Shell Tellus T46
BP Bartran HV 46
Castrol Hyspin T 46
Mobil DTE 15M
Texaco Rando HDZ 46
Exxon UNIVIS HP 46
Use of flame proof or vegetable hydraulic oil, please contact the
nearest Atlas Copco representative for information.
Grease Universal grease NLG12 .............................Operating temperature °C (°F)
lithium/molybdenum additive........................Max. 100° (212°)
Synthetic sodium or calcium grease.............Max. 140° (284°)
Example of grease grades
Shell Retinax AM
Esso MP Grease
BP Energrease LS-EP 2

© 2014 Atlas Copco Craelius AB | 2014-08-13 29

07 Maintenance Pumpac Ed.3
Safety and operating instructions

Troubleshooting
Troubleshooting chart
Trouble-shooting
Fault Cause Action to tale
Piston in the grout 1.Cylinder has not been cleaned. 1.Dismantle the cylinder and clean it properly.
cylinder blocked.
2.Reassemble the clamps in the correct position.
Pump supplies no 1.Hydraulic pressure setting valve is 1.Clean the pressure valve or change valve
grout flow. clogged. cartridge.
2.Pressure control valve screwed to 2.Adjust and set the correct pressure.
fully open position.
3.Clean the hose.
3.Suction hose clogged.
Pump supplies 1.Pump is vaccuming air. 1.Check the condition of the suction hose and
irregular flow and make sure the end of the hose is submerged
2.Ball valve is jammed.
pressure. below the surface.
3.Worn or damaged seal in the pump
2.Remove the valve and check that no dirt or
cylinder.
other particles are to be found between the ball
and valve seat.
3.Replace the seal.
Pressure gauge on 1.Gauge has not been cleaned 1.Clean the gauge properly or replace it.
the outlet Iine gives no properly.
reading.
Oil temperature too 1.Too little oil in the tank. 1.Top-up with new oil of the correct quality.
high during grouting
2.Malfunction of the hydraulic pump 2.Replace the pump.
sequences.
3.Either very little or no cooling water 3.Connect cooling water to the cooler coil.
connected to the cooler coil in the Check the water flow.
hydraulic tank.
Electric motor rotates 1.Phases incorrectly coupled. 1.Contact an authorized electrician to reconnect
in wrong direction. the two phases at their connections.
Electric motor 1.Flow setting too high in relation to 1.Reduce the flow or pressure.
protection breaker cuts pressure.
2.Check all fuses, etc. Consult an electrical
(overload).
2.Total malfunction of one phase. service engineer.

30 © 2014 Atlas Copco Craelius AB | 2014-08-13

08 Trouble shooting Pumpac Ed.1
 Safety and operating instructions

Disposal and environmental Chemicals

Chemicals such as flushing additives, other additives
instructions and coolants can be environmentally hazardous.
♦ Dispose of chemicals such as drilling additives, other
Always follow the local regulations in force for the additives, glycol etc. according to the manufacturer’s
handling and disposal of waste. instructions.
♦ Treat the chemicals in accordance with local
Oil and Grease regulations for both handling and waste disposal.
Leaking hydraulic connections and lubrication grease ♦ Avoid the use of cleaning agents containing solvents
are environmentally hazardous. Changing oils, like carbon tetrachloride. There are environmentally
replacing hydraulic hoses and different types of filter better alternatives now available on the market.
can be environmentally hazardous.
♦ Always collect oil residue, oil spillage, waste with Dust
oil content, lubrication grease residue and spillage. Rock dust can pose a health danger.
Treat the hazardous material in accordance with
local regulations. ♦ Use dust binding oil.

♦ Use biodegradable hydraulic fluids and lubrication

oils for Atlas Copco products wherever possible.
Metals (steel, aluminum, etc.)
Contact your local Atlas Copco office for further ♦ These products are recyclable and should be taken
information. care of according to national regulations.

Engine Plastics and rubber

Engine exhausts are poisonous and environmentally ♦ These products are often labeled according to
hazardous. different classes. In those cases they are recyclable,
they should be taken care of according to national
♦ Good ventilation is essential when the diesel engine regulations.
is running.
♦ Well-maintained air filters help to keep down Pressure vessel
emission levels. A pressure vessel can cause serious injury.
♦ Discarded accumulators or gas springs must be
Fuel
rendered harmless.
Fuel spillage is environmentally hazardous and a fire
hazard. ♦ A discarded pressure vessel that has not been
punctured must be treated like a pressure vessel.
♦ Always collect fuel residue and spillage. Treat in
accordance with local regulations.
Material Safety Data Sheets (MSDS/SDS)
Batteries
Batteries contain acids and heavy metals. For this Material Safety Data Sheets (MSDS/SDS) for the
reason, expended batteries can be hazardous to the chemical products included in the delivery are
environment and to health. available at the:

♦ Expended batteries must be sent for destruction in Atlas Copco Safety Data Sheets Repository
accordance with local regulations.

Full link
Electrical components
Some electronic components contain batteries and http://www-1.atlascopco.com/__C125712A0045C780.
other components which could be hazardous to the nsf/CustViewProd20?OpenView
environment and personal health. Certain types of
work lighting contain mercury and could therefore
constitute environmental and health hazards. Please download the specifications from this link.

♦ Treat the components according to local regulations

in force for destruction and waste disposal.

© 2014 Atlas Copco Craelius AB | 2014-08-11 31

09 Disposal Ed.3
Safety and operating instructions

Optional equipment
Valve seat HD
The standard valve seats can if needed be changed to
reinforced heavy duty (HD) seats.
HD seats are preferred when pumping high abrasive
fluids like microcement and when pumping at high
pressure, to prevent valve seat wear out.

Valve seat with heavy duty reinforcement (A)

AIB-100000774_01

32 © 2014 Atlas Copco Craelius AB | 2014-08-13

10 Optional equipment Pumpac Ed.0
 Safety and operating instructions

Technical specifications Capacity graph PUMPAC 110B22 110B15,

110B8
7,5 kW
PUMPAC®/PUMPAC BASIC
100 15 kW
Technical data and dimensions specified in this
chapter is assumed to be accurate at the time of the
80 22 kW
publication. 60
40
Valve system
Ball valve (Std). 20
Option: HD (Heavy duty), DV (Disc valve)
0 20 40 60 80 100 120 140
Hydraulic pump capacity ............................ 0 - 63 l/min
Oil tank volume ...................................................... 45 l
Grout cylinder ø 150 mm
For Oil grade, water/oil cooler, see the section
Lubricant recommendations. Grout flow ................................................. 0 - 200 l/min
Two grout pressure setting levels
Voltage Low pressure .................................................2 - 10 bar
Voltage, current (22 kW motor) 400 V, 41 A, 50Hz
High pressure ................................................8 - 50 bar
Voltage, current (15 kW motor) 400 V, 28 A, 50Hz
Electric motor 1470 rpm ..................................... 22 kW
For other voltage or freq. contact your AC dealer. Electric motor 1455 rpm ..................................... 15 kW

Grout cylinder ø 80mm

Capacity graph PUMPAC 150B22, 150B15
Grout flow ................................................... 0 - 60 l/min
Bar
Two grout pressure setting levels
60
Low pressure .................................................2 - 10 bar 15 kW
50
High pressure ..............................................8 - 200 bar 22 kW
40
Electric motor 1470 rpm ..................................... 22 kW
30

Capacity graph PUMPAC 80B22 20

10
L/min
250
0
200 22 kW 0 20 40 60 80 100 120 140 160 180 200 220 240
150
100 Hose couplings
50 Inlet .................................................. Quick coupling 2”
Outlet ................................................................ 1” BSP
0 10 20 30 40 50 60 70
Weight
Grout cylinder ø 110 mm Weight with 22 kW motor .................................. 470 kg
Grout flow ................................................. 0 - 120 l/min Weight with 15 kW motor .................................. 423 kg
Two grout pressure setting levels Note: To get the performance according to the
capacity graphs the hydraulic flow should be 0-65
Low pressure .................................................2 - 10 bar
l/min and max hydraulic pressure is 215 Bar.
High pressure ..............................................8 - 100 bar
Electric motor 1470 rpm ..................................... 22 kW
Electric motor 1455 rpm ..................................... 15 kW
Electric motor .................................................... 7,5 kW

© 2014 Atlas Copco Craelius AB | 2014-08-11 33

11 Technical specifications Pumpac Ed.2
Safety and operating instructions

Dimensions

PUMPAC®

C B

Dimensions mm in
A 960 37.8
B 1500 59
C 730 28.7

PUMPAC BASIC

C B

Dimensions mm in
A 860 33.8
B 1400 55
C 360 14.2

34 © 2014 Atlas Copco Craelius AB | 2014-08-11

11 Technical specifications Pumpac Ed.2
 Safety and operating instructions

Weight
Weight kg lb
Pumpac (with 22 kW motor) 470 1036
Pumpac (with 15 kW motor) 423 932.5
Pumpac Basic 215 474

Sound power level

Conditions dB(A) rel 1pW

Normal operation 85

Sound pressure level

Conditions dB(A) rel 20μPa

1 meter from rig 79

© 2014 Atlas Copco Craelius AB | 2014-08-11 35

11 Technical specifications Pumpac Ed.2
 © Copyright 2014, Atlas Copco Craelius AB, Märsta, Sweden. Any unauthorized use or copying of the contents or any part thereof is prohibited. This applies in
particular to trademarks, model denominations, part numbers and drawings. Illustrations and photos in this document may show equipment with optional extras.

www.atlascopco.com
6991 0903 01p Märsta, Sweden, 13 August 2014 Specifications and equipment subjects to change without notice. Consult your Atlas Copco Customer Center for specific information.