Multiquip C-30HD User Manual

PARTS AND OPERATION MANUAL

Concrete Pump

Model C-30HD

Revision #4 (03/06/01)

MULTIQUIP INC

18910 WILMINGTON AVE. 800-427-1244 CARSON, CALIFORNIA 90746 FAX: 800-672-7877 310-537-3700 800-421-1244 800-478-1244 FAX: 310-537-3927 FAX: 310-631-5032

E-mail:mq@multiquip.com • www:multiquip.com

Atlanta • Boise • Dallas • Houston • Newark Montreal, Canada • Manchester, UK Rio De Janiero, Brazil • Guadalajara, Mexico

. PARTS DEPARTMENT:

SERVICE DEPARTMENT/TECHNICAL ASSISTANCE:

PAGE 2 — C-30HD — PARTS & OPERATION MANUAL — REV. #4 (03/06/01)

HERE'S HOW TO GET HELP

PLEASE HAVE THE MODEL AND SERIAL NUMBER ON-HAND WHEN CALLING

PARTS DEPARTMENT

800-427-1244 or 310-537-3700 FAX: 800-672-7877 or 310-637-3284

SERVICE DEPARTMENT/TECHNICAL ASSISTANCE

800-478-1244 or 310-537-3700 FAX: 310- 537-4259

WARRANTY DEPARTMENT

888-661-4279, or 310-661-4279 FAX: 310- 537-1173

MAIN

800-421-1244 or 310-537-3700 FAX: 310-537-3927

C-30HD — PARTS & OPERATION MANUAL — REV. #4 (03/06/01) — PAGE 3

TABLE OF CONTENTS

Here's how to get help ............................................ 3

Table of contents..................................................... 4

Parts ordering procedures ...................................... 5

C-30HD

Specifications.......................................................... 6

Pump Warranty ....................................................... 7

Safety Instructions .................................................. 8

Important Hand Signals .......................................... 9

General Information .............................................. 10

How it Works ....................................................12-13

Operating Information/Clean-Up Procedures ..14-18

Concrete Mix Information ................................ 19-22

Slump Test Procedure ........................................... 23

Explanation Of Codes In Remarks Column .......... 24

Suggested Spare Parts ......................................... 25

Component Illustrations

Control Panel......................................................... 25

Frame ...............................................................26-27

Gasoline Engine Control .................................28-29

Diesel Engine Control ......................................30-31

Manifold Assembly (Exploded View) .................... 33

Concrete Delivery ............................................ 34-35

Clutch Assembly ................................................... 36

Crankshaft Assembly (Exploded View) ...........38-39

Crankshaft Assembly.......................................40-41

Countershaft Assembly ................................... 42-43

Compensator Piston Rod ................................44-45

Connnecting Rod Assembly (Old Style) ..........46-47

Connnecting Rod Assembly (New Style) ........48-49

Rocker Assembly .............................................50-51

Compensating Spring Assembly .......................... 52

Return Spring Assembly ....................................... 53

Oil System and Fuel System ...........................54-55

Central Grease Lubrication Panel ......................... 56

Axle Installation ................................................58-59

Hopper and Hood ............................................ 60-61

Optional Features

C-30MG Scaled Down Manifold/Cylinder Kit ........ 62

C-30MG Manifold Assembly............................64-65

C-30MG Piston Head Components.................66-67

C-30SP Optional Screw Conveyor

and Torque Limiter ...........................................68-69

Recommended Shotcrete System ..................70-71

Shotcrete Accessories .....................................72-73

Service Information

Service Procedures ......................................... 74-75

Manufacturing Changes................................... 76-78

Remote Controls, Engine RPM ............................ 79

Wiring Schematic ............................................. 80-81

Linkage Adjustment (Old Style Solenoid) ............ 82

Torque Limiter Model (C30SP Option) ................. 83

Bearing Installation ............................................... 84

Connecting Rod Assembly ................................... 85

Piston Head Lubrication System .......................... 86

Return Spring Adjustment Procedure .................. 87

Belt and Chain Adjustment ................................... 88

Roller Chain — Application Information .......... 89-90

Terms and Conditions of Sale — Parts .................91

NOTE: Specification and part number are subject to change without notice.

PAGE 4 — C-30HD — PARTS & OPERATION MANUAL — REV. #4 (03/06/01)

PARTS ORDERING PROCEDURES

Dealer account number

Dealer name and address

Shipping address (if different than billing address)

Return fax number

Applicable model number

Quantity, part number and description of each part

Specify preferred method of shipment:

UPS Ground

•

UPS Second Day or Third Day*

•

UPS Next Day*

•

Federal Express Priority One (please provide us with your Federal

•

Express account number)*

Airborne Express*

•

Truck or parcel post

•

*Normally shipped the same day the order is received, if prior to 2PM west coast time.

Earn Extra Discounts when

you order by FAX!

All parts orders which include complete part numbers and are received by fax qualify for the following extra discounts:

Number of line items ordered Additional Discount

1-9 items 3% 10+ items** 5%

Get special freight allowances when you order 10 or more line items via FAX!**

UPS Ground Service at no charge for freight

PS Third Day Service at one-half of actual freight cost

No other allowances on freight shipped by any other carrier. **Common nuts, bolts and washers (all items under $1.00 list price)

do not count towards the 10+ line items.

Extra Fax DiscountExtra Fax Discount

Extra Fax Discount

Extra Fax DiscountExtra Fax Discount

for Domestic USAfor Domestic USA

for Domestic USA

for Domestic USAfor Domestic USA

Dealers OnlyDealers Only

Dealers Only

Dealers OnlyDealers Only

Now! Direct TOLL-FREE access

to our Parts Department!

Toll-free nationwide:

800-421-1244

Toll-free FAX:

*DISCOUNTS ARE SUBJECT TO CHANGE*

Fax order discount and UPS special programs revised June 1, 1995

C-30HD — PARTS & OPERATION MANUAL — REV. #4 (03/06/01) — PAGE 5

800/6-PARTS-7 • 800-672-7877

C-30HD SPECIFICATIONS

PERFORMANCE

Pumping Rate .................................................................................................................. 25 cu. yds. per hour

Maximum Aggregate Size ................................................................................................1/2" minus (35mm)

Verticle Pumping Height ................................................................................................... Excess of 100 ft. (60 m)

Horizontal Pumping Distance ...........................................................................................400 to 500 ft. (300 m)

Engine — Gas.................................................................................................................. 30 HP Wisconsin VH4D

Engine — Diesel .............................................................................................................. 30 HP Hatz Z790

Pump ................................................................................................................................Reciprocating piston

Remote Control ................................................................................................................ Standard

Hopper Capacity ..............................................................................................................6 cu. ft.

Material Hose ...................................................................................................................2" or 2 1/2"

DIMENSIONS

L x W x H ..........................................................................................................................10 ft. x 4 1/2 ft. x 4 1/2 ft.

Weight ..............................................................................................................................2,200 lbs.

Tire Size ........................................................................................................................... 7.35 - 14

PAGE 6 — C-30HD — PARTS & OPERATION MANUAL — REV. #4 (03/06/01)

MAYCO PUMP WARRANTY

Mechanical Drive Models

MAYCO PUMP, hereinafter referred to as “Manufacturer’, warrants each new Mayco Pump sold by the manufacturer to be free from defects in material and workmanship, under normal use and service, for a period of one year after the date of delivery to the original retail purchaser. Manufacturer will, at its option, replace or repair at a point designated by the Manufacturer any part or parts which shall appear to the satisfaction of the Manufacturer upon inspection at such point to have been defective in material or workmanship. This warranty does not obligate the Manufacturer to bear any transportation charges or labor charges in connection with the replacement or repair the of the defective parts.

This warranty does not apply to any pump if attempts have been made to pump concrete materials which have separated, to any pump which has been repaired with other than Genuine Mayco Parts, nor to any pump which has been altered, repaired or used in such manner as to adversely affect its performance, nor to normal service or maintenance or where blockages have developed within the pump manifold or placing line or which has been operated in any other manner not recommended by the Manufacturer. Due to the abrasive nature of concrete, Mayco does not cover natural component wear.

Hydraulic Drive Models

MAYCO PUMP, hereinafter referred to as “Manufacturer”, warrants each new Mayco Pump sold by the manufacturer to be free from defects in material and workmanship, under normal use and service, for a period of one year or 2000 hours after the date of delivery to the original retail purchaser. The Manufacturer will, at its option, replace or repair at a point designated by Manufacturer any part or parts which shall appear to the satisfaction of Manufacturer upon inspection at such point to have been defective in material or workmanship. This warranty does not obligate Manufacturer to bear any transportation charges or labor charges in connection with the replacement or repair of the defective parts.

This warranty does not apply to any pump if attempts have been made to pump concrete materials which have separated, to any pump which has been repaired with other than Genuine Mayco Parts, nor to any pump which has been altered, repaired or used in such manner as to adversely affect it’s performance, nor to normal service or maintenance or where blockages have developed within the pump manifold or placing line or which has been operated in any other manner not recommended by the Manufacturer. Due to the abrasive nature of concrete, Mayco does not cover natural component wear.

THIS WARRANTY AND MANUFACTURER’S OBLIGATION HEREUNDER, IS IN LIEU OF ALL OTHER WARRANTIES, EXPRESS, IMPLIED OR STATUTORY AND ALL OTHER OBLIGATIONS OR LIABILITIES INCLUDING SPECIAL OR CONSEQUENTIAL DAMAGES OR CONTINGENT LIABILITIES ARISING OUT OF THE FAILURE OF ANY PUMP OR PART TO OPERATE PROPERLY, INCLUDING ANY WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE.

C-30HD — PARTS & OPERATION MANUAL — REV. #4 (03/06/01) — PAGE 7

SAFETY INSTRUCTIONS

1. Read the Mayco Owners Manual before moving or operating the unit.

2. Do not attempt to operate this pump without a thorough understanding of this technical manual.

3. To prevent damage to equipment or injury to personnel, these instructions must be followed carefully.

4. A copy of this manual shall accompany the pump at all times.

5. This equipment shall be operated only by experienced operators or students under the direct supervision of an experienced operator.

6. No unauthorized persons shall be permitted to assist or remain in the vicinity of the unit while it is in operation, or during the performance, inspection, cleaning, or repair or make-ready operation.

7. This equipment shall not be towed or operated by individuals who cannot read and understand the signs, decals, or operating instructions.

8. This equipment shall not be operated by individuals under the influence of alcohol or drugs.

9. Before towing, check the hitch and secure the safety chain to the towing vehicle. Also check for proper tire pressure.

10. Tow only with a vehicle and hitch rated to pull a 2200 lb. load.

11. If pump is equipped with ball hitch coupler, use only a 2” all steel ball rated for a minimum of 5000 lbs. Use a 1” hardened steel pull pin, if the pump is equipped with a pin hitch.

17. Do not use worn out hoses or couplings; inspect daily.

18. Do not disconnect the hose couplings or nozzle while they are under pressure. Relieve the pressure by manually swinging the clamp arm latch handle to the first open position at the exhaust cone outlet.

19. Never fill the fuel tank while the engine is running or hot; avoid the possibility of spilled fuel causing a fire.

20. Always carry a fire extinguisher of adequate size and a first aid kit.

21. Always wear safety glasses when spraying material.

22. The unit should not be towed in excess of 45 MPH (or less depending on road conditions).

23. Pull the tail light switch “ON” for night towing.

24. Do not tow the pump with the hopper full of material.

25. Do not tow the pump with the hoses attached.

blockage. This rapid surge of material could cause the lines to whip or move in a manner that could cause injury to personnel.

Inspect the lines at all times to prevent the above conditions.

CAUTION

If hoses or lines are blocked for any reason, or if the lines are kinked when starting up or during the pumping cycle, the pump pressure could straighten out the kink or force out the

12. Before start-up, check the hopper and remove all obstructions.

13. Keep all hands out of the hopper when the engine is running.

14. The engine must be turned off before performing any service operations.

15. Do not operate the pump with the hood open.

16. Replace any worn or damaged pump components immediately.

PAGE 8 — C-30HD — PARTS & OPERATION MANUAL — REV. #4 (03/06/01)

IMPORTANT HAND SIGNALS

C-30HD — PARTS & OPERATION MANUAL — REV. #4 (03/06/01) — PAGE 9

GENERAL INFORMATION

The following operating principles and operating suggestions should prove helpful in the successful operation of your concrete pump. Your new “small line” concrete pump has been designed to give you many years of service when operated properly. A study of the following paragraphs is important to the successful operation of your new Direct-flo Concrete Placer.

All concrete pumps require a high level of operator skill and more frequent service than most of the other construction equipment. The highly abrasive nature of concrete under pressure makes it extremely important that expendable wear components be inspected at regular intervals between jobs to prevent having to replace these items during a pour. Experience has proved that inconsistency of batched concrete mixes and frequent moving of the line requires the operator to be readily available at all times during pumping to stop the pump and prevent abuse to the unit which may occur if unexpected blockages develop.

PUMP MIX GUIDELINES

When ordering concrete, be certain to advise the concrete supplier that you require a “pump mix”. The Direct-flo manifold will pump a wide variety of materials, but certain basic principles must be followed to assure successful pumping, as follows:

1. Generally speaking, the washed concrete sand and #4 aggregate (pea gravel) should conform to A.S.T.M. standards in regard to sieve analysis. Sands in some areas are washed clean of the #100 and #200 mesh fines, which results in separation and jamming in the manifold while pumping under pressure. If this condition develops, check with your concrete suppliers engineers and get their recommendations for supplementing the lack of the fines. The use of locally accepted ad-mixs may be required. (For example, Pozzolith, Bentonite Clay, Plastiments, etc.) When properly prescribed, additives form the plastic paste sometimes necessary to hold the cement and aggregate together. NOTE: If jamming conditions in the pump or hose occur for any reason at all, do not attempt to use more power to correct the condition. Determine the cause of jamming, correct it and resume pumping. Trying to force material through under jammed conditions may result in damage to the drive system, thus voiding any warranty services.

2. As a general rule, the use of approximately six sacks of cement, 70% washed concrete sand and 30% #4 pea gravel per yard of concrete will result in a pumpable mix. The ideal nature of sand and rock in certain areas may permit you to increase the percentage of rock or adjust the mix considerably to meet the job requirements. When possible, you may experiment with various mixes in your area to determine the degree of versatility of the Direct-flo Pump.

3. Uniform gradition of the washed concrete sand and the 1/2” minus aggregate along with sufficient cement content and water are important to a successful pump operation.

4. A recommended pumpable mix design would be 70% sand and 30% aggregate-cement content to be a minimum of 6 sacks. (564 lbs.)

NOTE; Your local sand and rock engineers will give you the s.s.d. weights of sand and rock required in your local area which will yield one cubic yard per the above recommendation.

SAMPLE DESIGN MIX

6 1/2 sacks cement (611 lbs.) 1800 lbs. washed concrete sand 1000 lbs. pea gravel 230 lbs. water

5. Test laboratory data has proven in many areas that the above mix guidelines have produced concrete rated at 3000 psi (28 day test) and upwards of 5000 psi with an increase in cement.

6. In some areas where the gradation of sand and rock is ideal and sufficient cement is used along with admixtures, the Mayco small line concrete pump will handle up to a 50-50 ratio of sand and rock.

7. When the mix is designed for wet gunning applications, it is normal to increase the cement (up to 7.5 or 8 sacks) and change the sand to rock ratio to 85% sand and 15% rock.

8. The Mayco concrete pump will valve efficiently when using cellular-foam concrete mixes upwards of 70 lbs. per cubic foot wet density. (Below 70 lbs. materials (roof decks) the valving becomes inefficient.)

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NOTE PAGE

C-30HD — PARTS & OPERATION MANUAL — REV. #4 (03/06/01) — PAGE 11

C-30HD — HOW IT WORKS

The Mayco concrete pump has one main pumping piston which is valved by means of two ball checks. (A inlet, and B outlet.)

The secondary piston is used as a compensator piston to smooth out the pulsations of a single piston action. Note: The compensator will not start operating until material is pumped into the line and back pressure develops.

The compensator spring, which is installed on the compensator piston rod, deflects with each piston stroke. This “spring cushion”, in conjunction with the cam profile, produces and uninterrupted smooth flow of material under average pumping conditions.

An automatic, centrifugal clutch is installed to engage and disengage the pumping action without stopping or starting the engine. The centrifugal clutch is set at 1100 R.P.M. release. The engine idle speed is approximately 750 R.P.M.; therefore, the clutch is completely disengaged at idle. The throttle settings while pumping should always maintain an engine R.P.M. high enough to prevent the clutch from slipping and burning the clutch lining.

The return spring which is installed on the rocker arm, is installed to eliminate shock and stress between the cam roller and the cam weldment when the pump is in operation. If the return spring is removed or replaced for any reason, maintain the backing plate dimension of 3” as shown on Figure 3, to produce the proper pre-loading of the spring for a smooth performance.

Figure 1- The pumping cylinder retracts drawing the material past the ball (A) and filling the cylinder. The compensator piston is pumping the material out to the nozzle and causing ball (B) to seat preventing the material from returning to the pumping cylinder intake.

Figure 2- The pumping piston is forcing the material past ball (B) and out to the nozzle, also seating ball A so that the material will not flow back to the hopper. This action also fills the compensating piston for the next stroke.

Figure 3- Shows the relationship between the return spring, the compensator spring and the rocker arm to maintain a smooth performance. Do not tighten the bolt (Item 1) completely, the rod end must be able to move.

PAGE 12 — C-30HD — PARTS & OPERATION MANUAL — REV. #4 (03/06/01)

C-30HD — HOW IT WORKS

C-30HD — PARTS & OPERATION MANUAL — REV. #4 (03/06/01) — PAGE 13

C-30HD OPERATING INFORMATION

OPERATING SUGGESTIONS

1. A well-planned location of the pump and routing of the hose before starting a pour may save subsequent moves throughout the job.

2. Before concrete is discharged into the hopper, it is suggested that 3 to 4 gallons of water be sprayed into the hopper, followed by approximately 5 gallons of a creamy cement and water slurry (1/2 bag of cement to 5 gallons of water). This procedure lubricates the hose and prevents separation and blockages in the hose. Note: Getting the concrete to flow through the hose at the start of the pumping cycle can be one of the most critical operations of the pour. (Manually operate the throttle - when starting. NOT REMOTELY)

3. It is important that once the slurry procedure is completed, and you have started concrete flowing through the hose, do not stop the pour until all the slurry is pumped out and the concrete has reached the end of the hose. The only time to stop the pump at the start is if a blockage occurs.

4. When the pump is stopped for any reason during a pour; e.g., moving hose, waiting for redi-mix truck, the following suggestions are offered:

A. Leave the hopper full of concrete at the time of shutdown. It is important not to let the redi-mix driver wash too much water into the hopper, as this could cause separation of the concrete in the hopper.

B. If the shutdown period exceeds 2 to 3 minutes, turn off the engine so the vibration does not separate the mix in the hopper which can cause a blockage in the manifold when the pump is started.

C. If it is necessary to wait 10 minutes or more for another load of concrete, it is wise to start the pump and pump 6 or 8 strokes every 5 minutes to prevent setting of the mix in the system. If waiting time is excessive, it would be wise to wash out the pump and hoses and start over when the new truck arrives.

D. When pumping stiff mixes and there is waiting time between redi-mix trucks, it is advisable to add some water to the last hopper of material and “hand mix” to ensure an easier start with the following load.

E. When the pumping job requires a stiffer mix, the following method is suggested for starting: Take a water hose with a nozzle on it and apply water with a fine spray to the concrete as it comes down the redi-mix chute into the pump hopper after the slurry procedure is completed and you are ready to start pumping. Using this procedure will make it easier to pump through the clean hose. Note: Once the concrete has reached the end of the hose, do not apply any more water in this manner as this procedure is used on the start only.

F. Hose sizing is very important: We strongly recommend on harsh mixes, vertical pushes, stiff concrete, shotcrete, long pushes, that a 2 1/2” line be used as far as possible. The advantages of using the 2 1/2” line are improved pumpability, less pumping pressure and less wear on the pump.

5. Following the pump operation, proper wash out of all materials or “build-up” within the pump manifold and hoses will prevent problems when starting the next job.

6. A thorough inspection of the drive components and greasing of all bearings after each job will ensure adequate lubrication and service to the pump which is normally operating in wet, gritty conditions. Note: Over-greasing any bearing on your Mayco pump will not damage the bearing.

your pump to push through blockages due to separation of material in the hose or manifold, you will soon have breakdowns and costly repairs which are not covered under warranty. If a blockage occurs, find where it is and clear it before further pumping. Do not use horse-power; it will only make it worse.

hopper of concrete can cause severe damage or breakage of the axle and axle springs, excess strain and pressure on the hub and bearing assembly.

7. Warning: Common sense tells us that if you drive a truck into a brick wall, something is going to be damaged. The same holds true with your concrete pump. If you repeatedly pull the throttle all the way out and try to force

8. Warning: It will be necessary at times to move your pump from one job site location to another. Before moving the pump, make sure to pump the remaining concrete out of the hopper. Moving the pump with a full

PAGE 14 — C-30HD — PARTS & OPERATION MANUAL — REV. #4 (03/06/01)

C-30HD OPERATING INFORMATION

PUMPING TIPS AND TROUBLE SHOOTING

1. The effects of heat and excessive time on concrete: Hot concrete, commonly referred to as a hot load, is concrete that has been in the redi-mix truck in excess of 2 to 3 hours. On a hot day, this amount of time is even less. A brief explanation of why heat and time affect concrete: Concrete starts setting by drying up through a chemical reaction. The catalyst to this reaction is heat. When pumping a hot load, it is important to remember that when you have to stop pumping for any reason, add water to the concrete in the hopper and hand mix and move concrete in the hose every 5 minutes. If the shut down time becomes too long, wash out immediately.

2. ADMIXTURES: A remixtures that are designed into the concrete mix by the redi-mix company or an architectural engineering company. This section lists common admixtures and a brief explanation of their function.

A. POZZOLITH 300 R or the equivalent acts as a water retarder and a lubricant. On a lean mix, long pushes, stiff mixes, and vertical pushes, Pozzolith 300 R helps pumpability.

B. MBVR, air entraining, acts as a lubricant.

5. Damaged hoses with internal restrictions can cause blockages.

6. If a blockage occurs in a hose, “walk the hose” until you find the point of trouble. The hose will be soft immediately past the blockage. If this happens at the start, disconnect the hose at the first coupling past the blockage. Elevate the hose at that point with the blockage area hanging down.

extreme care! The hose line is under pressure and can cause serious injury.

down-stream edge of the packed area until it is free to flow. Shake all of the sand and gravel out to the end of the hose. Before reconnecting the hose, start the pump and run a small amount of concrete out to the end of the hose. This will assure that all of the separation is out of the hose.

7. The manifold is plugged if the volume at the discharge end of the hose stops, and the hose is soft. The drive belts will start to slip and the engine will lugdown.

To clear a plugged manifold,

dangerous condition will exist due to pressure build-up inside the manifold.

Follow these instructions carefully:

Note: Use

Using a hammer, you can pound the

great care must be taken as a

C. CALCIUM CHLORIDE, commonly referred to as C.C., is used as an accelerator. When pumping a load with calcium chloride, it is recommended that you wash out if the waiting time between delivery trucks becomes too long.

D. SUPER PLASTICIZERS, acts as an accelerator. The concrete will look very wet after the super plasticizer is added, but will begin to set up very fast. Wash out immediately if you do not have a truck waiting. Super plasticizers are used mainly on commercial jobs.

E. RED LABEL, acts as a water retarder and an accelerator. Red label will be used mainly on commercial jobs.

F. FLY ASH, is used to help increase the strength of the concrete and decrease the cement content per yard. This is one of the most common admixtures used.

NOTE: All admixtures will be shown on the redi-mix concrete ticket. Before starting the pumping job, ask the driver of the redi-mix truck to see the concrete ticket and note the admixtures that exist and take the proper action.

3. When pumping long distance or pumping stiff mixes, you can expect a drop in volume compared to shorter lines and wetter mixes due to the change in valve efficiency or cavitation.

4. Leaking manifold seals or hose coupling gaskets which leak water can cause separation and subsequent jamming at that point.

7.1 Stop the pump. Switch off the engine.

7.2 DO NOT open any of the delivery system joint clamps.

7.3 The senior experienced operator must warn all others to stand at least 20 feet away from the machine and turn their heads away from the manifold.

7.4 The operator must position himself/herself away from the hinged side of the manifold.

7.5 Wearing safety glasses, grasp the clamp arm weldment and carefully pull it open to the primary (safety) position. STOP count to 20. This will allow the pressure to release.

7.6 After the pressure has been released, open the clamp arm weldment and swing the hinged discharge cone open.

7.7 Remove blockage with around a 2-foot length of reinforcing steel rod. Flush the manifolds with water. Make sure the (3” x 2”) reducer is clear of any blockage before closing the discharge cone.

7.8 After the blockage has been cleared and the pump manifold has been thoroughly flushed with water, close the hinged discharged cone and lock into place.

7.9 Before reconnecting hose to the reducer, start the engine and pump two or three shovels of concrete through the reducer. This will insure that all the blockage has been cleared.

C-30HD — PARTS & OPERATION MANUAL — REV. #4 (03/06/01) — PAGE 15

C-30HD OPERATING INFORMATION

7.10 Shake out around 2 feet of concrete before reconnecting hose to pump. After this is done, connect hose to pump and resume the pumping operation.

8. If it is necessary to wait 1/2 hour or more for another load of concrete, it is advisable to consider the factors affecting the concrete that is already in the pump and system. To prevent setting of the mix in the system: 1) how old is the concrete ? 2) is there an accelerator, calcium chloride, red label, etc., in the concrete ? 3) the temperature of the day, 80, 90, degrees? 4) how much system you have out and how stiff was the mix you were pumping? If, for any reason, the mix should set up in the system, the following procedure is suggested:

Note: Use extreme care! The hose is under pressure!

Disconnect the hose from the pump and wash the pump out immediately. Reconnect the hose and fill the hopper with water. DO NOT try to push all the concrete out of all of the hose line at one time. For example: If you had 200 ft. of system out, you would disconnect each hose. Clean it out by pushing water through the first hose off the pump, then continue progressing through all the hoses, until all the system is clean. If waiting time is excessive, it would be wise to wash out the pump and hoses and start over when the new truck arrives. This can be avoided by being attentative to the pump and system, also taking into consideration the above 4 factors affecting the mix.

9. “Down-hill pumping” can be difficult on some jobs. The slurry procedure would be the same as explained on the pages titled Operating Suggestions. It is suggested that a sponge 2”x 4”x 6” be placed in the hose before the start of pumping. Wet the sponge before placing it in the hose. The reason for using the wet sponge is to keep the slurry from running too far ahead of the concrete and so reducing the possibility of separation. When the pump is stopped, the material can flow slowly down, due to gravity, and cause the hose to collapse. When pumping is resumed, you can expect a blockage at the point of hose collapse. To prevent this from happening, the hose can be “kinked off” at the discharge end when the pump is stopped to prevent the gravity flow of the material in the hose. The use of stiffer mixes when pumping down-hill will decrease gravity flow of the material in the hose and will assure a smoother operation between the cam roller bearing and cam plate. As with any job, make sure that the hose and the couplings are in good workable shape.

10. When pumping vertically: A. When pumping vertically up the side of a building, above

40 feet, we would recommend the installation of steel pipe securely fastened at intervals as necessary to support the pipe. Ninety degree, long radius pipe sweeps should be installed at the top and bottom of the steel line. Use a 25 ft. hose, or short section, off the pump; and for the balance of the horizontal distance to the vertical line, use steal pipe. This type of installation has been satisfactory on many jobs being pumped in excess of 100 feet high. Line pressures are always less using steel pipe as compared to hose.

B. When pumping vertically, using all hose, it is recommended not to go higher than 50 feet with hose. The hose should be tied off at intervals of 10 feet, if possible. Special attention should be given when tieing the hose off at the top as the hose will have a tendency to stretch when filled with concrete. This will increase the possibility of a blockage at the point where the hose is tied off. To avoid this, a long radius of 90 degree elbow is recommended. The suggested place to tie off is on the hose, under the clamp.

that pipe be used on all vertical pumping for safety and convenience.

If it is absolutely necessary to use hose, then use this section as a guide.

11. If the volume at the end of hose starts to decrease gradually and eventually almost stops, it is quite likely that the valve seats have had excessive wear and need replacement. Once they have reached a certain wear point, they may “channel out” rapidly and material will reciprocate past the ball on each stroke. The hollow steel ball should be replaced when it starts to show dents or appears to be badly worn. Sand and aggregate materials in some areas are extremely sharp and hard and therefore highly abrasive. Under these conditions when pumping stiff mixes, or to high elevations which cause line pressures, it will be noted that valve components may have short wear life. If this condition exists, it is advisable to remove the manifold only, and inspect the lower seat at the end of each day. If it appears that the seat is beginning to “channel out, replace before starting the next day’s pour. The upper valve seat can be inspected after each washout by running your finger around lower edge of seat where the ball makes contact. You can reach this from the inside of the hopper. Be sure that the engine is turned off.

Note: It is strongly recommended

PAGE 16 — C-30HD — PARTS & OPERATION MANUAL — REV. #4 (03/06/01)

C-30HD OPERATING INFORMATION

12. Slight pulsation of the hose will always be noticeable near the pump. Excessive pulsation of the hose near the pump is normally due to higher than average line pressures caused by stiff, harsh mixes, or extremely long pumping distances. The use of 2 1/2” I.D. hose in these extreme cases reduces line pressures or the addition of slight amounts of water to the mix, if permissible, will permit easier pumping. The use of certain pumping admixtures may help.

If excessive pulsation exists in the hose, it is advisable to use burlap or some means of wear protection under the hose at points where the hose may wear through the outer cover; e.g. over forms, steel or sharp curbs.

13. If the cam roller does not ride on the cam profile smoothly, it may be caused by insufficient line back-pressure; e.g., a wet mix with only 50 feet of hose. Add more hose as necessary. It can also be caused by cavitation or the passing of oversized aggregates through the valving, causing it to skip.

14. When using Snap-Joint couplings with gaskets to join hose, see that they are washed clean after each job. Keeping the hose ends clean (heavy duty) is very important for the best job setup. A thin coat of grease on the rubber gasket or dipping both coupling and gasket in water before coupling the hose will make for easier installation.

15. All new pumps are “water pressure tested” at the factory before shipment. This procedure permits a thorough inspection of entire drive system and valving under simulated full load conditions. The pump owner can do the same by attaching an adaptor to couple to the end of the discharge cone; e.g., the use of a standard 2” pipe cap with a 3/8” hole drilled in the center , screwed on to the end of the hinged cone or reducer at the pump. Fill the hopper with water after making sure that all sand and rock have been removed from the manifold. Operate the pump at full throttle and the 3/8” diameter hole restriction will create sufficient back-pressure to make a thorough inspection of all moving parts.

CLEAN UP PROCEDURE PART A

1. Ensure that there is no blockage in the hose and line (See Page 15, Para. 6) or in the manifold (See Page 15, Para. 7). If a blockage exists, clear it as it dictates how the machine will pump the next time it is used. At the end of every pour, or because of long delays during a pour, the pump and delivery system must be thoroughly cleaned by removing all concrete material.

2. Proper wash out of all materials or build up within the pump manifold and hoses following the pumping operation will prevent problems when starting the next job. After completion of the pour, pump the remaining concrete in the hopper through the discharge line.

3. Note: To avoid the possibility of separation during clean-up, do not pump the concrete below the inlet ball in the hopper. It is best to leave approximately 3 to 4 inches of concrete above the inlet ball.

4. Turn the pump engine off before filling the hopper with water. Engine vibration at idle may “separate” material in the hopper, causing jamming in manifold when pumping is resumed.

5. Fill hopper with water and resume pumping. The water will push the concrete through the line. When the water runs clear at the end of the hose, disconnect lines and shake out all the sand and sediment so the lines will be clean for the next pour.

6. It is important that the hinged discharge cone on the pump manifold be opened and all remaining concrete (rock and sand) be thoroughly washed out. This must be done after each job to prevent concrete build up in the discharge manifolds and 3” discharge elbow.

16. Before starting the pumping operation, the following check list procedure should be followed:

1. Check the engine oil.

2. Check the oil reservoir of the lubrication system to make sure that it is full.

3. Inspect the chain and belt adjustment.

4. Check the cam oiler.

5. Start and run the engine a minimum of five minutes before starting the pumping operation.

Note: When the redi-mix truck arrives, it is always a good idea to check the concrete ticket and make sure you have the proper mix design.

C-30HD — PARTS & OPERATION MANUAL — REV. #4 (03/06/01) — PAGE 17

C-30HD OPERATING INFORMATION

PART B

This section will explain the recommended procedure for using a sponge to clean out the lines. After completion of the pour, pump the remaining concrete in the hopper through the discharge line. Using a shovel, clean the sides of the hopper. (Note: The pump engine should be turned off, as explained in Part A of the Clean Up Procedure.) After the sides of the hopper have been cleaned, add a small amount of water to the remaining concrete in the hopper and hand mix.

Start the pump engine and pump the hopper all the way down. Disconnect the hose from the pump. Fill the hopper with water and pump the remaining concrete out of the pump. Open the hinged discharge cone and thoroughly wash out all remaining concrete (sand-sediment) from the cone and pump manifolds. Close the discharge cone and lock in place. Take a sponge (2”x 4”x 6”) and soak it with water. Take the hose that is disconnected from the pump and shake out the concrete so that about 2 feet of it is clear. Insert the sponge into the hose. Reconnect the hose to the pump. Fill the hopper with water and resume pumping. Run the pump approximately half throttle. The sponge will be discharged at the end of the line followed by clear water. At this point, the pump and lines will be completely clean and ready for the next job.

WARNINGS

1. Never put your hands, or any other parts of your body, in the hopper when the engine is running.

2. Never use muriatic acid to clear the pump. Acid will dissolve the chrome finish on the pumping cylinder.

3. When using a clean-out hook to clean out back into the redi-mix truck, use a safety chain to secure the clean-out hook to some solid part of the redi-mix truck to prevent the hook from jumping off the redi-mix truck’s hopper. Run the pump at half throttle.

4. Never use air to clean out the lines.

Always think safety first!

PAGE 18 — C-30HD — PARTS & OPERATION MANUAL — REV. #4 (03/06/01)

CONCRETE MIX INFORMATION

CONCRETE MIX DESIGNS-SCREEN ANALYSISTERMINOLOGY

The following information has been prepared to assist in the selection of concrete mix designs in certain areas where the use of concrete pumps is a new industry.

The result of years of experience by many concrete pump users and aggregate suppliers has proven the importance of certain requirements necessary to successful concrete pumping. The strength and quality of the concrete is relative to the cement/water ratio and the type of gradation of the aggregates used.

Special emphasis is given to the gradation of the fine aggregates, coarse aggregates sand and used in all pump mixes. Generally speaking, if the screen analysis of the local sand and rock conform to the A.S.T.M. specifications shown on Pages and 13 and the proper ratio of sand and rock are used in the mix, you can expect a pumpable mix.

If difficulty is experienced in pumping the mixes shown on Pages 11 and 12, consult your local aggregate supplier with this information and make the necessary adjustments.

DEFINITIONS ONE SACK CEMENT (U.S.)-94lbs. (42.58 KG) S.S.D.-Saturated Surface Dry: Meaning sand particles may

be saturated with moisture but there is no free water on the surface.

OVEN DRY-meaning all the moisture is removed from the sand particle.

SLUMP-a measure of moisture consistency. W/C SAND-washed concrete sand. #4 GRAVEL or ROCK-3/8” PEA GRAVEL (1/2” MINUS) #3 GRAVEL or ROCK-3/4” rock (1” minus) POZZOLITH-Master Builders Admixture -(Pozz) P.S.I.-compressive strength (Pounds per Square Inch) DEFICIENCIES IN SIEVE ANALYSIS of AGGREGATES

The uniform gradation of sand and aggregate in the concrete mix is extremely important in all pumping operations. It is highly possible that the lack of certain sieve sizes may prevent pumpability. In some areas it may be necessary to make up these deficiencies by the addition of “blending sands” to the local sand.

GENERAL RULE-supplement to improve pumpability. FLY ASH-use up to 15% of cement weight. POZZOLIN-use up to 13% of cement weight.

C-30HD — PARTS & OPERATION MANUAL — REV. #4 (03/06/01) — PAGE 19

CONCRETE MIX INFORMATION

The following information has been extracted from actual testing laboratory reports. The purpose of this printing is only to help create a better understanding of the importance of uniform gradation and proportioning of materials which affect pumpability of concrete mixes. These weights and proportions illustrate that when the sieve analysis is ideal, the sand/rock ratio can be adjusted (65% sand 35% rock) and pumpability should be excellent.

EXAMPLE #1 (A California Test Lab. Report) JOB: Building Foundations (Water Project) Sacks per cu./yd. 6.5 designed for 2,500 lbs. in 28 days Gallons per sack 7.1 Washed Sand-#200 wash 1.3 Organic matter-OK Specific gravity (SSD) Sand-2.58; Pea Gravel-2.60

Sieve analysis-percent passing

Material 1.5” 1” 3/4” 3/8” #4 #8 #16 #30 #50 #100 #200 W.C. Sand 100 99.7 79.1 60.4 36.5 14.3 4.0 1.1 Pea Gravel 100 3.0 % Comb. 100 66 51 39 23 9 3 1.0

DESIGN FOR ONE YARD OF CONCRETE (SATURATED & SURFACE DRY): Absolute volume of aggregate in one cu. yard: 17.78 cu. ft. Specific gravity of aggregates in one cu. yard: 2.58 Weight of aggregates in one cu. yard batch: 2850 lbs.

% BATCH SPEC. GRAVITY ABS. VOL. W.C. Sand 65 1800 2.58 11.56 PEA GRAVEL 35 1000 2.60 6.22 WATER 46 gal. 1 CEMENT 6.5 sk. 611 TOTAL 27.00 ADMIXTURE: None SLUMP 4” REMARKS This mix designed for pumping NOTE: Due to the availability of well-graded sand as shown in the above sieve analysis,

this mix pumped very successfully.

PAGE 20 — C-30HD — PARTS & OPERATION MANUAL — REV. #4 (03/06/01)

A.S.T.M. STANDARD SPECIFICATION FOR GRADING AGGREGATE

Screen Size of Operating Percentage Passing

U.S. Metric (by weight)

FINE AGGREGATE: Referred to as washed concrete sand.

3/8” 3/8” 9.51mm 100%

#4 4760 micron 4.76 mm 95 to 100%

#8 2380 micron 2.38 mm 80 to 100%

#16 1190 micron 1.19 mm 50 to 85%

#30 590 micron 1.19 mm 50 to 85%

#50 297 micron 297 µ 10 to 30%

#100 149 micron 149 µ 2 to 10%

3/8” (9.51 mm) PEA GRAVEL AGGREGATE: Referenced to as #4 Rock or Gravel or 1/2” minus (12.7 mm) size.

1/2” 1/2” 12.7 mm 100%

3/8” 3/8” 9.51 mm 85 to 100%

#4 4760 micron 4.76 mm 10 to 30%

#8 2380 micron 2.38 mm 0 to 10%

#16 1190 micron 1.19 mm 0 to 5%

C-30HD — PARTS & OPERATION MANUAL — REV. #4 (03/06/01) — PAGE 21

CONCRETE MIX INFORMATION

Consolidated Rock Products Co., Division of Tests 3/8” Pea Gravel STANDARD PUMP MIXES (one-half inch minus)

NOTE: All weights shown are one cubic yard with S.S.D. aggregates.

CRP Mix Number 6004 .......................... 6005 .............................6006 .......................... 6007

Design Slump (in.) 6” (15 cm) ............. 6” (15 cm) .................6” (15 cm) ............. 6” (15 cm)

Cement, SACK. 7.0 ................................ 7.0 ......................................7.0 ................................ 7.0

Cement, Lbs. 658 (298 kg) ............ 658 (298 kg) ................658 (298 kg) ............ 658 (298 kg)

w/Con Sand (1 lb.) 2031 (920 kg) ............ 2982 (943 kg) ................1879 (851 kg) ............ 1943 (880 kg)

Gravel #4(9.51 mm) 677 (307 kg) ............ 693 (314 kg) ................806 (365 kg) ............ 832 (377 kg)

TOTAL AGGREGATE 2708 (1227 kg) .......... 2775 (1257 kg) .............2685 (1216 kg) .......... 2775 (1257 kg)

ADMIXTURE

Pozzolight 311-1 lb. 1.4 (.63 kg) ............. 1.4 (.63 kg) ................. 1.4 (.63 kg) ............. —

Water, Design (gals.) 50.0 (189 liters) ......... 53.0 (200 liters) ............50.0 (189 liters) ......... 53.9 (200 liters)

Mater, Max. (gals.) 50.0 (189 liters) ......... 53.0 (200 liters) ............53.0 (200 liters) ......... 53.0 (200 liters)

NOTE: Multiply above kilograms and liters by 1.308 to obtain the proportions for one cubic meter of concrete.

Consolidated Rock Products Co., Division of Tests 3/8” Pea Gravel STANDARD PUMP MIXES (one-half inch minus) NOTE: All weights shown are one cubic yard with S.S.D. aggregates.

CRP Mix Number 6000 .......................... 6001 .............................6002 .......................... 6003

Design Slump (in.) 6” (15 cm) ............. 6” (15 cm) .................6” (15 cm) ............. 6” (15 cm)

Cement, SACK. 6.5 ................................ 6.5 ......................................6.5 ................................ 6.5

Cement. Lbs. 611 (276 kg) ........... 611 (276 kg) ................ 611 (276 kg) ............ 611 (276 kg)

w/Con Sand (1.1 lb.) 2062 (934 kg) ........... 2112 (957 kg) ................1924 (872 kg) ............ 1971 (893 kg)

Gravel #4 (9.51mm) 687 (311 kg) ........... 704 (319 kg) ................ 825 (374 kg) ............ 845 (383 kg)

TOTAL AGGREGATE 2749 (1245 kg) .......... 2816 (1276 kg) .............2749 (1245 kg) .......... 2816 (1276 kg)

ADMIXTURE

Pozzolight 311-1.3lb. 1.3 (.59 kg) ............. 1.3 (.59) ......................—

Water, Design (gals.) 50.0 (189 liters) ......... 53.0 (200 liters) ............50.0 (189 liters) ......... 53.9 (200 liters)

Mater, Max. (gals.) 50.0 (189 liters) ......... 53.0 (200 liters) ............53.0 (200 liters) ......... 53.0 (200 liters)

NOTE: Multiply above kilograms and liters by 1.308 to obtain the proportions for one cubic meter of concrete.

PAGE 22 — C-30HD — PARTS & OPERATION MANUAL — REV. #4 (03/06/01)

1. To obtain a representative sample, take samples at three or more regular intervals throughout the discharge of the mixer or truck. DO NOT take samples at the beginning or end of the discharge.

2. Dampen the inside of the cone and place it on a smooth, moist, nonabsorbent, level surface large enough to accommodate both the slumped concrete and the slump cone. Stand on the “foot pieces” throughout the test procedure to hold the cone firmly in place.

3. Fill the cone 1/3 full by volume and rod 25 times with a 1/2” dia x 24” lg. bullet-pointed steel rod. (This is a specific requirement which will produce non-standard results unless followed exactly.) Distribute rodding evenly over the entire cross section of the sample. (See figure A.)

4. Fill cone another 1/3 which will make the cone 2/3 full by volume. Rod this second layer 25 times with the rod penetrating into, but not through, the first layer. Distribute rodding evenly over the entire cross section of the layer. (See figure B.)

5. Fill cone to overflowing. Rod this layer 25 times with rod penetrating into but not through, the second layer. Distribute rodding evenly over the entire cross section of this layer. (See figure C.)

SLUMP TEST PROCEDURE

6. Remove the excess concrete from the top of the cone, using the tamping rod as a screed. (See figure D.)

7. Lift the cone vertically with a slow even motion. Do not jar the concrete or tilt the cone during this process. (See figure E.) Invert the withdrawn cone, and place it next to, but not touching the slumped concrete.

8. Lay a straight edge across the top of the slumped cone. Measure the amount of slump in inches from the bottom of the straight edge to the top of the slumped concrete at a point over the original center of the base (See Figure F). The slump operation must be complete in a maximum elapsed time of 11/2 minutes. Discard the concrete. DO NOT use it in any other tests.

C-30HD — PARTS & OPERATION MANUAL — REV. #4 (03/06/01) — PAGE 23

EXPLANATION OF CODE IN REMARKS COLUMN

How to read the marks and remarks used in this parts book.

Items Found In the “Remarks” Column

Serial Numbers-Where indicated, this indicates a serial number range (inclusive) where a particular part is used.

Model Number-Where indicated, this shows that the corresponding part is utilized only with this specific model number or model number variant.

Items Found In the “Items Number” Column

All parts with same symbol in the number column,

■

, belong to the same assembly or kit

If more than one of the same reference number is listed, the last one listed indicates newest (or latest) part available.

, #, +, %, or

NOTE

The contents of this catalog are subject to change without notice

PAGE 24 — C-30HD — PARTS & OPERATION MANUAL — REV. #4 (03/06/01)

C-30HD SUGGESTED SPARE PARTS

C-30HD Concrete Pump

1 Units

Qty. P/N Description

6 ...... EM14904 ..................... PISTON CUP KITS

4 ...... EM18804 ..................... 4 1/2" STEEL BALL

4 ...... EM14818 ..................... 4" STEEL BALL

6 ...... EM14903 ..................... BALL STOP PIN KIT

10 ...... EM18801 ..................... 0-RING MANIFOLD

1 ...... EM14308 ..................... CHAIN

2 ...... EM26313 ..................... HALF LINK

2 ...... EM26314 ..................... MASTER LINK

1 ...... EM14334 ..................... COMPENSATOR SPRING

2 ...... EM14408 ..................... BRONZE RING

2 ...... EM903092 ................... CAM ROLLER BEARING

2 ...... EM14315 ..................... V-BELT

2 ...... EM14842 ..................... LOWER SEAT

2 ...... EM14843 ..................... UPPER SEAT

2 ...... EM26310 ..................... CLUTCH LINING

10 ...... EM18409 ..................... O-RING

2 ...... EM20763 ..................... FUEL FILTER

2 ...... EM26746 ..................... OIL FILTER

2 ...... EM20328TKIT ............. BEARING KIT

1 ...... EM28004DD ................ REDUCER 3" X 2"

1 ...... EM23946 ..................... 3" ELBOW

2 ...... EM28904 ..................... 3" CLAMP

4 ...... EM28904-1 .................. 3" GASKETS

1 ...... EM14159 ..................... HOPPER SCREEN

1 ...... EM14401 ..................... OIL PUMP

1 ...... EM20709 ..................... SOLENOID

2 ...... EM2074........................ THROTTLE LINKAGE

NOTE

Part number on this Suggested Spare Parts List may super cede/ replace the P/N shown in the text pages of this book.

C-30HD Concrete Pump

3 Units

Qty. P/N Description

10 ...... EM14904 ..................... PISTON CUP KITS

10 ...... EM18804 ..................... 4 1/2" STEEL

10 ...... EM14818 ..................... 4" STEEL BALL

12 ...... EM14903 ..................... BALL STOP PIN KITS

25 ...... EM18801 ..................... MANIFOLD O-RINGS

3 ...... EM14308 ..................... CHAINS

10 ...... EM26313 ..................... HALF LINK

10 ...... EM26314 ..................... MASTER LINK

2 ...... EM14334 ..................... COMPENSATOR SPRING

4 ...... EM14408 ..................... BRONZE RING

2 ...... EM903092 ................... CAM ROLLER BEARING

4 ...... EM14315 ..................... V-BELT

6 ...... EM14842 ..................... LOWER SEAT

6 ...... EM14843 ..................... UPPER SEAT

3 ...... EM26310 ..................... CLUTCH LINING

20 ...... EM18409 ..................... O-RING

3 ...... EM207063 ................... FUEL FILTER

3 ...... EM26746 ..................... OIL FILTER

2 ...... EM20328TKIT ............. BEARING KIT

2 ...... EM28004DD ................ REDUCER 3" x 2"

2 ...... EM23946 ..................... 3" ELBOW

4 ...... EM28904 ..................... 3" CLAMP

10 ...... EM28904-1 .................. 3" GASKET

2 ...... EM14159 ..................... HOPPER SCREEN

2 ...... EM14401 ..................... OIL PUMP

2 ...... EM20709 ..................... SOLENOID

4 ...... EM20714 ..................... THROTTLE LINKAGE

1 ...... EM14300 ..................... CAM

1 ...... EM14801 ..................... T-MANIFOLD

1 ...... EM14819 ..................... Y-MANIFOLD

2 ...... EM14335 ..................... PISTON ROD

1 ...... EM14205P ................... PLASTIC FUEL TANK

1 ...... EM26788 ..................... REMOTE SWITCH

1 ...... EM903176 ................... CONN. ROD BEARING

1 ...... EM14305 ..................... CRANKSHAFT

2 ...... EM14807 ..................... PUMP CYLINDER

2 ...... EM18800 ..................... COMPENSATOR CYLINDER

1 ...... EM14320A ................... CLUTCH

2 ...... EM60HB....................... CLUTCH DISK

C-30HD — PARTS & OPERATION MANUAL — REV. #4 (03/06/01) — PAGE 25

EM26735

EM26753

EM26732

C-30HD — CONTROL PANEL

EM26733

EM26739

EM26736

EM14730

EM26789

EM20708

Before starting the engine, refer to the HATZ diesel or WISCONSIN air cooled engine manual for break-in instructions.

1. IGNITION-is a push/pull type control, to start the pump engine, the ignition control must be pulled out.

2. CHOKE-when starting the cold engine, close choke by pulling choke control to extreme out position. Once engine is running, push choke control all the way in.

3. STARTER-push in to start engine.

4. THROTTLE-is a variable speed type control. Turning the throttle to the left unlocks it allowing the control to be pulled out to the desired speed. Once the desired speed has been reached, turning the throttle control to the right locks it in place. Note-always unlock the throttle control before it is pushed in because if this is not done first, possible damage could result to the locking mechanism.

5. TAIL LIGHT-pull turns on tail light and push turns it off. Before starting the concrete pumping procedure, let the engine

warm up a minimum of five minutes. Also thoroughly read and understand the service manual for the C-30-HD concrete pump and become totally familiar with its operation before pumping.

EM40711

PAGE 26 — C-30HD — PARTS & OPERATION MANUAL — REV. #4 (03/06/01)

NOTE PAGE

C-30HD — PARTS & OPERATION MANUAL — REV. #4 (03/06/01) — PAGE 27

C-30HD — FRAME

PAGE 28 — C-30HD — PARTS & OPERATION MANUAL — REV. #4 (03/06/01)

C-30HD — FRAME

C-30HD CONCRETE PUMP FRAME

NO. PART NO. PART NAME QTY. REMARKS

1 EM117 BOLT, HEX 1/2-13X2 4

2 EM923346 WASHER, LOCK 1/2" ........................................ 4 ........................ REPLACES EM606

3 EM406 NUT, HEX 1/2-13 4 4 EM130 BOLT, SQ. HEAD 1/2-13X2 1/2" 5 5 EM20349 OILER PLUG 1

6 EM14137 FRONT STAND ASSY (OLD STYLE) ............... 1 ........................ PRIOR TO: 12-31-96

6 EM25610 SWIVEL JACK STAND....................................... 1 ........................ S/N 970101 & ABOVE

6A EM508530 SUPPORT SWIVEL JACK .................................1 ........................ S/N 970101 & ABOVE

7 EM20135 SAFETY CHAIN 1 12 EM14138 TEE HANDLE ASSY 2 13 EM14100 PUMP BOX ASSY 1 14 EM14116 JOURNAL BLOCK 4

15 EM963180 BOLT, HEX 3/4-10X5 ......................................... 4 ........................ REPLACES EM131

16 EM923350 WASHER, LOCK 3/4" 4 17 EM104 BOLT, HEX 5/8-11X2 3 18 EM602 WASHER, LOCK 5/8 3 19 EM620 WASHER, WILLIAM 5/8 3 20 EM26536 TAIL LIGHT 1 21 EM963614 BOLT, HEX 3/4-10X3 2 22 EM14142 FRAME ASSEMBLY 1 23 EM14136 REAR STAND ASSY 1 24 EM14711 BATTERY HOLD DOWN 1 25 EM14165 WILLIAMS RE9B, 3/4X4 2 26 EM619 WASHER, WILLIAM 3/4" 2 27 EM968446 NUT, HEX 3/4-10 4 28 EM145 BOLT, HEX 1/4-20X11 2 29 EM14119 CHAIN GUARD 1

30 EM929028 HOOD LATCH.................................................... 2 ........................ REPLACES EM20107-1

32 EM14120 HOOD REST ASSY 1

EM26117 LUBE PLATE KIT ............................................... 1 ........................ NOTE: THIS KIT IS USED TO

ENCLOSE THE FRAME TO CREATE A SPLASH TYPE LUBRICATION SYSTEM. (CONTACT FACTORY FOR DETAILS)

C-30HD — PARTS & OPERATION MANUAL — REV. #4 (03/06/01) — PAGE 29

C-30HD — GASOLINE ENGINE CONTROL

PAGE 30 — C-30HD — PARTS & OPERATION MANUAL — REV. #4 (03/06/01)

C-30HD — GASOLINE ENGINE CONTROL

C-30HD CONCRETE PUMP GASOLINE ENGINE

NO. PART NO. PART NAME QTY. REMARKS

1 EM147 BOLT, 1/2-13X2.1/2" 4

2 EM923346 WASHER, LOCK 1/2" ................................ 4 ............. REPLACES EM606

3 EM406 NUT, HEX 1/2-13" 4 4 EM14705 POSITIVE CABLE 1 5 EM20720 NEGATIVE CABLE 1 6 EM14710 BATTERY 12V 1 6A EM509755 BATTERY BOX 1 S/N ABOVE 980401 7 EM140 BOLT, 1/4-20X5/8" 2 8 EM20705 RELAY 1

9 EM968435 HEX NUT, 1/4-20" ...................................... 2 ............. REPLACES EM400

10 EM600 WASHER, LOCK 1/4" 2 11 EM123 BOLT, 3/8-16X1.1/4" 1 12 EM612 WASHER, LOCK 3/8" 1 13 EM968009 NUT, HEX 3/8-16 1 14 EM20714 LINKAGE 1

15 EM924028 PIN, COTTER 3/32X7/8" ........................... 2 ............. REPLACES EM707

16 EM979 DECAL, STARTER 1 17 EM26792 100 FT. EXTENSION 1 18 EM977 DECAL, CHOKE 1 19 EM40711 3 WAY SWITCH 1 20 EM946 DECAL, REMOTE CONTROL 1 21 EM26736 STARTER 1 22 EM978 DECAL,TAIL LIGHT 1 23 EM980 DECAL, THROTTLE 1 24 EM976 DECAL, IGNITION 1 25 EM20701 ENGINE 30 HP WISE VH4D 1 26 EM26788 REMOTE CORD ASSY 1 27 EM26793 ADAPTER 1 28 EM20713 EXTENSION 1

29 30 EM20704 CLAMP BRACKET ASSY 1

31 32 33 34

35 EM16754 SWITCH 1

EM20709 SOLENOID 1

EM14728 SOLENOID ASSY COMLETE ................... 1 ............. INCLS. ITEMS W/

EM20711 SOLENOID SPRING 1

EM20710 SOLENOID PLUNGER 1

EM20709-2 RUBBER BOOT 1

EM456 NUT, NYLOCK 5-40 1

C-30HD — PARTS & OPERATION MANUAL — REV. #4 (03/06/01) — PAGE 31

C-30HD — DIESEL ENGINE CONTROL

PAGE 32 — C-30HD — PARTS & OPERATION MANUAL — REV. #4 (03/06/01)

C-30HD — DIESEL ENGINE CONTROL

C-30HD CONCRETE PUMP DIESEL ENGINE CONTROL-C-30HD

NO. PART NO. PART NAME QTY. REMARKS

1 EM968011 NUT, LOCK 1/2-13 .................................... 4 ............. REPLACES EM404

2 EM923035 WASHER, FLAT 1/2”.................................. 4 ............. REPLACES EM609

3 EM963692 BOLT, 1/2-13X1.1/2” .................................. 4 ............. REPLACES EM110

4 EM621 WASHER, WILLIAM 1/2” 2 5 EM20733 DIESEL ENGINE, HATZ Z790 1

6 EM620 WASHER, PLAIN 5/8 ................................. 4 ............. REPLACES EM14347

7 EM176 BOLT SOCKET HD, 3/8-16X1.1/4” 2 8 EM138 BOLT, HEX 3/8-16X1 3 9 EM612 WASHER, LOCK 3/8” 2 10 EM14602 BRACKET ASSY 1 11 EM20791 CONTROL BOX 1 12 EM175 BOLT SOCKET HD, 3/8-16X1.1/4 2 13 EM20719 BATTERY 12V 1 14 EM16707 GROUND CABLE 1 15 EM20721 POSITIVE CABLE 1 16 EM20735 EXHAUST CLAMP 1 REPLACES EM176847 17 EM20734 EXHAUST ELBOW 1 18 EM20790 LINKAGE ASSY 1 19 EM20790-5 SPRING 1 20 EM601 LOCK WASHER 2 21 EM20761 YOKE BAR 1 22 EM20758-1 YOKE SUPPORT 1 23 EM272 BOLT, ALLEN HEAD 8X30MM 2 24 EM20731 CONTROL CHAIN

25 EM26732 ENGINE CONTROL .................................. 1 ............. REPLACES EM20730

26 EM20763 INLINE FILTER 1

27 EM923035 WASHER, FLAT 1/2” .................................. 2 ............. REPLACES EM609

28 EM26788 REMOTE CONTROL 1

29 EM940062 NUT, LOCK 1/2-14 .................................... 1 ............. REPLACES EM26789-3

30 EM20727 CONTROL BRKT. 1 31 EM26789 RECEPTAGLE 1 32 EM146 BOLT, ALLEN HEAD 12X25MM S.H. 2 33 EM20709 SOLENOID 1

34 EM963550 BOLT, 1/4-20X3/4 ...................................... 4 ............. REPLACES EM112

35 EM16730 RETURN SPRING ..................................... 1 ............. REPLACES EM20728

36 EM600 WASHER, LOCK 1/4 4 37 EM26792 CORD ASSY, 100 FT. 1 38 EM26793 ADAPTER FOR CORD 1 39 EM20760 ROD 1

NOTE: EffectiveS/N971001

The throttle control has been updated — Consult factory for part numbers.

C-30HD — PARTS & OPERATION MANUAL — REV. #4 (03/06/01) — PAGE 33

NOTE PAGE

PAGE 34 — C-30HD — PARTS & OPERATION MANUAL — REV. #4 (03/06/01)

C-30HD — MANIFOLD ASSEMBLY

Note: EXPLODED VIEW OF PAGES 34 & 35

C-30HD — PARTS & OPERATION MANUAL — REV. #4 (03/06/01) — PAGE 35

C-30HD — CONCRETE DELIVERY

PAGE 36 — C-30HD — PARTS & OPERATION MANUAL — REV. #4 (03/06/01)

C-30HD — CONCRETE DELIVERY

C-30HD CONCRETE PUMP CONCRETE DELIVERY

NO. PART NO. PART NAME QTY. REMARKS

281 EM23837 REDUCER, 3X2 .......................................................... 1 .................... PRIOR TO JULY 1, 1990

281 EM28004-DD REDUCER, 3X2 .......................................................... 1 .................... AFTER JULY 1, 1990

282 EM963180 BOLT, 3/4-10X5 .......................................................... 2 .................... REPLACES EM131

283 EM14809 EXHAUST GATE ......................................................... 1 ....................PRIOR TO JULY 1, 1990

283 EM14850 EXHAUST GATE ......................................................... 1 .................... AFTER JULY 1, 1990

284 EM968446 NUT, HEX 3/4-10 ........................................................ 2 .................... REPLACES EM407

285 BALL INSERT ............................................................. 1 .................... SEE NOTE

286 EM18801 “O” RING 5 287 EM14818 STEEL BALL, 4” 1

288 EM968266 NUT, JAM 3/4-16 ........................................................ 6 ..................... REPLACES EM421

289 EM618 WASHER, SPECIAL 3/4 6 290 EM18409 “O” RING 6 291 EM14801 PRIMARY VALVE 1 292 EM136 STUD, 3/4-16X8 3 293 EM137 T-BOLT, 3/4-10X14 2 294 EM14817 VALVE SEAT 1 295 EM14810 JOLTER SPRING 1 296 EM14845 CLAMP ARM 1

297 EM23839 3” COUPLING “B” VIC ................................................ 1 .................... PRIOR TO JULY 1, 1990

297 EM28904 3" COUPLING "B" HD ................................................ 1 .................... AFTER JULY 1, 1990

298 EM23840 3” COUPLING S/J VIC ................................................ 1 ....................PRIOR TO JULY 1, 1990

298 EM28904 3" COUPLING "B" HD ................................................ 1 ..................... AFTER JULY 1, 1990

299 EM23838 ELBOW, 3”-90° ........................................................... 1 ....................PRIOR TO JULY 1, 1990

299 EM23946 ELBOW. 3"-90° ........................................................... 1 .................... AFTER JULY 1, 1990

300 EM135 BOLT, 1-1/4-12X6 1 301 EM14819A MANIFOLD ASSY 1

302 EM968446 NUT, HEX 3/4-10 ........................................................ 2 .................... REPLACES EM407

303 EM619 WASHER, WILLIAM 3/4 2 304 EM18804 STEEL BALL, 4 1/2” 1

305 BALL INSERT ............................................................. 1 .................... SEE NOTES

306 EM160 BOLT, 3/8-16X3/4 1 307 EM451 NUT, LOCK 1-1/4-12 1

Not Shown in diagram: 4" Urethane Ball (P/N EM26817); 4" Seat (P/N EM26816)

Notes on item #285 — Machines prior to July 1, 1990 use P/N 18803 Ball Insert; On machines after July 1, 1990, P/N 18803 was replaced by the Duraseat P/N

14843. This new seat is more durable and can be used on older units.

Notes on item #305 — Machines prior to July 1, 1990 use P/N 18806 insert (used in conjunction with 14817 seat); On machines after July 1, 1990, these parts are replaced by 14842 Duraseat.

C-30HD — PARTS & OPERATION MANUAL — REV. #4 (03/06/01) — PAGE 37

C-30HD — CLUTCH ASSEMBLY — ALL MACHINES PRIOR TO S/N 960801 (August 1996)

203

199

200

201

202

C-30HD CONCRETE PUMP CLUTCH ASSEMBLY ALL MACHINES UP TO S/N 960801

NO. PART NO. PART NAME QTY. REMARKS

196 EM14320 CLUTCH ASSEMBLY (8" DIA) ................................... 1 .................... INCLS. ALL ITEMS W/

197*EM918050 CLUTCH SPRING ...................................................... 2 .................... REPLACES EM26309

198*EM923346 1/2 LOCK WASHER.................................................... 1 ....................REPLACES EM606

199*EM963564 1/2-13X1 1/4 HEX BOLT ............................................ 1 .................... REPLACES EM139

200*EM628 SPECIAL WASHER 1 201*EM26321 ROTOR ASSEMBLY 1 202*EM26310 CLUTCH LINING 1 203*EM26322 CLUTCH HOUSING 1

204*EM902204 CLUTCH BEARING .................................................... 2 .................... REPLACES EM26311

205*EM926066 RETAINING RING ....................................................... 2 .................... REPLACES EM801

206*EM926053 RETAINING RING ....................................................... 1 .................... REPLACES EM800

C-30HD — CLUTCH ASSEMBLY — ALL MACHINES S/N 960801 THRU 980400 (August 1996)

Note: CLUTCH ASSY (BLM 6") P/N

EM14320A HAS BEEN REPLACED BY CLUTCH ASSY P/N EM14320

(8" CLUTCH)

THE CLUTCH PACK FOR 6" CLUTCH IS STILL AVAILABLE UNDER P/N EM60HB

PAGE 38 — C-30HD — PARTS & OPERATION MANUAL — REV. #4 (03/06/01)

NOTE PAGE

C-30HD — PARTS & OPERATION MANUAL — REV. #4 (03/06/01) — PAGE 39

C-30HD — CRANKSHAFT ASSEMBLY

PAGE 40 — C-30HD — PARTS & OPERATION MANUAL — REV. #4 (03/06/01)

C-30HD — CRANKSHAFT ASSEMBLY

C-30HD CONCRETE PUMP CRANKSHAFT ASSEMBLY

NO. PART NO. PART NAME QTY. REMARKS

1 EM14305 CRANKSHAFT 1 2 EM14322 SPACER 1 3 EM14326 “O” RING 2 4 EM14325 BEARING CONE 2 5 EM14323 BEARING CONE SPACER 1 6 EM14324 BEARING CUP 1 7 EM14303 BEARING BLOCK 1 8 EM14302 CAM BUSHING SPACER 1 9 EM14306 CRANKSHAFT KEY 2

10 KEY ............................................................ 1 ............. INCLUDED W/ ITEMS 12 +16

11 EM14300 CAM WELDMENT 1 12 EM14301 CAM BUSHING 1 13 EM14304 CAM BEARING 1 14 EM30190 SET COLLAR 1 15 EM14307 SPROCKET, 60 TOOTH 1 16 EM14309 BUSHING 1

C-30HD — PARTS & OPERATION MANUAL — REV. #4 (03/06/01) — PAGE 41

C-30HD — CRANKSHAFT ASSEMBLY

156

PAGE 42 — C-30HD — PARTS & OPERATION MANUAL — REV. #4 (03/06/01)

C-30HD — CRANKSHAFT ASSEMBLY

C-30HD CONCRETE PUMP CRANKSHAFT ASSEMBLY

NO. PART NO. PART NAME QTY. REMARKS

132 EM14322 SPACER 1 133 EM14326 “O” RING 2

134 EM923350 LOCK WASHER .......................................................... 2 ....................REPLACES EM610

135 EM968446 NUT, HEX 3/4-10 ........................................................ 4 .................... REPLACES EM407

136 EM702 SCREW, SET HALF DOG POINT 3/8-16X3/4 2

137 EM916001 LUBE FITTING, 1/8-27 NPT ...................................... 2 ....................REPLACES EM16179

138 EM14300 CAM WELDMENT 1

139 EM968013 NUT, HEX 5/8-11 ........................................................ 4 .................... REPLACES EM419

140 EM923348 WASHER, LOCK 5/8 .................................................. 3 .................... REPLACES EM602

141 EM620 WASHER, WILLIAMS 5/8 4 142 EM128 BOLT, HEX 5/8-11X4 2 143 EM14304 CAM BEARING 1 144 EM175 BOLT, SOC HD 3/8-16X1 1/4 1 145 EM14301 CAM BUSHING 1 146 EM14302 CAM BUSHING SPACER 1 147 EM14325 BEARING CONE 2 148 EM14303 BEARING BLOCK 1 149 EM129 BOLT, HEX 3/4-10X8 1/2 2 150 EM14324 BEARING CUP 1 151 EM14323 BEARING CONE SPACER 1 152 EM104 BOLT, HEX 5/8-11X2 1 153 EM14306 CRANKSHAFT KEY 2 154 EM14305 CRANKSHAFT 1 155 EM703 SCREW, SET 3/8-16X3/8 2 156 EM30139 SET COLLAR 1

C-30HD — PARTS & OPERATION MANUAL — REV. #4 (03/06/01) — PAGE 43

C-30HD — COUNTER SHAFT ASSEMBLY

PAGE 44 — C-30HD — PARTS & OPERATION MANUAL — REV. #4 (03/06/01)

C-30HD — COUNTER SHAFT ASSEMBLY

C-30HD CONCRETE PUMP COUNTER SHAFT ASSEMBLY

NO. PART NO. PART NAME QTY. REMARKS

155 EM14307 SPROCKET, 60 TOOTH 1 156 EM14308 CHAIN 1 157 EM14309 BUSHING 1 158 EM26313 OFFSET LINK 1 159 EM702 SCREW, SET 3/8-16X3/4 1 160 EM703 SCREW, SET 3/8-16X3/8 1 161 EM14318 SPROCKET, 13 TOOTH 1 161 EM14319 BUSHING 1 163 EM14312 COUNTER SHAFT 1

164 EM968011 NUT, HEX 1/2-13 ........................................................ 4 .................... REPLACES EM404

165 EM923346 WASHER, LOCK 1/2 .................................................. 4 .................... REPLACES EM606

166 EM14315 BELT, BP90 (GASOLINE) 1

167 EM900127 BELT, B87 (DIESEL) ................................................... 2 .................... REPLACES EM14321

168 EM14314 BUSHING 1 169 EM14313 PULLEY 1 170 EM14316 KEY 1 171 EM14311 CAM BEARING 2 172 EM124 BOLT, HEX 1/2-13X4 4 173 EM621 WASHER, WILLIAM 1/2 4

174 EM916001 LUBE FITTING ........................................................... 2 ....................REPLACES EM16179

175 EM14317 KEY 1 176 EM161 BOLT, HEX 5/16-18X1 3

177 EM492378 BOLT, HEX 3/8-16X1 3/4 ............................................ 3 .................... REPLACES EM177

178 EM123 BOLT, HEX 3/8-16X1 1/4 3 179 EM26314 CONNECTING LINK 1

C-30HD — PARTS & OPERATION MANUAL — REV. #4 (03/06/01) — PAGE 45

C-30HD — COMPENSATOR PISTON ROD

PAGE 46 — C-30HD — PARTS & OPERATION MANUAL — REV. #4 (03/06/01)

C-30HD — COMPENSATOR PISTON ROD

C-30HD CONCRETE PUMP COMPENSATOR PISTON ROD

NO. PART NO. PART NAME QTY. REMARKS

104 EM18800 PUMPING CYLINDER 1

105 EM968446 NUT, HEX 3/4-10 ........................................................ 4 .................... REPLACES EM407

106 EM14413 FACE PLATE 2 107 EM18409 “O” RING 4 108 EM14412 BUSHING 2 109 EM14411 PISTON CUP 2 110 EM14408 BRONZE RING 2 111 EM14410 RING & FELT HOLDER 2 112 EM16493 FELT RING 2 113 EM20816 “O” RING 2

114 EM903162 BEARING CONE ........................................................ 4 .................... REPLACES EM20815

115 EM916001 LUBE FITTING ........................................................... 2 ....................REPLACES EM16179

116 EM14806 PISTON GUIDE 1

117 EM903163 BEARING CUP ........................................................... 2 .................... REPLACES EM20812

118 EM20814 BUSHING 2 119 EM20813 SPACER 2 120 EM14805 ROD END 1 121 EM14331 BACKING PLATE 1 122 EM14333 RETURN SPRING 1 123 EM14332 GUIDE ROD 1 124 EM14105 ANCHOR PLATE 1 125 EM20412 OILER FITTING MINI-BARB 2 126 EM14409 OILER PLATE 2 127 EM14407 “O” RING 2

128 EM916001 LUBE FITTING ........................................................... 3 ....................REPLACES EM16179

129 EM14336 PISTON GUIDE 1 130 EM14334 COMPENSATOR SPRING 1 131 EM704 PIN, LG SPIRAL 1/2X2 1 132 EM14335 PISTON ROD 1

C-30HD — PARTS & OPERATION MANUAL — REV. #4 (03/06/01) — PAGE 47

C-30HD — CONNECTING ROD ASSEMBLY 20328 (OLD STYLE)

PAGE 48 — C-30HD — PARTS & OPERATION MANUAL — REV. #4 (03/06/01)

C-30HD — CONNECTING ROD ASSEMBLY 20328 (OLD STYLE)

C-30HD CONCRETE PUMP CONNECTING ROD ASSEMBLY EM20328 (OLD STYLE)

NO. PART NO. PART NAME QTY. REMARKS

A EM20328 CONNECTING ROD ASSY ........................................ 1 .................... INCLS. ALL ITEMS W/

87 EM14808 PISTON ROD WELDMENT 1

88 EM968446 3/4-10 HEX NUT ........................................................ 1 ....................REPLACES EM407

89 EM14807 PUMPING CYLINDER 1 90 91 92 93 94 95 96 97 98 99 100*EM20328-1 CONNECTING ROD 1

101 EM703 SCREW, SET LG CUP 3/8-16X3/8 2 103 EM20338 SPACER 1

EM402150 SPACER ...................................................................... 2 .................... REPLACES EM20329

EM2330 O-RING 2

EM402999 SPACER ...................................................................... 2 .................... REPLACES EM20331

EM916004 LUBE FITTING ........................................................... 1 .................... REPLACES EM16153

EM903175 BEARING .................................................................... 1 .................... REPLACES EM20333

EM402149 BUSHING .................................................................... 1 .................... REPLACES EM20332

EM402996 SPACER ...................................................................... 1 .................... REPLACES EM20335

EM20336 “O” RING 2

EM903176 BEARING .................................................................... 1 .................... REPLACES EM20337

EM916001 LUBE FITTING ........................................................... 1 .................... REPLACES EM16179

C-30HD — PARTS & OPERATION MANUAL — REV. #4 (03/06/01) — PAGE 49

C-30HD — CONNECTING ROD ASSEMBLY 20328T (NEW STYLE)

PAGE 50 — C-30HD — PARTS & OPERATION MANUAL — REV. #4 (03/06/01)

C-30HD — CONNECTING ROD ASSEMBLY 20328T (NEW STYLE)

C-30HD CONCRETE PUMP CONNECTING ROD ASSEMBLY EM20328T (NEW STYLE)

NO. PART NO. PART NAME QTY. REMARKS

A EM20328T CONNECTING ROD ASSY ........................................ 1 .................... INCLS. ALL ITEMS W/

87 EM14808 PISTON ROD WELDMENT 1

88 EM968446 NUT, HEX 3/4-10 ........................................................ 1 .................... REPLACES EM407

89 EM14807 PUMPING CYLINDER 1 90 91 92 93 94 95 96 97 98 99 100*EM20364 CONNECTING ROD 1

101 EM703 SCREW, SET, LG CUP 3/8-16X3/8 1 102 EM702 SCREW, SET, POG POINT 3/8-16X3/8 1 103 EM20338 SPACER 1

EM20816 O-RING 2

EM903162 BEARING CONE ........................................................ 2 .................... REPLACES EM20815

EM20813 SPACER 1

EM916004 LUBE FITTING ........................................................... 1 .................... REPLACES EM16153

EM903175 BEARING CUP ........................................................... 1 .................... REPLACES EM20333

EM20814 BUSHING 1

EM402996 SPACER ...................................................................... 1 .................... REPLACES EM20335

EM20336 “O” RING 2

EM903176 BEARING .................................................................... 1 .................... REPLACES EM20337

EM916001 LUBE FITTING ........................................................... 1 .................... REPLACES EM16179

C-30HD — PARTS & OPERATION MANUAL — REV. #4 (03/06/01) — PAGE 51

C-30HD — ROCKER ASSEMBLY

PAGE 52 — C-30HD — PARTS & OPERATION MANUAL — REV. #4 (03/06/01)

C-30HD — ROCKER ASSEMBLY

C-30HD CONCRETE PUMP ROCKER ASSEMBLIES

NO. PART NO. PART NAME QTY. REMARKS

68 EM202 BOLT, HEX 1-8X6 LG 1 69 EM133 BOLT, HEX 1-14X2 LG 2 70 EM627 WASHER, STAR 1” 3 71 EM14329 ROCKER ARM SHAFT 1

72 EM916001 LUBE FITTING, 1/8-27 NPT ...................................... 3 .................... REPLACES EM16179

73 EM20326-2 BUSHING 4 74 EM105 BOLT, HEX 1-14X6 LG 2 75 EM603 WASHER, LOCK 1” 3 76 EM14328 ROCKER ARM ASSEMBLY 1 77 EM417 NUT, LOCK 1-14 3

78 EM402434 BUSHING .................................................................... 1 .................... REPLACES EM20346

79 EM20347 SPACER 3

80 EM903092 CAM ROLLER ............................................................ 1 .................... REPLACES EM20345

81 EM23044 GREASE BOLT 1 82 EM14846 CAM ROCKER ARM 1 83 EM405 NUT, LOCK 3/4-10 1 84 EM402456 OILER PLUG 1

86 EM963180 BOLT, HEX 3/4-10X5 LG ............................................ 1 .................... REPLACES EM131

87 EM923157 CAM OILER SEAL SPACER ....................................... 1 ....................REPLACES EM607

C-30HD — PARTS & OPERATION MANUAL — REV. #4 (03/06/01) — PAGE 53

EM14409

C-30HD — COMPENSATING SPRING ASSEMBLY

EM18409

EM14335

EM16179

EM20412

EM14334

EM20415

NOTE: If it is necessary to replace the spring, remove the piston head assembly which allows the guide weldment to be removed from the piston rod.

EM16179

NOTE: Grease the compensator piston rod daily at both fittings. Failure to grease regularly may cause the piston rod to “seize” in the guide tube resulting in severe pulsations of material in the hose.

PAGE 54 — C-30HD — PARTS & OPERATION MANUAL — REV. #4 (03/06/01)

EM14806

EM704

EM20812

EM16179

EM903092

EM14105

(PART OF PUMP BOX ASSEMBLY)

C-30HD — RETURN SPRING ASSEMBLY

EM14846

EM14805

EM14332

EM14334

EM14333

EM14331

C-30HD — PARTS & OPERATION MANUAL — REV. #4 (03/06/01) — PAGE 55

C-30HD — OIL SYSTEM AND FUEL SYSTEM

PAGE 56 — C-30HD — PARTS & OPERATION MANUAL — REV. #4 (03/06/01)

C-30HD — OIL SYSTEM AND FUEL SYSTEM

C-30HD CONCRETE PUMP OIL SYSTEM AND FUEL SYSTEM

NO. PART NO. PART NAME QTY. REMARKS

176 EM20426 MINI BARB ELBOW 2 177 EM20427 FUEL LINE A/R

178 FUEL TANK .......................................... 1 ........................... SEE NOTE

179 EM401 NUT, HEX 5/16-18 6

180 EM968354 WASHER, LOCK 5/16 ......................... 6 ........................... REPLACES EM601

181 EM923023 WASHER, FLAT 5/16 ...........................10 ......................... REPLACES EM614

182 EM101 BOLT, HEX 5/16-18X1 1/2 4

183 FUEL TANK STRAP .............................2 ........................... SEE NOTE

184 EM20787 FUEL TANK CAP ................................. 1 ........................... SEE NOTE FOR PLASTIC FUEL TANK

185 EM20349 OIL PLUG 1 186 EM20412 MINI BARB FITTING 3 187 EM20415 CLEAR PLASTIC TUBE A/R 188 EM20417 NIPPLE 1 189 EM20418 TEE FITTING 1

190 EM911004 STREET ELBOW .................................1 ........................... REPLACES EM20416

191 EM20421 METERING VALVE 2 192 EM14401 ELECTRIC OIL PUMP 1

193 EM963030 BOLT, HEX 5/16-18X1 .........................2 ........................... REPLACES EM163

194 EM923027 WASHER, FLAT 3/8 ............................. 2 ........................... REPLACES EM611

195 EM14198 OIL RESERVOIR 1 196 EM1440 INSERT FITTING 1

Notes: Item #178 and 183 (A) — Machines prior to 1993 use P/N 14701 Fuel Tank (8 gal. capacity) and #14703 Fuel Tank Straps (two required). (B) — Machines after 1993 use P/N 14205 Fuel Tank (18 gal. capacity) and #16185 Fuel Tank Straps (two required). (C) — Machines after 2/1/95 use P/N 14205P Plastic Fuel Tank (18 gal. capacity); P/N 2108 Gas Cap. Fuel tank straps not required. Note: interchangeable with P/N

14205.

C-30HD — PARTS & OPERATION MANUAL — REV. #4 (03/06/01) — PAGE 57

C-30HD — CENTRAL GREASE LUBRICATION PANEL EFFECTIVE S/N 970101

FITTING LOCATION AND PLASTIC HOSE LENGTH

EM509306 PANEL ASSY COMPLETE

NOTE: P/N EM16495 GREASE LINE (sold per foot)

EM505489 HOSE GREASE ZERK-12 REQUIRED

EM505490 45° GREASE ZERK-1 REQUIRED

POSITION LOCATION LENGTH OF LINES

1 ....................................................FLANGE BEARING (CRANKSHAFT) ................................................... 28"

2 ....................................................CONNECTING ROD ............................................................................ 31"

3 ....................................................CAM BEARING .................................................................................... 28"

4 ....................................................STEEL BEARING BLOCK (SQUARE) .................................................. 34"

5 ....................................................ROCKER ARM UPPER (CRANKSHAFT SIDE) .................................... 10"

6 ....................................................PILLOW BLOCK BEARINGS (COUNTERSHAFT) ............................... 15"

7 ....................................................LOWER ROCKER ARM ....................................................................... 28"

8 ....................................................ROCKER ARM LOWER (CHAIN SIDE) ................................................ 26"

9 ....................................................PILLOW BLOCK BEARINGS (COUNTERSHAFT) ............................... 20"

10 ..................................................ROCKER ARM UPPER (PULLEY SIDE) .............................................. 20"

11 ..................................................CONNECTING ROD LOWER .............................................................. 40"

12 ..................................................PISTON GUIDE .................................................................................... 42"

13 ..................................................PISTON ROD .......................................................................................

TOTAL LENGTH OF LINES REQUIRED .............................................. 364"

42"

PAGE 58 — C-30HD — PARTS & OPERATION MANUAL — REV. #4 (03/06/01)

NOTE PAGE

C-30HD — PARTS & OPERATION MANUAL — REV. #4 (03/06/01) — PAGE 59

C-30HD — AXLE INSTALLATION

212

PAGE 60 — C-30HD — PARTS & OPERATION MANUAL — REV. #4 (03/06/01)

C-30HD — AXLE INSTALLATION

C-30HD CONCRETE PUMP AXLE INSTALLATION

NO. PART NO. PART NAME QTY. REMARKS

A EM26615A TIRE ASSY ................................................................. 2 .................... INCLS. ALL ITEMS W/

209 EM26518 HUB CAP 2 210*EM20603 TIRE 2

211*EM20602 WHEEL 2

212 EM20601 HUB ASSEMBLY ......................................................... 2 ....................INCLS. ALL ITEMS W/

213 EM14600 AXLE 1 214 EM705 PIN, COTTER 3/16X1 1/2 2

215# EM26305 GREASE SEAL 2 216

# EM903168 INNER BEARING ........................................................ 2 .................... REPLACES EM26301

217# EM903169 INNER CUP ................................................................ 2 ....................REPLACES EM26303

# EM26300 HUB 2

218 219

# EM903012 OUTER CUP ............................................................... 2 ....................REPLACES EM26304

220# EM903113 OUTER BEARING ...................................................... 2 ....................REPLACES EM26302

221# EM26329 WASHER 2

222# EM968481 CASTLE NUT ............................................................. 2 .................... REPLACES EM420

223# EM26306 DUST COVER 2 224# EM26519 NUT 12 225# EM20612 STUD 12

C-30HD — PARTS & OPERATION MANUAL — REV. #4 (03/06/01) — PAGE 61

C-30HD — HOPPER AND HOOD

PAGE 62 — C-30HD — PARTS & OPERATION MANUAL — REV. #4 (03/06/01)

C-30HD — HOPPER AND HOOD

C-30HD CONCRETE PUMP HOPPER AND HOOD

NO. PART NO. PART NAME QTY. REMARKS

56 DURASEAT ................................................ 1 ............. SEE NOTE BELOW

57 EM18801 “O” RING 1

58 EM923348 5/8” LOCK WASHER .................................. 3 ............. REPLACES EM602

59 EM104 5/8-11X2 LG HEX BOLT 3 60 EM14140 HOOD 1 61 EM14141 HOPPER 1 62 EM14159 HOPPER SCREEN 1 63 EM14140-17 DOOR HINGE 1 64 EM14140-16 HOOD DOOR 1 65 EM14140-4 HOOD DOOR SUPPORT 2 66 EM14140-5 HOOD SUPPORT BRKT 2 67 EM406 1/2-13 HEX NUT 2 68 EM124 1/2-13X4 LG HEX BOLT 2 69 508659 LATCH 1

EM14164 KIT, DECAL SAFETY ................................. 1 ............. COMPONENTS NOT SHOWN

Note on item 56: A — Machines, built after July 1, 1990 use Duraseat P/N 14843 — This new seat is more durable and can be used on older units.

C-30HD — PARTS & OPERATION MANUAL — REV. #4 (03/06/01) — PAGE 63

C-30MG — SCALED DOWN MANIFOLD/CYLINDER KIT MODEL C-30MG

The above manifold/cylinder and piston assembly can be ordered as a kit to be installed on model C-30K, C-30SP or model C-30D pumps. This unit has a volume delivery of 4 to 13 cu. yds. per hour. When installed on a standard pump, the unit will pump brick mortar as well as 1/2” minus aggregate mixes in excess of volume pump for numerous applications such as high-rise grouting-spancrete-mud jacking-capping wells-tunnel grouting-pumping pilings and shotcrete.

Note: If the above assembly is installed on model C-30D pumps it will be necessary to replace the compensator piston rod assembly with the new style used on the model C-30K, and model C-30 HD.

200 ft. vertical. It is a high pressure-low

PAGE 64 — C-30HD — PARTS & OPERATION MANUAL — REV. #4 (03/06/01)

NOTE PAGE

C-30HD — PARTS & OPERATION MANUAL — REV. #4 (03/06/01) — PAGE 65

C-30MG — MANIFOLD ASSEMBLY C-30MG

PAGE 66 — C-30HD — PARTS & OPERATION MANUAL — REV. #4 (03/06/01)

C-30MG — MANIFOLD ASSEMBLY C-30MG

C-30MG CONCRETE PUMP MANIFOLD ASSEMBLY-C30-MG

NO. PART NO. PART NAME QTY. REMARKS

1 EM14832 PUMPING CYLINDER 1 2 EM14827 MANIFOLD 1 3 EM14824 STEEL BALL, 3-1/4 1 4 EM14422 SQ. SEAL 1 5 EM14823 VALVE SEAT 1 6 EM14822 VALVE HOUSING 1 7 EM803 BALL STOP STUD 3 8 EM618 WASHER, 3/4 6

9 EM968266 NUT, JAM 3/4-16 ....................................... 6 ............. REPLACES EM421

10 EM14833 ADAPTOR 1 11 EM802 RETAINING RING 1 12 EM14829 O-RING 1 13 EM18801 O-RING 1 14 EM14824 STEEL BALL, 3-1/4 1 15 EM14826 INSERT 1 16 EM18801 O-RING 1 17 EM14823 VALVE SEAT 1 18 EM14836 VALVE SEAT ADAPT. 1

19 EM963180 BOLT, 3/4-10X5 ......................................... 1 ............. REPLACES EM131

20 EM968446 NUT, HEX 3/4-10 ....................................... 1 ............. REPLACES EM407

21 EM14832 COMP CYLINDER 1 22 EM14828 REDUCER 1 23 EM135 BOLT, 1/4-20X6 1 24 EM14845 CLAMP ARM 1 25 EM14810 SPRING 1 26 EM14830 O-RING 1 27 EM160 BOLT, 3/8-16X3/4 1 28 EM14829 O-RING 1 29 EM802 RETAINING RING 1 30 EM14833 ADAPTOR 1 31 EM18409 O-RING 6 32 EM618 WASHER, 3/4 6

33 EM968266 NUT, JAM 3/4X16 ...................................... 6 ............. REPLACES EM421

34 EM451 NUT, HEX 1-1/4-12 1

C-30HD — PARTS & OPERATION MANUAL — REV. #4 (03/06/01) — PAGE 67

C-30MG — PISTON HEAD COMPONENTS

PAGE 68 — C-30HD — PARTS & OPERATION MANUAL — REV. #4 (03/06/01)

C-30MG — PISTON HEAD COMPONENTS

C-30MG CONCRETE PUMP PISTON HEAD COMPONENTS C30-MG

NO. PART NO. PART NAME QTY. REMARKS

1 EM968446 NUT, HEX 3/4-10 ....................................... 2 ............. REPLACES EM407

2 EM14420 FACE PLATE 2 3 EM18409 O-RING 2 4 EM14418 SLEEVE 2 5 EM14419 PISTON CUP 2 6 EM14417 BACK PLATE 2 7 EM14416 FELT SPACER 2 8 EM14423 FELT RING 2 9 EM14421 OILER PLATE 2 10 EM18409 O-RING 2 11 EM14808 PISTON ROD 2

C-30HD — PARTS & OPERATION MANUAL — REV. #4 (03/06/01) — PAGE 69

C-30SP — OPTIONAL SCREW CONVEYOR AND TORQUE LIMITER MODEL C30-SP

PAGE 70 — C-30HD — PARTS & OPERATION MANUAL — REV. #4 (03/06/01)

C-30SP — OPTIONAL SCREW CONVEYOR AND TORQUE LIMITER MODEL C30-SP

C-30SP CONCRETE PUMP OPTIONAL SCREW CONVEYOR AND TORQUE LIMITER C30-SP

NO. PART NO. PART NAME QTY. REMARKS

1 EM14175 HOPPER 1

2 EM968011 NUT, HEX 1/2-13 ....................................... 2 ............. REPLACES EM404

3 EM923346 WASHER, LOCK 1/2 ................................. 2 ............. REPLACES EM606

4 EM26108 SCREW FEEDER 1 5 EM147 BOLT, HEX 1/2-13X2.1/2 2 6 EM26108-4 PLUG 1 7 EM721 KEY 1 8 EM14170 EXTENSION 1 9 EM14340 SPROCKET CHAIN 1 10 EM14338 TORQUE LIMITER 1 11 EM14341 SPROCKET 1 12 EM14716 BUSHING 1 13 EM14339 SPROCKET 1 14 EM26359 DRIVE SHAFT 1 15 EM720 KEY 1

16 EM916001 OILER ........................................................ 1 ............. REPLACES EM16179

17 EM26109 CHAIN GUARD 1 18 EM147 BOLT, HEX 1/2-13X2.1/2 8

19 EM923346 WASHER, LOCK 1/2 ................................. 8 ............. REPLACES EM606

20 EM621 WASHER, WILLIAM 4 21 EM18138 SEAL SPACER 8 22 EM18135 FLANGE BEARING 2 23 EM18138 SEAL SPACER 8 24 EM18136 SPACER PLATE 2 25 EM18137 SHAFT SEAL 2 26 EM18136 SPACER PLATE 2 27 EM18137 SHAFT SEAL 2

C-30HD — PARTS & OPERATION MANUAL — REV. #4 (03/06/01) — PAGE 71

RECOMMEMDED SHOTCRETE SYSTEM

For swimming pool construction, ditch lining, tunnel lining, slope stabilization, etc.

PAGE 72 — C-30HD — PARTS & OPERATION MANUAL — REV. #4 (03/06/01)

RECOMMEMDED SHOTCRETE SYSTEM

NO. PART NO. PART NAME QTY. REMARKS

1 EM28904........... 3" “B” COUPLING

2 EM23946........... 3"-90° ELBOW

3 EM28903........... 2 1/2" S/J COUPLING

4 EM28005DD ..... 3"X 2 1/2 REDUCER

5 EM28061........... 2 1/2"X 10FT. PIPE

6 EM24849........... 2 1/2"X 50FT. HOSE

7 EM28001DD ..... 2 1/2"X 2" REDUCER

8 EM23815D ........ 2 1/2"X 2" REDUCER

W/AIR VIBRATOR

9 EM28902 ........... 2" S/J COUPLING

10 EM23101........... AIR VIBRATOR

11 EM28131........... 2"X 2 ELBOW

12 EM24841........... 2"X 25 FT. HOSE

13 EM23808D ........NOZZLE ASSEMBLY

14 EM23806........... 1 3/8" NOZZLE TIP

15 EM23807........... 1 1/4" NOZZLE TIP

General recommendations

■

If the site will permit, use steel pipe from the pump to the pool perimeter. It will reduce line pressures which is highly recommended.

■

The vibrator on the reducer by the pool improves pumpability.

■

Turn both air vibrators off whenever the pump is stopped to prevent separation of mix.

■

The air vibrators are low consumption (4.2 scfm).

■

Leave the air on at the nozzle when the pump is stopped to prevent clogging of air the hoses in the air insert.

■

Use item #11 (steel elbow) at the edge of the pool to prevent collapse of the rubber hose, which can cause blockage.

C-30HD — PARTS & OPERATION MANUAL — REV. #4 (03/06/01) — PAGE 73

C-30HD SHOTCRETE ACCESSORIES

PAGE 74 — C-30HD — PARTS & OPERATION MANUAL — REV. #4 (03/06/01)

C-30HD SHOTCRETE ACCESSORIES

C-30HD CONCRETE PUMP SHOTCRETE ACCESSORIES

NO. PART NO. PART NAME QTY. REMARKS

302 EM26107 HOPPER SCREEN 1 303 EM23101-1 AIR VIBRATOR 1 304 EM132 BOLT, 1/2-13X2 2 305 EM23407 AIR HOSE 1 306 EM23408 BUSHING 1 307 EM23411 VALVE 1 308 EM912073 NIPPLE 2 309 EM23409 COUPLING 1

310 EM923346 WASHER, 1/2 LOCK ................................. 2 ............. REPLACES EM606

311 EM406 NUT, HEX 1/2-13 2 312 EM23818 2"X25' GROOVED HOSE

EM24841 2"X25' RAISED HOSE

EM23845 2"X50' GROOVED HOSE 313*EM23802 ADAPTER 1 314*EM23803 GUN BODY 1 315*EM20816 “O” RING 1 316*EM23804 AIR INSERT 1 317*EM23805 NOZZLE CLAMP 1 318*EM23806 NOZZLE TIP, 1 3/8" 1 319*EM23807 NOZZLE TIP, 1 1/4" 1

320*EM911076 STREET ELBOW ....................................... 1 ............. REPLACES EM23412

321 AIR HOSE NOT SUPPLIED BY MAYCO

322 EM23808 NOZZLE ASSEMBLY ................................. 1 ............. INCLS. ITEMS W/

NOTE: Use a 1 3/8" rubber nozzle tip for a wide spray pattern. Use a 1 1/4" rubber nozzle tip for a narrow spray pattern. DO NOT INSTALL THE NOZZLE AT THE END OF THE HOSE UNTIL THE FIRST MATERIAL HAS PASSED THROUGH THE ENTIRE HOSE LENGTH.

Disassemble and clean the nozzle assembly thoroughly after each job. Grease all threads before reassembly. Do not close the air valve when pumping is stopped as a continued air flow keeps the air passages clean.

C-30HD — PARTS & OPERATION MANUAL — REV. #4 (03/06/01) — PAGE 75

C-30HD — SERVICE PROCEDURES

1. CRANKSHAFT AND CAM ASSEMBLY PROCEDURE

A. Set bearing block (part #EM14303) into hydraulic press. Place bearing cup into bearing block and press in evenly. Bearing cup should be aligned equally on both sides of bearing block.

B. Set crankshaft into hydraulic press with the long end towards the top. Install spacer (part #EM14322), O-ring (part #EM14326) and bearing cone (part #EM14325) onto crankshaft. Place bearing block on crankshaft until the bearing cone is riding in the bearing cup. Insert bearing cone spacer (part #EM14323) onto crankshaft and inside bearing block. Install second bearing cone until it is seated inside bearing cup. Place O-ring and spacer (part #EM14302) on crankshaft. Set cam weldment on top of spacer. Install crankshaft key and cam key on cam bushing (part #EM14301). Slide cam bushing down crankshaft and align the bushing, cam and crankshaft. Install sleeve over crankshaft and align with hydraulic press. Install cam bushing bolts loosely. Press bushing down onto bearing assembly. Leaving pressure on the bushing, tighten cam bolts evenly to 40-50 foot pounds. Release pressure on the bushing, re-apply pressure to bushing and tighten bolts evenly to 40-50 foot pounds. Repeat procedure 3 to 4 times. After bushing is tight into cam, remove from hydraulic press. Remove one bolt at a time, using Loctite, install bolts and torque to 65-70 foot pounds. Counter sink set screw hole and install dog point set screw and second set screw both with Loctite.

C. Place cam bearing onto crankshaft keeping bearing loose. *Note: Make sure the eccentric lock is facing toward the outside of the pumping unit.

D. Set crankshaft assembly into the pump box and align both bearing assemblies with the pump box mountings.

E. After crankshaft assembly is securely fastened to the pump box, place sprocket (part #EM14307) onto the cam side of the crankshaft assembly. Install bushing (part #EM14309) into sprocket. Align sprocket with sprocket on countershafts and tighten bolts.

F. Install chain part #EM14308. To adjust, loosen locknuts on pusher bolts and tighten chain to approximately 1/2” slack in the chain. Once chain is adjusted properly, tighten down locknuts.

2. BALL AND SEAT REPLACEMENT PROCEDURE

A. Remove 3”x 2” reducer and 3” elbow from the pump outlet. Remove exhaust gate and Y-manifold (secondary manifold). Check ball seat and ball stop pin for wear. If any wear is detected, the part should be replaced. Remove T-manifold (primary manifold). Check all parts for wear. Remove hopper and hopper seat and inspect.

B. Loosen the piston nuts and remove the piston cup assembly and cylinders. Inspect all parts for wear and replace parts with excessive wear. Check oiler pump for proper operation.

C. Clean all parts thoroughly, removing all foreign material and concrete slurry. Once parts are clean, install concrete cylinders. Place oiler plate O-ring in place and coat with oil. Install small O-ring on piston rod. Run oiler line through the cylinders and connect in the oiler fitting on the oiler plate. Push oiler plate into cylinder. Install ring and felt holder, soak felt ring in oil, then install around felt holder in cylinder. Make sure the bronze ring is flat, then push it up flush with the ring and felt holder. Coat piston cup with oil and push it inton the cylinder. Install bushing into center of piston cup. Put small O-ring on rod, place face plate on rod and tighten down securely. Repeat these procedure on the opposite cylinder.

D. Thoroughly check T-manifold, ball stoppings and both steel balls for wear. Insert an O-ring in the top flange and in the leading edge of the manifold. Put the manifold onto the primary side of the pump and install bolts leaving them loose.

E. Check Y-manifold for wear, install all O-rings, ball stop pin, ball and seat. Align and install Y-manifold to T-manifold and cylinder assembly. Tighten Y-manifold bolts first before tightening T-manifold bolts. After manifolds are tight, check Orings for slippage.

F. Insert seat into frame hole directly above the T-manifold. The seat orifice should fit inside the frame itself, then the seat sits on top of the orifice. On the dura-seat, set the big end of the seat in the frame. The seat, or the small part of the duraseat, fits into the bottom of the hopper.

G. After tightening the manifold bolts and inserting the seats in place, set the hopper over the seat and align the bolt holes. Tighten bolts, check O-ring and seat for alignment.

H. Check exhaust gate for wear, install and align gate onto Ymanifold. Insert O-ring into exhaust gate flange and close gate. Lock down lever and adjust clamp arm.

I. Install 3” elbow and 3”x 2” reducer. Fill hopper half full and check for leaks.

PAGE 76 — C-30HD — PARTS & OPERATION MANUAL — REV. #4 (03/06/01)

C-30HD — SERVICE PROCEDURES

3. CLUTCH LINING REPLACEMENT (FOR EM14320 CLUTCH ASSEMBLY ONLY)

A. Remove worn out lining and rivets. Check clutch springs and flyweights for wear.

B. Cut 1/8” off of each end of clutch lining. Slide lining into place. Insert one rivet into clutch lining hole. (Make sure rivet goes from inside out.) Wedge a flathead screwdriver between clutch flyweight and rivet head. Adjust screwdriver so that the rivet sticks out from the clutch housing approximately 1/8 of an inch. With a flat punch, pen the ends on the rivet so that it locks in place with the clutch housing. Repeat this procedure for all remaining clutch rivets.

PREVENTIVE MAINTENANCE It is extremely important to maintain this pump due to

the highly abrasive nature of concrete material.

Mayco recommends checking after every 8 hours of operation.

1. Engine; Refer to engine owner’s manual.

2. Inspect all drive components for loose or worn bolts.

3. Drive belt/chain should be checked to remove all slack. Refer to adjustment procedure.

4. Always carry extra “O” rings.

5. Keep entire pump clean of concrete to prevent build-up.

6. Always grease all fittings daily. Use only premium grade grease. *Note: Over greasing will not damage machine.

C-30HD — PARTS & OPERATION MANUAL — REV. #4 (03/06/01) — PAGE 77

C-30HD — SERVICE INFORMATION MANUFACTURING CHANGES

EM14845

EM135

When ordering the new Manifold P/N EM14819, the following items are necessary to complete the new Clamp Arm Assembly:

EM451...................Nut, Hex 1-1/4-12

EM14810...............Jolter Spring

EM14845...............Clamp Arm

EM135...................Bolt

EM451

EM14841-1

EM14810

EM14819-2 EM14841-1

Manifold Assembly Part No. EM14819 Standard Equipment on all new C-

30HD models as of March 1989.

PAGE 78 — C-30HD — PARTS & OPERATION MANUAL — REV. #4 (03/06/01)

C-30HD — SERVICE INFORMATION MANUFACTURING CHANGES

NEW ROCKER ARM ASSEMBLY PART NO. EM14846

Interchanges with Plaster Pump

Standard Equipment on all new C-30HD models as of July 1, 1990

Part No. EM20342 Old Rocker Arm Assembly

Interchanges with Plaster Pump. NO LONGER AVAILABLE.

C-30HD — PARTS & OPERATION MANUAL — REV. #4 (03/06/01) — PAGE 79

C-30HD — SERVICE INFORMATION MANUFACTURING CHANGES

EM20714

EM20715

ENGINE RPM (GAS) IDLE 950 RPM +/- 50 MAX. 2525 RPM +/- 85

New Remote Control Assembly Conversion: Part No. EM14728

ENGINE RPM (DIESEL) IDLE 1050 RPM +/- 50 MAX. 2525 RPM +/- 25

Adjustment Make sure the rod is screwed completely into the

carburetor bellcrank and the nut is locked down. The rod should be aligned in the center of the tube assembly by shimming the solenoid inside the clamp assembly so there is no binding. The solenoid should be pushed toward the carburetor and the spring completely compressed. Then allow the spring to push the solenoid back through the clamp

0.75 inch and tighten the clamp. The solenoid is not adjusted. Be sure to coat the rod and tube with grease.

PAGE 80 — C-30HD — PARTS & OPERATION MANUAL — REV. #4 (03/06/01)

C-30HD — SERVICE INFORMATION: REMOTE CONTROL

1. Turn Bell Crank on carburetor with Swivel End up. Bell Crank

2. Drill .156 dia. hole through Bell Crank swivel on Throttle

side of carburetor. Insert Rod & Spring assembly P/N EM14729 and fasten with cotter pin. Carburetor

3. Insert linkage P/N EM20714 into Bell Crank on solenoid

side of carburetor and fasten with nut.

4. Insert linkage P/N EM20714 into extension on Remote

Control unit and bolt bracket P/N EM20704 on clutch side of engine.

C-30HD — PARTS & OPERATION MANUAL — REV. #4 (03/06/01) — PAGE 81

C-30HD — REMOTE CONTROL SCHEMATIC

PAGE 82 — C-30HD — PARTS & OPERATION MANUAL — REV. #4 (03/06/01)

C-30HD — REMOTE CONTROL SCHEMATIC

C-30HD — PARTS & OPERATION MANUAL — REV. #4 (03/06/01) — PAGE 83

C-30HD — SERVICE INFORMATION LINKAGE ADJUSTMENT — OLD STYLE SOLENOID

(OBSOLETE)

SIDE VIEW FROM STARTER SIDE OF ENGINE

EM14706

EM16701

EM26730

P/N EM26730

EM26315

EM14707

Important Adjust linkage as follows:

1. Energize the solenoid which will “bottom” the solenoid plunger.

2. Screw eyebolt into bell crank swivel until all slack is removed from chain, and “idle set screw” is full idle position. Note: Remove gas line to carburetor to permit easy installation of eye bolt in bell crank.

EM14708

3. Tighten jam-nut to prevent eye bolt from unscrewing.

PAGE 84 — C-30HD — PARTS & OPERATION MANUAL — REV. #4 (03/06/01)

C-30HD — SERVICE INFORMATION: TORQUE LIMITER (MODEL C30-SP ONLY)

(Overload Safety Device Installed on Screw Conveyor Shaft)

While pumping, if the Screw Conveyor at the bottom of the hopper is fouled or stopped because of rocks, the Torque Limit slips to prevent chain breakage.

If this condition exists, stop the pump and rotate the large pulley by hand in reverse direction to free the Screw.

If the rock blockage is severe, it may be necessary to disconnect the Drive Chain and turn the Screw Conveyor Shaft using a wrench at the end nearest to the Jolter Cam.

Reconnect the chain and resume pumping.

C-30HD — PARTS & OPERATION MANUAL — REV. #4 (03/06/01) — PAGE 85

C-30HD — SERVICE INFORMATION: BEARING INSTALLATION

After the cam bushing is installed as per instructions below, remove the three “dog type” allen set screws (B) to allow detents to be drilled. Use a 9/32” drill to “detent” half (minimum 1/8” deep). Then “chase” the threads with a 3/8-16 bottom tap and blow out the chips after drilling, to be certain that the “dog type” allen set screws bottom in the detents to prevent the taper bushing from sliding laterally. If this procedure is not followed closely the heavy loading of the bearing during pumping operations causes the Timken cone bearings to create lateral forces which will move the taper bushing and allow the Timken cone bearings to separate from the race and subsequently fail.

Caution: Position the ‘O’ ring on the O.D. of the bearing spacer during assembly to assure proper bearing adjustment.

Note: It is important that the bearing assembly is installed properly.

1. Install the bearing components on the crankshaft making

full contact with the back side of the crank disc as indicated by the symbol

2. Install the bushing in the cam weldment and slide it onto

the crankshaft until contact is made with the bearing spacer.

3. Tighten the 3 allen socket head screws “A” while exerting

pressure on the bushing towards the bearing spacer.

4. Drill (detent) the shaft under the allen set screws “B” to

prevent the bushing from the sliding away from the bearning spacer when the pump is under a load.

PAGE 86 — C-30HD — PARTS & OPERATION MANUAL — REV. #4 (03/06/01)

C-30HD — SERVICE INFORMATION CONNECTING ROD ASSEMBLY EM20328T (NEW STYLE)

NOTE: Inspect the bolt regularly as it must remain tight to hold the bearing assebly on the crabk throw pin.

(EM104)

(EM602)

EM20335-

EM20338 —

EM20336 —

EM20337 —

EM20816 —

EM20336-

EM20364-

EM20333-

EM20816-

C-30HD — PARTS & OPERATION MANUAL — REV. #4 (03/06/01) — PAGE 87

C-30HD — SERVICE INFORMATION: CONCRETE PISTON HEAD LUBRICATION SYSTEM

Illustration represents the oil pressurized system (oil pump)

The Mayco model C30-HD pump is the only pump available utilizing a direct oil pressurized system (oil pump) and enclosed lubrication box. This combination will prolong the piston cup life and meet environmental standards.

1. Oil injection system — Check the reservoir every 8 hours.

Use a good grade of SAE 30 oil. *Note: Use SAE 10 wt. in cool weather. When the piston cups are new, open the metering valves to full open or approximately 15 drops of oil per minute drip from the rear of each cylinder. (For the first 25 yards)

2. Lubrication box — We recommend utilizing soluble type oil (water and oil mixture). The oil level should be periodically checked and maintained at a height of 5 inches or one-half of the cylinder height.

*Note: IMPORTANT! During freezing temperatures, completely drain the water box and cover hopper.

As the piston cups naturally wear, fine cement particles will accumulate in the box. Once the concrete paste reaches a height of 3/4 inches from the bottom, the box should be drained and cleaned, and the pump should be serviced.

*Note: If preferred, the oil pump may be disconnected. (Contact Mayco Service Department)

PAGE 88 — C-30HD — PARTS & OPERATION MANUAL — REV. #4 (03/06/01)

C-30HD — SERVICE INFORMATION RETURN SPRING ADJUSTMENT PROCEDURE

Do not tighten 3/4” bolt completely so that rod end will be free to move.

The above return spring is installed to eliminate shock and stress between the cam roller and the cam weldment when the pump is in operation. If spring EM14333 is removed or replaced for any reason, maintain the backing plate dimension as shown to produce proper pre-loading of the spring for a smooth performance.

C-30HD — PARTS & OPERATION MANUAL — REV. #4 (03/06/01) — PAGE 89

C-30HD — SERVICE INFORMATION BELT AND CHAIN ADJUSTMENT

PILLOW BLOCK BEARING BOLTS

PULLEY

LOCK NUTS

PUSHER

BOLTS

CHAIN

BELTS

3/4" MAX.

DEFLECTION

1. Loosen the pillow bearing bolts only to the point where the

bolts will remain snug.

2. Unlock the two pusher bolt lock nuts.

3. Turn each pusher bolt clockwise an equal amount until the

chain is to proper adjustment of approximately 3/8" to 1/2” slack in the chain. It is very important that the pulley side and the chain side (pillow block bearings) are within 1/16” of an equal distance.

4. This distance can be checked by using a tape measure or

a straight edge ruler, measuring from the inside of the pusher bolt bracket to the face of the pillow block bearing.

5. The drive chain should be adjusted regularly to remove all

slack. Once all slack is removed, do not over-adjust, as this will overload the shaft bearings. A slack chain on the crank drive creates backlash and shock loads on the shafts and bearings which results in shorter wear/life of the drive components. Lubricate the chain regularly. Note-it is advisable to carry a spare chain and master links for replacement in the field if necessary.

PUSHER BOLT BRACKET

6. Drive belts should be regularly adjusted to prevent slippage. To adjust the belts, loosen the engine mounting bolts and move the engine until there is a maximum 3/4" deflection in the belts, retighten the engine mounting bolts.

7. Frequent inspections should be made on all drive components to make certain that all bolts and nuts remain tight.

NOTE: PRIOR TO ADJUSTING CHAIN — PLACE THE

LOBE OF THE CAM IN THE DOWN POSITION. THE CHAIN SHOULD HAVE 83 RIVITS INCLUDES (ONE EACH, HALF LINK AND FULL LINK)

PAGE 90 — C-30HD — PARTS & OPERATION MANUAL — REV. #4 (03/06/01)

ROLLER CHAIN — APPLICATION INFORMATION

Roller chain properly selected, installed and maintained is an extremely versatile means of power transmission. It is possible, however, to greatly reduce a chain’s life and even induce failure if the chain is abused through improper installation, operating or maintenance procedures. In certain applications, failure can lead to personal injury or property damage.

Recommendations and comments on how to get the most from your roller chain drive are given on the following pages.

WORKING LOADS

UTS-Ultimate Tensile Strength-is the one time pull required to break the chain. The Tensile Strength figures given in the Diamond catalog are not allowed working loads. For single strand chain, the load (pull) applied to the chain in service should never exceed 1/6th of the UTS for the chain being used except as noted below.

It is possible to exceed the allowable working loads for a limited number of cycles, but you should contact Diamond Chain Company before this is considered. A roller chain should never be loaded

above 50% of UTS for even one cycle. To do so will damage the chain structure and reduce its capacity.

The UTS or one time breaking load of multiple strand chain is the UTS of a single strand chain times the number of strands; i.e., two strand chain is twice as strong as single.

When allowable working loads are considered, however, the capacity of each strand in a multiple strand chain is only 65% of the single strand rating; thus, three-strand chain would rate not three times single but only 1.95 times. This is because the chain load cannot be exactly distributed across all three strands of the threestrand chain.

The chain should be installed so the slack span is properly tensioned. To check chain tension, turn one sprocket to tighten the upper span of the chain while holding the other sprocket fixed. The lack span should have 4-6% of span length in the mid-span movement for horizontal drives and 2-3% for vertical drives.

A roller chain’s capacity can be significantly reduced if it is twisted or bent sideways in the direction of the pin axis. Exercise particular care in alignment of hoist or other applications where loads are suspended near personnel.

LUBRICATION

As a chain articulates in entering and leaving a sprocket,

relative movement between pin and bushing surfaces. These surfaces wear causing chain elongation. If a lubricant film can be maintained between the pin and bushing, the wear rate is very slow and the chain wear life very long. Maintaining the oil film is relatively simple at low speeds but becomes increasingly difficult as the speed increases.

It is recognized that good lubrication is not possible in many applications, so shorter wear life must be accepted in these situations.

In general, chain wear leads to rough or unsatisfactory service prior to actual chain breakage. Good lube can help to prevent

INSTALLATION AND DRIVE ALIGNMENT

chain failure by providing protection against rust or corrosion. Rusting can allow pits to form in the surfaces of the chain parts causing stress concentration points. This can lead to chain failure at relatively low loads.

The clearance between pin and bushings is very small, on the order of .003 to .005 inches. A lubricant must be thin

Chain and sprockets must be installed correctly. Sprockets must be properly aligned and sprocket shafts must be parallel so the drive will run in a plane perpendicular to them. Axial alignment should be checked with a straight edge which will extend across the finished sides of the sprockets. They should be true-running with minimum wobble and eccentricity. The higher the drive speed, the more important these details become.

enough to flow into the chain. SAE 30 weight oil is about right for room temperature. Lighter oil should be used for lower ambients and heavier for higher operating temperatures. Grease should not be used as it cannot penetrate chain clearances.

there is

C-30HD — PARTS & OPERATION MANUAL — REV. #4 (03/06/01) — PAGE 91

DIAMOND CHAIN COMPANY — ROLLER CHAIN APPLICATION INFORMATION

WHEN DISASSEMBLING OR ASSEMBLING CHAINS: WARNING: — The components of a chain are hardened parts.

Striking these parts may cause metal chips to break off from the chain or the tools used resulting in personal injury. During all stages of chain disassembly and assembly, wear safety glasses to prevent metal parts or chips from entering your eyes and have personnel in the immediate area do likewise.

A. Pin Removal

1) If chain is of cotter pin- type construction, remove cotters.

2) If chain is riveted type construction, grind pin heads off so pin ends are flush with the linkplate.

3) Drive pins out of linkplate using a Diamond pin extractor Model #113 or 135. Some multiple strand chains or large pitch models will require a hammer and punch or a press to remove the pins.

WARNING

B. Installation of Coversides

Diamond coversides are manufactured three different ways: (1) Slip Fit, (2) Modified Press Fit, and (3) Full Press Fit. Modified and Full Press Fits require some patience and tools to assemble and/or disassemble. Use vice grips, plumbers pliers or a small hammer to drive coversides onto pins.

C. Installation of Spring Locks and Cotterpins

After coversides have been installed, install spring locks or cotters (depending on chain design). Avoid using bent or worn cotters or spring locks. After spring locks (or cotters) are installed, lightly tap pin ends to position these parts snug against the coverside for additional support.

WHEN INSTALLING CHAIN DRIVES ON EQUIPMENT: WARNING — You may be seriously injured if you attempt to

install chain on equipment under power. Shut off power and lock out gears and sprockets before attempting installation.

Once installed, the chain drive must be guarded to prevent personal injury or properly damage in the event the chain separates during operation. If chain drive is not guarded, contact equipment manufacturer for recommendations on guarding before using equipment.

Knowing more about how the chain is constructed may help in assembly and disassembly. Further information may be obtained by calling or writing Diamond Chain Company.

PAGE 92 — C-30HD — PARTS & OPERATION MANUAL — REV. #4 (03/06/01)

Effective: July 1, 2000

TERMS AND CONDITIONS OF SALE — PARTS

PAYMENT TERMS

Terms of payment for parts are net 10 days.

FREIGHT POLICY

All parts orders will be shipped collect or prepaid with the charges added to the invoice. All shipments are F.O.B. point of origin. Multiquip’s responsibility ceases when a signed manifest has been obtained from the carrier, and any claim for shortage or damage must be settled between the consignee and the carrier.

MINIMUM ORDER

The minimum charge for orders from Multiquip is $15.00 net. Customers will be asked for instructions regarding handling of orders not meeting this requirement.

RETURNED GOODS POLICY

Return shipments will be accepted and credit will be allowed, subject to the following provisions:

1. A Returned Material Authorization must be approved by Multiquip prior to shipment.

2. To obtain a Return Material Authorization, a list must be provided to Multiquip Parts Sales that defines item numbers, quantities, and descriptions of the items to be returned.

a. The parts numbers and descriptions

must match the current parts price list.

b. The list must be typed or computer

generated.

c. The list must state the reason(s) for

the return.

d. The list must reference the sales

order(s) or invoice(s) under which the items were originally purchased.

e. The list must include the name and

phone number of the person requesting the RMA.

3. A copy of the Return Material Authorization must accompany the return shipment.

4. Freight is at the sender’s expense. All

5. Parts must be in new and resalable

6. The following items are not returnable:

7. The sender will be notified of any material

8. Such material will be held for 5 working

9. Credit on returned parts will be issued at

10. In cases where an item is accepted for

11. Credit issued will be applied to future

PRICING AND REBATES

parts must be returned freight prepaid to Multiquip’s designated receiving point.

condition, in the original Multiquip package (if any), and with Muiltiquip part numbers clearly marked.

a. Obsolete parts. (If an item is listed

in the parts price book as being replaced by another item, it is obsolete.)

b. Any parts with a limited shelf life

(such as gaskets, seals, “O” rings, and other rubber parts) that were purchased more than six months prior to the return date.

c. Any line item with an extended dealer

net price of less than $5.00. d. Special order items. e. Electrical components. f. Paint, chemicals, and lubricants. g. Decals and paper products. h. Items purchased in kits.

received that is not acceptable.

days from notification, pending instructions. If a reply is not received within 5 days, the material will be returned to the sender at his expense.

dealer net price at time of the original purchase, less a 15% restocking charge.

which the original purchase document can not be determined, the price will be based on the list price that was effective twelve months prior to the RMA date.

purchases only.

Prices are subject to change without prior notice. Price changes are effective on a specific date and all orders received on or after that date will be billed at the revised price. Rebates for price declines and added charges for price increases will not be made for stock on hand at the time of any price change.

Multiquip reserves the right to quote and sell direct to Government agencies, and to Original Equipment Manufacturer accounts who use our products as integral parts of their own products.

SPECIAL EXPEDITING SERVICE

A $20.00 to $50.00 surcharge will be added to the invoice for special handling including bus shipments, insured parcel post or in cases where Multiquip must personally deliver the parts to the carrier.

LIMITATIONS OF SELLER’S LIABILITY

Multiquip shall not be liable here under for damages in excess of the purchase price of the item with respect to which damages are claimed, and in no event shall Multiquip be liable for loss of profit or good will or for any other special, consequential or incidental damages.

LIMITATION OF WARRANTIES

No warranties, express or implied, are made in connection with the sale of parts or trade accessories nor as to any engine not manufactured by Multiquip. Such warranties made in connection with the sale of new, complete units are made exclusively by a statement of warranty packaged with such units, and Multiquip neither assumes not authorizes any person to assume for it any other obligation or liability whatever in connection with the sale of its products. A part from such written statement of warranty, there are no warranties, express, implied or statutory, which extend beyond the description of the products on the face hereof.

C-30HD — PARTS & OPERATION MANUAL — REV. #4 (03/06/01) — PAGE 93

PARTS AND OPERATION MANUAL

HERE'S HOW TO GET HELP

PLEASE HAVE THE MODEL AND SERIAL NUMBER ON-HAND WHEN CALLING

PARTS DEPARTMENT

800-427-1244 or 310-537-3700 FAX: 800-672-7877 or 310-637-3284

SERVICE DEPARTMENT/TECHNICAL ASSISTANCE

800-478-1244 or 310-537-3700 FAX: 310- 537-4259

WARRANTY DEPARTMENT

888-661-4279, or 310-661-4279 FAX: 310- 537-1173

MAIN

800-421-1244 or 310-537-3700 FAX: 310-537-3927

MULTIQUIP INC.

POST OFFICE BOX 6254 CARSON, CA 90749 310-537-3700 • 800-421-1244 FAX: 310-537-3927 E-MAIL: mq@multiquip.com WWW: multiquip.com

Quebec, Canada • Manchester, UK • Rio De Janiero, BR • Guadalajara, MX

Atlanta • Boise • Dallas • Houston • Newark

Multiquip C-30HD User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual