OPERATION MANUAL
SERIES
MODEL C30HDGA
CONCRETE PUMP
(ZENITH 416 GAMMA GASOLINE ENGINE)
Revision #1 (09/09/19)
To find the latest revision of this publication or
associated parts manual, visit our website at:
www.multiquip.com
THIS MANUAL MUST ACCOMPANY THE EQUIPMENT AT ALL TIMES.
PROPOSITION 65 WARNING
PAGE 2 — MAYCO C30HDGA CONCRETE PUMP • OPERATION MANUAL — REV. #1 (09/09/19)
Grinding/cutting/drilling of masonry, concrete, metal and
other materials with silica in their composition may give
off dust or mists containing crystalline silica. Silica is a
basic component of sand, quartz, brick clay, granite and
numerous other minerals and rocks. Repeated and/or
substantial inhalation of airborne crystalline silica can
cause serious or fatal respiratory diseases, including
silicosis.In addition, California and some other
authorities have listed respirable crystalline silica as a
substance known to cause cancer. When cutting such
materials, always follow the respiratory precautions
mentioned above.
WARNING
Grinding/cutting/drilling of masonry, concrete, metal and
other materials can generate dust, mists and fumes
containing chemicals known to cause serious or fatal
injury or illness, such as respiratory disease, cancer,
birth defects or other reproductive harm. If you are
unfamiliar with the risks associated with the particular
process and/or material being cut or the composition of
the tool being used, review the material safety data
sheet and/or consult your employer, the material
manufacturer/supplier, governmental agencies such as
OSHA and NIOSH and other sources on hazardous
materials. California and some other authorities, for
instance, have published lists of substances known to
cause cancer, reproductive toxicity,or other harmful
effects.
Control dust, mist and fumes at the source where
possible. In this regard use good work practices and
follow the recommendations of the manufacturers or
suppliers, OSHA/NIOSH, and occupational and trade
associations.Water should be used for dust
suppression when wet cutting is feasible. When the
hazards from inhalation of dust, mists and fumes cannot
be eliminated, the operator and any bystanders should
always wear a respirator approved by NIOSH/MSHA for
the materials being used.
WARNING
SILICOSIS WARNING RESPIRATORY HAZARDS
SILICOSIS/RESPIRATORY WARNINGS
MAYCO C30HDGA CONCRETE PUMP • OPERATION MANUAL — REV. #1 (09/09/19) — PAGE 3
C30HDGA Concrete Pump
Proposition 65 Warning ........................................... 2
Silicosis/Respiratory Warnings ................................ 3
Safety Information ............................................. 5–10
Specifications ........................................................ 11
Dimensions ............................................................ 12
Important Hand Signals ......................................... 13
General Information ......................................... 14–16
Components (Pump) ....................................... 18–19
Components (Control Box) .................................... 20
Components (Engine) ............................................ 21
Inspection ........................................................ 22–24
Startup/Shutdown .................................................. 25
Operation ......................................................... 26–30
Maintenance .................................................... 31–39
Trailer Maintenance ......................................... 40–41
Trailer Guidelines ............................................. 42–55
Troubleshooting ............................................... 56–57
Engine Fault Codes ......................................... 58–63
Appendix — Concrete Mix Information ............ 64–66
Wiring Diagram (Wiring Harness) .......................... 67
Electrical Component Locator ......................... 68–69
TABLE OF CONTENTS
NOTICE
Specifications are subject to change without notice.
PAGE 4 — MAYCO C30HDGA CONCRETE PUMP • OPERATION MANUAL — REV. #1 (09/09/19)
SAFETY INFORMATION
Do not operate or service the equipment before reading
the entire manual. Safety precautions should be followed
at all times when operating this equipment.
Failure to read and understand the safety
messages and operating instructions could
result in injury to yourself and others.
SAFETY MESSAGES
The four safety messages shown below will inform you
about potential hazards that could injure you or others. The
safety messages specifi cally address the level of exposure
to the operator and are preceded by one of four words:
DANGER, WARNING, CAUTION
SAFETY SYMBOLS
Potential hazards associated with the operation of this
equipment will be referenced with hazard symbols which
may appear throughout this manual in conjunction with
safety messages.
DANGER
Indicates a hazardous situation which, if not avoided,
WILL result in DEATH or SERIOUS INJURY.
WARNING
Indicates a hazardous situation which, if not avoided,
COULD result in DEATH or SERIOUS INJURY.
CAUTION
Indicates a hazardous situation which, if not avoided,
COULD result in MINOR or MODERATE INJURY.
or NOTICE.
Symbol Safety Hazard
Lethal Exhaust Gas Hazards
Explosive Fuel Hazards
Burn Hazards
Respiratory Hazards
Eye and Hearing Hazards
OFF
Accidental Starting Hazards
NOTICE
Addresses practices not related to personal injury.
MAYCO C30HDGA CONCRETE PUMP • OPERATION MANUAL — REV. #1 (09/09/19) — PAGE 5
Pressure Hazards
Hydraulic Fluid Hazards
Rotating Parts Hazards
SAFETY INFORMATION
GENERAL SAFETY
PUMP SAFETY
pump volatile, explosive, fl ammable or low fl ash
The engine fuel exhaust gases contain poisonous carbon
monoxide. This gas is colorless and odorless, and can
The engine of this equipment requires an adequate free
operate this equipment in any
pump corrosive chemicals or water containing
toxic substances. These fl uids could create serious
health and environmental hazards. Contact local
emergency or safety devices.
These devices are intended for operator safety.
severe injury,
. Disconnection of any of
CAUTION
NEVER operate this equipment without proper protective
clothing, shatterproof glasses, respiratory protection,
hearing protection, steel-toed boots and other protective
devices required by the job or city and state regulations.
NEVER operate this equipment when not
feeling well due to fatigue, illness or when
on medication.
NEVER operate this equipment under the infl uence of
drugs or alcohol.
NOTICE
This equipment should only be operated by trained and
qualifi ed personnel 18 years of age and older.
DANGER
NEVER
point fl uids. These fl uids could ignite or explode.
cause death if inhaled.
fl ow of cooling air. NEVER
enclosed or narrow area
where free fl ow of the air is
restricted. If the air fl ow is
restricted it will cause injury
to people and property and
serious damage to the
equipment or engine.
NEVER operate the equipment in an explosive
atmosphere or near combustible materials. An
explosion or fi re could result causing severe
bodily harm or even death.
WARNING
DANGEROUS
GAS FUMES
Whenever necessary, replace nameplate, operation and
safety decals when they become diffi cult read.
Manufacturer does not assume responsibility for any
accident due to equipment modifi cations. Unauthorized
equipment modifi cation will void all warranties.
NEVER use accessories or attachments that are not
recommended by Multiquip for this equipment. Damage
to the equipment and/or injury to user may result.
ALWAYS know the location of the nearest
fi re extinguisher.
ALWAYS know the location of the nearest
fi rst aid kit.
ALWAYS know the location of the nearest phone or keep
a phone on the job site. Also, know the phone numbers
of the nearest ambulance, doctor and fi re department.
This information will be invaluable in the case of an
emergency.
NEVER
authorities for assistance.
NEVER disconnect any
Disconnection of these devices can cause
bodily harm or even death
these devices will void all warranties.
PAGE 6 — MAYCO C30HDGA CONCRETE PUMP • OPERATION MANUAL — REV. #1 (09/09/19)
CAUTION
NEVER lubricate components or attempt service on a
Refer to the Engine Owner’s Manual for engine technical
questions or information recommended by Multiquip for
this equipment. Damage to the equipment and or injury
remove the ignition key when leaving the pump
block the wheels on the unit when using on
use properly rated hoses and clamps —
allow the pump a proper amount of time to
Fix damage to machine and replace any broken parts
store equipment properly when it is not being
used. Equipment should be stored in a clean, dry location
out of the reach of children and unauthorized personnel.
place hands or fingers inside engine
operate the engine with heat shields or
running machine.
NEVER block or restrict flow from discharge hose.
Remove kinks from discharge line before starting pump.
Operation with a blocked discharge line can cause clutch
to fail.
DO NOT operate this equipment unless the hopper grate,
guards and safety devices are attached and in place.
CAUTION must be exercised while servicing this
equipment. Rotating and moving parts can cause injury
if contacted.
Keep hands out of the hopper when the engine is
running.
NOTICE
In winter drain water from the lubrication box to prevent
freezing.
ALWAYS be sure the operator is familiar with proper
safety precautions and operation techniques before
using pump.
Keep all inexperienced and unauthorized people away
from the equipment at all times.
Before start-up, check the hopper and remove all foreign
matter and debris.
DO NOT use worn or damaged hose couplings, inspect
all hoses and couplings for wear. Replace any worn or
defective hoses or couplings immediately.
Unauthorized equipment modifications will void all
warranties.
Check all fasteners periodically for tightness. Also check
towing tongue bolt, lock nut and wheel lug nuts for wear.
Test the pump’s emergency stop switch. The purpose
of this test is to shut down the engine in the event of an
emergency.
SAFETY INFORMATION
to user may result.
ALWAYS
unattended.
ALWAYS
a slope.
ALWAYS
1,500 PSI or higher.
ALWAYS
cool before servicing.
ALWAYS keep the machine in proper running condition.
ALWAYS ensure pump is on level ground before use.
immediately.
ALWAYS
ENGINE SAFETY
WARNING
DO NOT
compartment when engine is running.
NEVER
guards removed.
DO NOT remove the engine oil drain plug
while the engine is hot. Hot oil will gush
out of the oil tank and severely scald any
persons in the general area of the pump.
CAUTION
NEVER touch the hot exhaust manifold,
muffl er or cylinder. Allow these parts to cool
before servicing equipment.
Multiquip strongly encourages the operator to take the
safety training courses offered by the American Concrete
Pumping Association (www.concretepumpers.com).
MAYCO C30HDGA CONCRETE PUMP • OPERATION MANUAL — REV. #1 (09/09/19) — PAGE 7
SAFETY INFORMATION
NOTICE
FUEL SAFETY
BATTERY SAFETY
drop the battery. There is a possibility that the
keep the battery charged. If the battery is not
charge battery if frozen. Battery can explode.
When frozen, warm the battery to at least 61°F (16°C).
recharge the battery in a well-ventilated
environment to avoid the risk of a dangerous concentration
If the battery liquid (dilute sulfuric acid) comes into
, rinse eyes immediately with plenty
of water and contact the nearest doctor or hospital to
NEGATIVE battery terminal
keep battery cables in good working condition.
NEVER run engine without an air fi lter or with a dirty air
fi lter. Severe engine damage may occur. Service air fi lter
frequently to prevent engine malfunction.
NEVER tamper with the factory settings
of the engine or engine governor. Damage
to the engine or equipment can result
if operating in speed ranges above the
maximum allowable.
DANGER
DO NOT start the engine near spilled fuel or combustible
fl uids. Fuel is extremely fl ammable and its vapors can
cause an explosion if ignited.
ALWAYS refuel in a well-ventilated area, away from
sparks and open fl ames.
ALWAYS use extreme caution when working with
fl ammable liquids.
DO NOT fi ll the fuel tank while the engine is running
or hot.
DANGER
DO NOT
battery will explode.
DO NOT expose the battery to open fl ames,
sparks, cigarettes, etc. The battery contains
combustible gases and liquids. If these
gases and liquids come into contact with a
fl ame or spark, an explosion could occur.
WARNING
ALWAYS wear safety glasses when
handling the battery to avoid eye irritation.
The battery contains acids that can cause
injury to the eyes and skin.
Use well-insulated gloves when picking up
the battery.
ALWAYS
charged, combustible gas will build up.
DO NOT
DO NOT overfi ll tank, since spilled fuel could ignite if it
comes into contact with hot engine parts or sparks from
the ignition system.
Store fuel in appropriate containers, in well-ventilated
areas and away from sparks and fl ames.
NEVER use fuel as a cleaning agent.
DO NOT smoke around or near the
equipment. Fire or explosion could result
from fuel vapors or if fuel is spilled on a
hot engine.
To prevent leakage, tighten the fuel cap until it clicks.
Slowly open fuel cap to release pressure.
ALWAYS
of combustible gases.
If the battery liquid (dilute sulfuric acid)
comes into contact with clothing or skin,
rinse skin or clothing immediately with
plenty of water.
contact with eyes
seek medical attention.
CAUTION
ALWAYS disconnect the
before performing service on the equipment.
ALWAYS
Repair or replace all worn cables.
PAGE 8 — MAYCO C30HDGA CONCRETE PUMP • OPERATION MANUAL — REV. #1 (09/09/19)
TRANSPORTING SAFETY
CAUTION
TOWING SAFETY
Check the tire air pressure on both towing vehicle and
Trailer tires should be infl ated to 80 psi cold.
safety
attach trailer’s safety chains to towing
make sure the vehicle and trailer directional,
backup, brake and trailer lights are connected and
• Secure portable power cables in cable tray with tie
unless
posted otherwise. Recommended off-road towing is not
Avoid sudden stops and starts. This can cause skidding
or jack-knifi ng. Smooth, gradual starts and stops will
Trailer should be adjusted to a level position at all times
Raise and lock trailer wheel stand in up position when
underneath wheels to prevent
underneath the trailer’s bumper
Use the trailer’s swivel jack to adjust the trailer height to
NEVER allow any person or animal to stand underneath
the equipment while lifting.
NOTICE
Before lifting, make sure that the equipment parts are not
damaged and screws are not loose or missing.
ALWAYS make sure forklift forks are inserted into pockets
(if applicable) as far as possible when lifting the pump.
ALWAYS shut down engine before transporting.
NEVER lift the equipment while the engine is running.
Tighten fuel tank cap securely to prevent fuel from
spilling.
Use one-point suspension hook and lift straight upwards.
DO NOT lift machine to unnecessary heights.
ALWAYS tie down equipment during transport by
securing the equipment with straps, rope or chains.
CAUTION
Check with your local county or state safety
towing regulations, in addition to meeting
Department of Transportation (DOT)
Safety Towing Regulations, before towing
your pump.
In order to reduce the possibility of an accident while
transporting the pump on public roads, ALWAYS make
sure the trailer that supports the pump and the towing
vehicle are mechanically sound and in good operating
condition.
ALWAYS shut down engine before towing.
Make sure the hitch and coupling of the towing vehicle
are rated equal to or greater than the trailer gross vehicle
weight rating.
SAFETY INFORMATION
trailer.
Also check the tire tread wear on both vehicles.
ALWAYS make sure the trailer is equipped with a
chain.
ALWAYS properly
vehicle.
ALWAYS
working properly.
DOT requirements include the following:
• Connect and test electric brake operation.
wraps.
The maximum speed for highway towing is 55 MPH
to exceed 15 MPH or less depending on type of terrain.
improve towing.
Avoid sharp turns to prevent rolling.
when towing.
towing.
Place chock blocks
rolling while parked.
Place support blocks
to prevent tipping while parked.
a level position while parked.
ALWAYS inspect the hitch and coupling for wear. NEVER
tow a trailer with defective hitches, couplings, chains, etc.
MAYCO C30HDGA CONCRETE PUMP • OPERATION MANUAL — REV. #1 (09/09/19) — PAGE 9
SAFETY INFORMATION
ENVIRONMENTAL SAFETY/DECOMMISSIONING
Decommissioning is a controlled process used to safely
retire a piece of equipment that is no longer serviceable.
If the equipment poses an unacceptable and unrepairable
safety risk due to wear or damage, or is no longer cost
effective to maintain (beyond life-cycle reliability) and is to
be decommissioned (demolition and dismantlement), be
sure to follow the rules below.
EMISSIONS INFORMATION
The diesel engine used in this equipment has been
designed to reduce harmful levels of carbon monoxide
(CO), hydrocarbons (HC) and nitrogen oxides (NOx)
This engine has been certifi ed to meet US EPA evaporative
Attempting to modify or make adjustments to the engine
emission system by unauthorized personnel without proper
training could damage the equipment or create an unsafe
Additionally, modifying the fuel system may adversely affect
evaporative emissions, resulting in fi nes or other penalties.
The emission control label is an integral part of the emission
If a replacement emission label is needed, please contact
NOTICE
DO NOT pour waste or oil directly onto the ground, down
a drain or into any water source.
Contact your country’s Department of Public
Works or recycling agency in your area and
arrange for proper disposal of any electrical
components, waste or oil associated with
this equipment.
When the life cycle of this equipment is over, remove
battery and bring to appropriate facility for lead
reclamation. Use safety precautions when handling
batteries that contain sulfuric acid.
When the life cycle of this equipment is over, it is
recommended that the frame and all other metal parts
be sent to a recycling center.
Metal recycling involves the collection of metal from
discarded products and its transformation into raw
materials to use in manufacturing a new product.
Recyclers and manufacturers alike promote the process
of recycling metal. Using a metal recycling center
promotes energy cost savings.
NOTICE
contained in diesel exhaust emissions.
emissions requirements in the installed confi guration.
condition.
Emission Control Label
system and is strictly controlled by regulations.
The label must remain with the engine for its entire life.
your authorized engine distributor.
PAGE 10 — MAYCO C30HDGA CONCRETE PUMP • OPERATION MANUAL — REV. #1 (09/09/19)
SPECIFICATIONS
Table 1. C30HDGA Pump Specifications
Pump Type Reciprocating Piston
Pumping Rate Up to 25 cu. yds. per hour*
Vertical Pumping Height Up to 150 ft. (45.73 m)
Horizontal Pumping Distance 400 - 500 ft. (122 - 152 m)*
Max. Concrete Piston Face Pressure 500 PSI
Maximum Aggregate Size 1/2 in. minus (12.7 mm)
Hopper Capacity 6 cu. ft. etc.
Material Hose
Weight 2,950 lbs. (1,338 Kg)
Lube oil Box 7 Gallons (26.5 Liters)
Remote Control 125 ft. cable Standard
Tire Size
* Volume output will vary depending on mix design, slump, line size used and job site conditions.
2" or 2-1/2"
(50.8 or 63.5 mm)"
7.35" x 14"
(187 x 356 mm)
Table 2. Engine Specifications
Model ZENITH 416 GAMMA
Type
Bore × Stroke
Compression Ratio 11:1
Displacement 97.1 cu. (1,591 cc)
Continuous Output 45 H.P. @2700 R.P.M.
Fuel Tank Capacity Approx. 11 U.S. Gallons (42 liters)
Fuel Type Unleaded Gasoline
Lube Oil Capacity 3.49 qts. (3.3 liters)
Engine Speed
Full Load
Engine Speed
Full Idle
Air Cleaner Air Horn Type
Engine Lubrication
Starting Method Electric Start
Spark Plug B4ES
Spark Plug Gap
Dimension (L x W x H) 20.10 x 22.50 x 25.80 in. (509.9 x 527.5 x 654.5 mm)
Dry Net Weight 178 lbs (126.3 Kg.)
4 stroke, overhead valve, single cylinder
horizontal shaft gasoline engine
3.032 in. × 3.362 in.
(77 mm × 85.4 mm)
2650 rpm ±100 (No Load 2750 rpm +/- 50)
(Load 2750 rpm +/- 100)
950 rpm ±100
SAE 10W-30 (Oil Grade)
SG or SF (Service Class)
0.8 - 0.9 in
(0.031-0.035 mm).
MAYCO C30HDGA CONCRETE PUMP • OPERATION MANUAL — REV. #1 (09/09/19) — PAGE 11
DIMENSIONS
F
A
B
Table 3. Pump Dimensions
Reference
Letter
A 76 (1930)
B 14.5 (368)
C 16 (406)
Dimensions
in. (mm)
MAYC0
C-30HDGA
C
D
145 IN. (3.68 M) DISCHARGE
CONE IN TRAVEL
POSITION
D 161 (4089)
E 63.5 (1612)
F 59.5 (1511)
PAGE 12 — MAYCO C30HDGA CONCRETE PUMP • OPERATION MANUAL — REV. #1 (09/09/19)
E
IMPORTANT HAND SIGNALS
DRIVE IN BACK UP
CHUTE UP CHUTE DOWN
STOP PUMP LITTLE BIT
STOP START PUMP
SPEED UP
ADD WATER
4-GALLONS
SLOW PUMP
DOWN
ALL DONE
CLEAN-UP
PULL FORWARD
Figure 1. Operation Hand Signals
BACK IN
MAYCO C30HDGA CONCRETE PUMP • OPERATION MANUAL — REV. #1 (09/09/19) — PAGE 13
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 Directflow 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-flow
manifold will pump a wide variety of materials, but certain
basic principles must be followed to assure successful
pumping, as follows:
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.
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-flow Pump.
Uniform gradation 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.
A recommended pumpable mix design would be 70% sand
and 30% aggregate-cement content to be a minimum of
6 sacks. (564 lbs.)
NOTICE
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 - 3000 Psi 3/8 in. Slump 4- 5 in.
Type II Cement 6.49 sack/cu. yd 611 lbs.
Sand Sat. Surf. Dry 2000 lbs.
#4 Gravel Sat. Surf. Dry 864 lbs.
#3 Gravel Sat. Surf. Dry 0 lbs.
Water 48 Gallons 400 lbs.
Total Weight 3,906 lbs
Admixture WRDA-79 26 oz.
Water 7.40 gal/sack
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-mixes 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.
NOTICE
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
PAGE 14 — MAYCO C30HDGA CONCRETE PUMP • OPERATION MANUAL — REV. #1 (09/09/19)
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.
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.
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.
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.
GENERAL INFORMATION
HOW IT WORKS
The C30HDGA 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.
The pumping cylinder (Figure 2) 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.
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. The
engine idle speed is approximately 900 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 2. Pumping Cylinder
MAYCO C30HDGA CONCRETE PUMP • OPERATION MANUAL — REV. #1 (09/09/19) — PAGE 15
GENERAL INFORMATION
The pumping piston (Figure 3) 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 4 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.
The return spring 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 (3-inches) as shown to produce proper preloading of the spring for a smooth performance.
Figure 3. Pumping Pistons
Figure 4. Return Spring, Compensator Spring and Rocker Arm Interaction
PAGE 16 — MAYCO C30HDGA CONCRETE PUMP • OPERATION MANUAL — REV. #1 (09/09/19)
NOTES
MAYCO C30HDGA CONCRETE PUMP • OPERATION MANUAL — REV. #1 (09/09/19) — PAGE 17
1
3
5
10
6
7 8
9
12
13
14
27
17
21
23
20
11
22
2
4
18
19
15
MAYC0
C-30HDGA
24
25
26
16
COMPONENTS (PUMP)
Figure 5. Pump Components
PAGE 18 — MAYCO C30HDGA CONCRETE PUMP • OPERATION MANUAL — REV. #1 (09/09/19)
COMPONENTS (PUMP)
Figure 5 illustrates the location of the major components
for the C30HDGA Concrete Pump. The function of each
component is described below:
1. Discharge Cone — Connect 3" elbow to this discharge
port, then connect 3" x 2" reducer to elbow.
2. Discharge Cone Safety Latch — When towing of the
pump is required, ALWAYS secure the discharge cone
to latch located on the manifold.
3. Rear Running Lights — ALWAYS check and make
sure both the right and left running lights are functioning
correctly before towing the pump.
4. Hopper — Concrete from a Redi-Mix truck is poured into
this hopper. The hopper can hold 6.0 cu. ft of concrete.
NEVER put hands or any other parts of you body into
the hopper.
5. Safety Grill — The safety grill should be locked at all
times when the pump is being towed. Under normal
working conditions, raise and place the safety grill on
the support hooks which are located on splash guard.
6. Compartment Hood — NEVER operate the pump with
the hood removed. Installed on the pump frame is a safety
interlock device which will disable high speed if the hood
is removed or in the up position (open).
7. Hood Fastener — When the hood is in the down position,
secure the rubber latch to this fastener.
8. Hood Lift Handle — Grip this handle, pull upward then
back to raise the compartment hood.
9. Control Box — Contains the mechanical and electrical
components required to run the pump. Below is a list of
those components:
• Throttle Control Switch
• Pumping Control
• Check Engine Indicator
• Hood Open Indicator
• Engine Hour Meter
• Ignition Switch
• Remote Connector
10. Radiator/Cap — Fill with a water/anti-freeze type solution
as recommended in the maintenance section of this
manual. ALWAYS make sure that the radiator is filled to
the proper operating level before starting the engine.
11. Fuel Tank/Cap — Fill with unleaded fuel. Fuel tank (cell)
holds approximately 11 gallons (42 liters). DO NOT top
off fuel. Wipe up any spilled fuel immediately.
12. Tow End Jack Stand — Use this jack stand to level and
support the pump.
13. Tow Hitch Coupler — Requires a 2-inch ball hitch or a
3-inch pintle. Capable of towing 5,000 lbs.
14. Safety Chain — ALWAYS attach safety chain to the
towing vehicle. NEVER tow the pump with the safety
chain unattached.
15. Engine Safety Device — This device will return the
engine speed to idle if the compartment hood is in the
up position. The compartment hood must be in the down
position for the pump to operate at high rpm's.
16. Grease Port Console — This console allows for the
remote lubrication of components on the pump.
17. Access Door — There are four access doors on the
pump. Remove these door to gain access to drive and
piston assemblies when maintenance is required.
18. Drive Chain — Keep this chain properly lubricated and
aligned at all times. Lubricate this chain as specified in
the maintenance section of this maintenance.
19. Steel Latch — Secure this rubber latch to the hood
fastener whenever the pump is in use or being towed.
20. Tires Ply — The tire ply (layers) number is rated in letters;
This trailer uses 4-ply tires.
21. Chock Blocks — Place these blocks (not included as
part of your concrete pump package) under each trailer
wheel to prevent rolling.
22. Pump End Jack Stand — Use this jack stand to level
and support the pump.
23. Discharge Cone Release Lever — secures the
discharge cone to the "Y" manifold; also relieves manifold
pressure.
24. Documentation Box — Contains engine and pump
operation, parts and maintenance information.
25. Lubrication Box — This box is empty when shipped from
the factory. Please fill with 7 gallons ( 26.5 liters) of SAE
motor oil for first time use. Also check the dual clean-out
point on bottom of lubrication box for a secure tight fit.
26. Overflow Bottle — Fill with coolant. Maintain coolant at
proper level. See fluid level markings on side of bottle.
27. Cam Bearing — Felt ring must be periodically lubricated
applying 4 or 5 drops of 30 wt. motor oil until the felt
ring is moist.
MAYCO C30HDGA CONCRETE PUMP • OPERATION MANUAL — REV. #1 (09/09/19) — PAGE 19
COMPONENTS (CONTROL BOX)
Figure 6. Pump Control Box Components
Figure 6 illustrates the location of the major components
for the C30HDGA Control Box. The function of each
component is described below:
1. Throttle Control Switch — This is a variable speed
type control. Holding the control switch to the left
increases the engine speed. To place the engine at
IDLE speed, hold the control switch to the right and
let the engine run for 3-5 minutes.
2. Emergency Stop Button — In the event of an
emergency or to shutdown the engine, push RED
emergency stop button inward. This will stop the
engine. To restart engine, emergency stop button must
be released from the stop position. Simply pull back on
the emergency stop button to release.
3. Ignition Switch — Insert the ignition key here to start
the engine. Turn the key clockwise to the ON position,
then continue turning clockwise to the START position
and release. To stop the engine turn the key fully
counter-clockwise to the STOP position.
4. Remote Control Input Connector — Insert the
remote control input cable into this connector.
5. Pumping Control Switch — This 3-position switch
controls the pumping of the pump. The left most
position is for use with the remote control unit, the
center position is for off (prevents pumping), and the
right most position is for normal pump operation.
6. Hourmeter — Display's the number of hours the pump
has been in use.
7. Hood Open Lamp — When lit (red) indicates that the
hood has been raised (open) during pumping operation.
This condition will force the engine into idle mode.
8. Check Engine Lamp — When lit (yellow) indicates that
an engine error as occurred. See Table 7 for a listing
of engine diagnostic error codes.
PAGE 20 — MAYCO C30HDGA CONCRETE PUMP • OPERATION MANUAL — REV. #1 (09/09/19)
COMPONENTS (ENGINE)
Figure 7. Zenith 416 Gamma Engine Components
Figure 7 illustrates the location of the basic components
for the Zenith 416 Gamma gasoline engine. The function
of each component is described below:
1. Air Filter — Prevents dirt and other debris from
entering the fuel system. Remove wing-nut on top of air
filter cannister to gain access to filter element. Replace
only with manufacturer's recommended type air filter.
2. Fuse Connector — Contains fuses for electrical
system. Replace with only recommended type fuses.
3. Oil Filler Port Cap — Remove this cap to add engine
oil to the crankcase. Fill with recommended type oil
as specified.
4. Spark Plug — Provides spark to the ignition system.
Set spark plug gap to 0.6 - 0.7 mm (0.028 - 0.031 inch).
Clean spark plug once a week.
5. Dipstick — Remove this dipstick to determine if engine
oil is low. Maintain oil level at the "H" marking on the
dipstick. NEVER run engine with low oil.
7. Oil Filter — Replace this oil filter as recommended in
the maintenance section of this manual.
8. Fan V-Belt — ALWAYS make sure that V-belt is
properly tensioned. A loose or defective V-belt can
adversely affect the performance of the pump.
9. Crankcase Drain Plug — Remove this plug to
drain engine oil from the crankcase. Replace
with recommended engine oil as specified in the
maintenance section of this manual.
10. Cooling Fan Blades — Make sure that the blades of
the cooling fan are not bent or broken. A damaged fan
blade can cause the engine to run hot and overheat.
11. Control Relays — Includes a main relay, fuel pump
relay and starter relay. Replace only with recommended
type relays.
12. Starter Motor/Solenoid — NEVER allow concrete or
any foreign debris to come in contact with the starter
motor/solenoid.
6. Alternator — Provides power to the electrical system.
Replace only with manufacturer's recommended type
alternator.
MAYCO C30HDGA CONCRETE PUMP • OPERATION MANUAL — REV. #1 (09/09/19) — PAGE 21
13. Fuel Filter/Fuel Pump/Fuel Regulator — Replace
or clean the fuel filter, fuel pump or fuel regulator as
specified in the maintenance section of this manual.
Loading...