Zenith C-30HDG User Manual

OPERATION AND PARTS MANUAL
SERIES
MODEL C-30HDG
CONCRETE PUMP
(ZENITH 416 GASOLINE ENGINE)
Revision #6 (04/02/12)
To find the latest revision of this
www.multiquip.com
THIS MANUAL MUST ACCOMPANY THE EQUIPMENT AT ALL TIMES.
C-30HDG PUMP — PROPOSITION 65 WARNING
PAGE 2 — MAYCO C-30HDG PUMP — OPERATION AND PARTS MANUAL — REV. #6 (04/02/12)
C-30HDG PUMP — SILICOSIS/RESPIRATORY WARNINGS
WARNING
SILICOSIS WARNING RESPIRATORY HAZARDS
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.
MAYCO C-30HDG PUMP — OPERATION AND PARTS MANUAL — REV. #6 (04/02/12) — PAGE 3
TABLE OF CONTENTS
MAYCO C-30HDG (ZENITH) CONCRETE PUMP
Proposition 65 Warning ..............................................2
Silicosis/Respiratory Warnings ................................... 3
Table of Contents .......................................................4
Parts Ordering Procedures ........................................ 5
Pump Specifications ...................................................6
Engine Specifications ................................................. 6
Pump Dimensions ...................................................... 7
Safety Message Alert Symbols .............................. 8-9
Rules For Safe Operation .................................. 10-12
Towing Guidelines .............................................. 14-15
Trailer Safety Guidelines .................................... 16-18
Operation And Safety Decals ................................... 20
Important Hand Signals ........................................... 21
Pump Components ............................................ 22-23
Control Box Components ......................................... 24
Engine Components ................................................ 25
General Information .................................................26
How It Works ...................................................... 27-28
Operating Information ........................................ 29-33
Inspection ........................................................... 34-36
Startup ............................................................... 36-37
Shutdown Procedures ..............................................37
Maintenance (Pump) ......................................... 38-47
Engine Troubleshooting ...................................... 48-49
Engine Fault Codes ............................................. 50-53
Wiring Diagram (Zenith Wiring Harness) ........... 54-55
Wiring Diagram ........................................................56
Pin Connections ......................................................57
Wiring Diagram (Tail Lights) ..................................... 58
Appendix —
Slump Test Procedure ........................................60
Concrete Mix Information ............................. 61-63
Recommended Shotcrete System ............... 64-65
Recommended Shotcrete Accessories........ 66-67
Explanation of Codes in Remarks Column ..............68
Suggested Spare Parts ............................................ 69
COMPONENT DRAWINGS
Nameplate and Decals....................................... 70-71
Compensator Piston Rod Assembly .................. 72-73
Connecting Rod - Drive Side Assembly ............. 74-75
Rocker Assembly ............................................... 76-77
Countershaft Assembly ...................................... 78-79
Crankshaft Assembly ......................................... 80-81
Manifold Assembly ............................................. 82-83
Frame Assembly ................................................ 84-85
Axle Assembly .................................................... 86-87
Muffler, Air filter And Stop Switch Assembly ...... 88-89
Clutch Assy ........................................................ 90-91
Engine Mounting Brackets Assembly ................ 92-93
Radiator, Mounting Bracket And Hoses Assy .... 94-95
Control Box Assembly ........................................ 96-97
Battery Assembly ............................................... 98-99
Fuel Tank Assembly ....................................... 100-101
Hopper Assy................................................... 102-103
Hood Assembly .............................................. 104-105
Lubrication Panel Assembly ........................... 106-107
Remote Control Cable Assembly ................... 107-108
Terms and Conditions Of Sale — Parts .................109
Mayco Pump Warranty ...........................................110
Specification and part number are subject to change without notice.
PAGE 4 — MAYCO C-30HDG PUMP — OPERATION AND PARTS MANUAL — REV. #6 (04/02/12)
PARTS ORDERING PROCEDURES
Ordering parts has never been easier!
Choose from three easy options:
January 1
Effective:
st
, 2006
Best Deal!
Order via Internet (Dealers Only):
Order parts on-line using Multiquip’s SmartEquip website!
N View Parts Diagrams
N Order Parts N Print Specification Information
Goto www.multiquip.com and click on
Order Parts
Order via Fax (Dealers Only):
All customers are welcome to order parts via Fax. Domestic (US) Customers dial: 1-800-6-PARTS-7 (800-672-7877)
Non-Dealer Customers: Contact your local Multiquip Dealer for parts or call 800-427-1244 for help in locating a dealer near you.
to log in and save!
Order via Phone:
If you have an MQ Account, to obtain a Username and Password, E-mail us at: parts@multiquip.
com.
To obtain an MQ Account, contact your District Sales Manager for more information.
Use the internet and qualify for a 5% Discount on Standard orders for all orders which include complete part numbers.*
Note: Discounts Are Subject To Change
Fax your order in and qualify for a 2% Discount on Standard orders for all orders which include complete part numbers.*
Note: Discounts Are Subject To Change
Domestic (US) Dealers Call:
1-800-427-1244
International Customers should contact their local Multiquip Representatives for Parts Ordering information.
When ordering parts, please supply:
R Dealer Account Number R Dealer Name and Address R Shipping Address (if different than billing address) R Return Fax Number R Applicable Model Number R Quantity, Part Number and Description of Each Part
NOTICE
All orders are treated as Standard Orders and will
ship the same day if received prior to 3PM PST.
R Specify Preferred Method of Shipment: UPS/Fed Ex DHL
N Priority One Tr uck  N Ground N Next Day N Second/Third Day
www.multiquip.com
WE ACCEPT ALL MAJOR CREDIT CARDS!
MAYCO C-30HDG PUMP — OPERATION AND PARTS MANUAL — REV. #6 (04/02/12) — PAGE 5
C-30HDG PUMP — PUMP SPECIFICATIONS
Table 1. C-30HDG 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)
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PAGE 6 — MAYCO C-30HDG PUMP — OPERATION AND PARTS MANUAL — REV. #6 (04/02/12)
C-30HDG PUMP — PUMP DIMENSIONS
Figure 1. C-30HDG Concrete Pump Dimensions
MAYCO C-30HDG PUMP — OPERATION AND PARTS MANUAL — REV. #6 (04/02/12) — PAGE 7
C-30HDG PUMP — SAFETY MESSAGE ALERT SYMBOLS
FOR YOUR SAFETY AND THE SAFETY OF OTHERS!
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.
This Owner's Manual has been
NOTE
Refer to the engine manufacturers instructions for data relative to its safe operation.
Before using this pump, ensure that the operating individual has read and understands all instructions in this manual.
developed to provide complete instructions for the safe and efficient operation of the Mayco Model C-30HDG Concrete Pump.
HAZARD SYMBOLS
Potential hazards associated with operation of the pump will be referenced with Hazard Symbols which appear throughout this manual, and will be referenced in conjunction with Safety Message Alert Symbols. Some examples are listed below:
WARNING - LETHAL EXHAUST GASES
structure that does not provide ample free flow air.
WARNING - EXPLOSIVE FUEL
SAFETY MESSAGE ALERT SYMBOLS
The three (3) Safety Messages shown below will inform you about potential hazards that could injure you or others. The Safety Messages specifically address the level of exposure to the operator, and are preceded by one of three words: DANGER, WARNING, or CAUTION.
could ignite if it comes into contact with hot engine parts or
DANGER
You WILL be KILLED or SERIOUSLY injured if you do not follow directions.
sparks from the ignition system. Store fuel in approved containers, in well-ventilated areas and away from sparks and flames. NEVER use fuel as a cleaning agent.
Gasoline engine exhaust gases contain poisonous carbon monoxide. This gas is colorless and odorless, and can cause death if inhaled. NEVER operate this equipment in a confined area or enclosed
Gasoline
vapors can cause an explosion if ignited. DO NOT start the engine near spilled fuel or combustible fluids. DO NOT fill the fuel tank while the engine is running or hot.
DO NOT overfill tank, since spilled fuel
is extremely flammable, and its
WARNING
You COULD be KILLED or SERIOUSLY injured if you do not follow directions.
CAUTION
You CAN be injured if you do not follow directions
PAGE 8 — MAYCO C-30HDG PUMP — OPERATION AND PARTS MANUAL — REV. #6 (04/02/12)
WARNING - BURN HAZARDS
Engine components can generate extreme heat. To prevent burns, DO NOT touch these areas while the engine is running or immediately after operations. NEVER operate the engine with heat shields or heat guards removed.
C-30HDG PUMP — SAFETY MESSAGE ALERT SYMBOLS
WARNING - ROTATING PARTS
NEVER operate equipment with covers,
or guards removed. Keep
hair
and clothing away from all moving
parts to prevent injury.
fingers, hands
CAUTION - ACCIDENTAL STARTING
ALWAYS place the Engine ON/OFF switch
in the OFF position and remove the ignition key when the pump is not in use.
CAUTION - OVER-SPEED CONDITIONS
NEVER tamper with the factory settings of
the engine governor or settings. Personal injury and damage to the engine or equipment can result if operating in speed ranges above maximum allowable.
CAUTION - RESPIRATORY HAZARDS
,
ALWAYS wear approved protection.
CAUTION - SIGHT AND HEARING HAZARDS
ALWAYS wear approved
hearing
protection.
CAUTION - EQUIPMENT DAMAGE MESSAGES
Other important messages are provided throughout this manual to help prevent damage to your concrete pump, other property, or the surrounding environment.
respiratory
eye
and
DO NOT operate at pressures exceeding the rating of the entire material delivery system.
This
pump
, other property, or the surrounding environment could be damaged if you do not follow instructions.
Use snap pins on all snap couplings.
WARNING
MAYCO C-30HDG PUMP — OPERATION AND PARTS MANUAL — REV. #6 (04/02/12) — PAGE 9
C-30HDG PUMP — RULES FOR SAFE OPERATION
DANGER - Read This Manual!
Failure to follow instructions in this manual may lead to serious injury or even death! This equipment is to be operated by trained and qualified personnel only! This equipment is for industrial use only.
The following safety guidelines should always be used when operating the Mayco C-30HDG Concrete Pump:
General Safety
DO NOT operate or service this equipment before reading this entire manual.
ALWAYS read, understand, and follow procedures in Operator’s Manual before attempting to operate equipment.
ALWAYS be sure the operator is familiar with proper safety precautions and operations techniques before using pump
This equipment should not be operated by persons under 18 years of age.
ALWAYS read, understand and follow procedures in Operator’s Manual before attempting to operate equipment.
ALWAYS be sure the operator is familiar with proper safety precautions and operations techniques before using pump
NEVER operate this equipment without proper protective clothing, shatterproof glasses, steel-toed boots and other protective devices required by the job.
Whenever necessary, replace nameplate, operation and safety decals when they become difficult read.
Manufacture does not assume responsibility for any accident due to equipment modifications.
NEVER use accessories or attachments, which are not recommended by Multiquip for this equipment. Damage to the equipment and/or injury to user may result.
NEVER touch the hot exhaust manifold, muffler or cylinder. Allow these parts to cool before servicing engine or concrete pump.
High Temperatures – Allow the engine to cool before adding fuel or performing service and maintenance functions. Contact with serious burns.
The engine section of this concrete pump requires an adequate free flow of cooling air. pump in any enclosed or narrow area where free flow of the air is restricted. If the air flow is restricted it will cause serious damage to the concrete pump or engine and may cause injury to people. Remember the concrete pump's engine gives off
DEADLY
gas.
ALWAYS refuel in a well-ventilated area, away from sparks and open flames.
hot!
components can cause
NEVER
carbon monoxide
operate the concrete
NEVER operate this equipment when not feeling well due to fatigue, llness or taking medicine.
NEVER operate this equipment under the influence of
ALWAYS wear proper respiratory (mask), hearing and eye protection equipment when operating the concrete pump.
drugs
or
alcohol
PAGE 10 — MAYCO C-30HDG PUMP — OPERATION AND PARTS MANUAL — REV. #6 (04/02/12)
.
ALWAYS use extreme caution when working with flammable liquids. When refueling, stop the engine and allow it to cool. DO NOT explosion could result from fuel vapors, or if fuel is spilled on a hot engine.
NEVER operate the concrete pump in an explosive atmosphere or near combustible materials. An explosion or fire could result causing severe
smoke
around or near the machine. Fire or
bodily harm
or even death.
Topping-off to filler port is dangerous, as it tends to spill fuel.
Stop the engine when leaving the concrete pump unattended.
DO NOT leave the pump unattended. Use chock blocks if parking pump on a grade.
Maintain this equipment in a safe operating condition at all times.
C-30HDG PUMP — RULES FOR SAFE OPERATION
CAUTION must always be observed while servicing this pump. Rotating parts can cause injury if contacted.
ALWAYS stored the pump in a clean, dry location out of the reach of children.
ALWAYS use extreme care when operating near obstructions, on slippery surfaces, grades and side slopes.
Unauthorized equipment modifications will void all warranties.
Refer to the questions or information.
Before start-up, check the hopper and remove all obstructions.
Keep all hands out of the hopper when the engine is running.
DO NOT operate the pump with the hood open.
Replace any worn or damaged pump components immediately.
ALWAYS turn the engine before performing maintenance.
ALWAYS make sure pump is correctly secured to the trailer. Check all supports attaching the pump to the trailer and make sure they are tight.
ALWAYS make sure that the pump's trailer is placed on solid level ground so that it cannot slide or shift around, endangering workers. Place blocks under the trailer's bumper to make it level (prevents tipping), and use a chocked block underneath the wheels to prevent rolling. Also keep the immediate area free of bystanders.
Engine Owner's Manual
OFF
for engine technical
before performing must be
A copy of this manual shall accompany the pump at all times.
DO NOT use worn out hoses or couplings; inspect daily.
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.
The pump should NEVER be towed in excess of 45 MPH (or less depending on road conditions).
If hose lines are
kinked
pressure could straighten out the kink or force out the blockage. This rapid surge of material could cause the lines to
whip
Inspect the hose lines at all times
DO NOT tow the pump with the hopper full of material.
DO NOT tow the pump with the hoses attached.
NEVER disconnect any These devices are intended for operator safety. Disconnection of these devices can cause severe injury, bodily harm or even death! Disconnection of any of these devices will void all warranties.
ALWAYS make sure the delivery system used, pipe hose clamps ect., exceed the rated pressure of the pump. In addition the pumping system should be checked for worn components prior to start up. Use snap pins on all snap couplings.
blocked
when starting up or during pumping cycle, the pump
for any reason, or if the lines are
move or
in a manner that could cause injury to personnel.
emergency or safety devices
.
Before towing, check the hitch and secure the safety chain to the towing vehicle. Also check for proper tire pressure.
Tow only with a vehicle and hitch rated to tow a 2,950 lbs. (1,338 Kg) load.
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.
ALWAYS check the machine for loosened threads or bolts before starting.
MAYCO C-30HDG PUMP — OPERATION AND PARTS MANUAL — REV. #6 (04/02/12) — PAGE 11
C-30HDG PUMP — RULES FOR SAFE OPERATION
Maintenance Safety
NEVER lubricate components or attempt service on a running machine.
ALWAYS allow the machine a proper amount of time to cool before servicing.
Keep the machinery in proper running condition.
Fix damage to the machine immediately and always replace broken parts.
Dispose of hazardous waste properly. Examples of potentially hazardous waste are used motor oil, fuel and fuel filters.
DO NOT use food or plastic containers to dispose of hazardous waste.
DO NOT pour waste, oil or fuel directly onto the ground, down a drain or into any water source.
Lifting
The pump has an operating weight of approximately 2,950 lbs. (1,338 Kg). Use lifting equipment capable of lifting this weight.
Emergencies
ALWAYS know the location of the nearest and
first aid kit
Also know the phone numbers of the nearest
doctor
invaluable in the case of an emergency.
and
. Know the location of the nearest telephone.
fire department
. This information will be
fire extinguisher
ambulance
,
PAGE 12 — MAYCO C-30HDG PUMP — OPERATION AND PARTS MANUAL — REV. #6 (04/02/12)
NOTES
MAYCO C-30HDG PUMP — OPERATION AND PARTS MANUAL — REV. #6 (04/02/12) — PAGE 13
C-30HDG PUMP — TOWING GUIDELINES
Towing Safety Precautions
CAUTION - Local Towing Regulations
Check with your county or state safety towing regulations department before towing your concrete pump.
To reduce the possibility of an accident while transporting the pump on public roads, always make sure that the trailer and the towing vehicle are in good operating condition and both units are mechanically sound.
The following list of suggestions should be used when towing the pump:
Make sure that the hitch and coupling of the towing vehicle are rated equal to, or greater than the trailer "gross vehicle weight rating" (GVWR).
ALWAYS inspect the hitch and coupling for wear. NEVER tow the light tower's trailer with defective hitches, couplings, chains etc.
CHECK the tire air pressure on both the towing vehicle and the trailer. Also check the tire tread wear on both vehicles.
ALWAYS make sure the trailer section of the pump is equipped with a "Safety Chain".
ALWAYS attach trailer's safety chain to frame of towing vehicle.
ALWAYS make sure that the vehicle and trailer directional, backup, brake, and trailer lights are connected properly and are working properly.
Remember in most cases the maximum speed unless otherwise posted for highway towing is 45 MPH, however before towing your pump, check your local state, and county vehicle towing requirements. Recommended off-road towing is not to exceed 10 MPH or less depending on type of terrain.
Place
chocked blocks
while parked.
Depending on soil conditions and location it may be necessary to place bumper to prevent
Inflate tires to correct pressure, inspect tires for cuts, and excessive wear. See Table 3 (Tire Wear Troubleshooting).
underneath wheel to prevent
support blocks
tipping
, while parked.
underneath the trailer's
rolling,
Check wheel mounting lug nuts with a torque wrench. Torque wheel lug nuts as described in the "
Requirements
Make sure brakes are synchronized and functioning properly.
Check tightness of suspension hardware (nuts and bolts).
Avoid sudden stops and starts. This can cause skidding, or jackknifing. Smooth, gradual starts and stops will improve gas milage.
Avoid sharp turns to prevent rolling.
Retract wheel stand when transporting.
DO NOT transport pump with fuel in the fuel tank.
CAUTION -
If the trailer coupler is deformed replace entire coupler. NEVER tow the pump with a defective trailer coupler. There exist the possibility of the trailer separating from the towing vehicle.
Pump Trailer Vehicle Connection
1. Check the vehicle hitch ball, and trailer coupler for signs of wear or damage. Replace any parts that are worn or damaged before towing.
2. Use only the 2-inch ball diameter with a towing capability of 5,000 lbs. (2,268 kg) as indicated on the trailer's coupler. Use of any other ball diameter will create an extremely dangerous condition which can result in separation of the coupler and ball or ball failure.
3. Be sure the coupler is secured to the hitch ball and the lock lever is down (locked).
4. Attach safety chains as shown in Figure 2. Remember to
cross
5. After towing for about 50 miles recheck the entire towing system for tightness.
Recommended Maintenance
1. Smear ball socket and clamp face with chassis grease. Periodically oil pivot points and were surfaces of coupler with SAE 30 W motor oil.
2. When parking or storing the concrete pump, keep the coupler off the ground so dirt and other debris will not build up in the ball socket.
Lug Nut Torque
", Table 5.
Never Use Defective Couplers
the safety chains.
PAGE 14 — MAYCO C-30HDG PUMP — OPERATION AND PARTS MANUAL — REV. #6 (04/02/12)
C-30HDG PUMP — TOWING GUIDELINES
Figure 2 shown below illustrates the typical towing application that should be used when towing the pump.
Figure 2. Towing Applications
MAYCO C-30HDG PUMP — OPERATION AND PARTS MANUAL — REV. #6 (04/02/12) — PAGE 15
C-30HDG PUMP — TRAILER SAFETY GUIDELINES
Trailer Safety Precautions
CAUTION -
ALWAYS make sure that the trailer is in good operating condi-
tion. Check the tires for proper inflation and wear. Also check the wheel lug nuts for proper tightness.
This section is intended to provide the user with trailer service and maintenance information. Remember periodic inspection of the trailer will ensure safe towing of the equipment and will prevent damage to the equipment and personal injury.
It is the purpose of this section to cover the major maintenance components of the trailer. The following trailer components will be discussed in this section:
Tires
Lug Nut Torquing
Suspension
Electrical
General Trailer Safety
The following list defines the major trailer components:
1. Fuel Cell – Provides an adequate amount of fuel for the equipment in use. Fuel cells must be empty when transport­ing equipment.
2. Frame Length – This measurement is from the ball hitch to the rear bumper (reflector).
3. Frame Width – This measurement is from fender to fender.
4. Jack Stand – Trailer support device with maximum pound requirement from the tongue of the trailer.
5. Coupler – Type of hitch used on the trailer for towing. This unit employes a 2 in. ball.
6. Tires Size – Indicates the diameter of the tire in inches (10, 12, 13, 14, etc. ), and the width in millimeters (175, 185, 205 etc.). The tire diameter must match the diameter of the tire rim. This unit employes 7.35 x 14 in. tires.
7. Tires Ply – The tire ply (layers) number is rated in letters: 2-ply, 4-ply, 6-ply, 8-ply, 10-ply etc. This unit employes 4-ply tires.
8. Wheel Hub – The wheel hub is connected to the trailer's axle.
9. Tire Rim – Tires are mounted on a tire rim. The tire rim must match the size of the tire.
10. Lug Nuts – Used to secure the wheel to the wheel hub. Always use a torque wrench to tighten down the lug nuts. See Table 5 and Figure 4 for lug nut tightening and sequence. This unit employes 5 lug nuts to secure the wheel to the hub.
11. Axle – This trailer employes a torsion bar type suspension, which can support 3,500 lbs.
12. Electrical – Electrical connectors (looms) are provided with the trailer so that brake lights and turn signal lights can be connected to the towing vehicle. See for proper wiring connections.
Trailer Wiring Diagram
PAGE 16 — MAYCO C-30HDG PUMP — OPERATION AND PARTS MANUAL — REV. #6 (04/02/12)
C-30HDG PUMP — TRAILER SAFETY GUIDELINES
Tires/Wheels/Lug Nuts
Tires and wheels are a very important and critical components of the trailer. When specifying or replacing the trailer wheels it is important the wheels, tires, and axle are properly matched.
CAUTION -
DO NOT attempt to repair or modify a wheel. DO NOT install
an inter-tube to correct a leak through the rim. If the rim is cracked, the air pressure in the inter-tube may cause pieces of the rim to explode (break-off) with great force and can cause serious eye or bodily injury.
Tires Wear/Inflation
Tire inflation pressure is the most important factor in tire life. Pressure should be checked cold before operation. DO NOT bleed air from tires when they are hot. Check inflation pressure weekly during use to insure the maximum tire life and tread wear.
Table 3 (Tire Wear Troubleshooting) will help pinpoint the causes and solutions of tire wear problems.
General Trailer Safety
ALWAYS
installing force fitted parts. Failure to comply may result in serious injury.
wear safety glasses when removing or
Torsion Bar Suspension
The torsion bar suspension and associated hardware (Figure 3) should be visually inspected every 6,000 miles for signs of excessive wear, elongation of bolt holes, and loosening of fasteners. Replace all damaged parts (suspension) immedi­ately.
Figure 3. Major Suspension Components
MAYCO C-30HDG PUMP — OPERATION AND PARTS MANUAL — REV. #6 (04/02/12) — PAGE 17
C-30HDG PUMP — TRAILER SAFETY GUIDELINES
Lug Nut Torque Requirements
It is extremely important to apply and maintain proper wheel mounting torque on the trailer. Be sure to use only the fasteners matched to the cone angle of the wheel. Proper procedure for attachment of the wheels is as follows:
1. Start all wheel lug nuts by hand.
2. Torque all lug nuts in sequence (Figure 4). DO NOT torque the wheel lug nuts all the way down. Tighten each lug nut in 3 separate passes as defined by Table 4.
3. After first road use, retorque all lug nuts in sequence. Check all wheel lug nuts periodically.
stnemeriuqeReuqroTeriT.4elbaT
eziSleehW
"2152-0204-5356-05
"3152-0204-5356-05
"4152-0206-05021-09
"5152-0206-05021-09
"6152-0206-05021-09
ssaPtsriF
SBL-TF
ssaPdnoceS
SBL-TF
ssaPdrihT
SBL-TF
Figure 4. Wheel Lug Nuts Tightening Sequence
NEVER!
use an pneumatic air gun to tighten
wheel lug nuts.
PAGE 18 — MAYCO C-30HDG PUMP — OPERATION AND PARTS MANUAL — REV. #6 (04/02/12)
NOTES
MAYCO C-30HDG PUMP — OPERATION AND PARTS MANUAL — REV. #6 (04/02/12) — PAGE 19
C-30HDG PUMP — OPERATION AND SAFETY DECALS
Figure 5 display's the operation and safety decals as they appear on the concrete pump, should any of these decals become damaged or unreadable, contact the Multiquip Parts Department for a replacement set.
Figure 5. Operation and Safety Decals
PAGE 20 — MAYCO C-30HDG PUMP — OPERATION AND PARTS MANUAL — REV. #6 (04/02/12)
C-30HDG PUMP — IMPORTANT HAND SIGNALS
Figure 6 display's the basic hand signals commonly used in concrete pumping operations.
Figure 6. Operation Hand Signals
MAYCO C-30HDG PUMP — OPERATION AND PARTS MANUAL — REV. #6 (04/02/12) — PAGE 21
C-30HDG PUMP — PUMP COMPONENTS
Figure 7. Major Pump Components
PAGE 22 — MAYCO C-30HDG PUMP — OPERATION AND PARTS MANUAL — REV. #6 (04/02/12)
C-30HDG PUMP — PUMP COMPONENTS
Figure 7 illustrates the location of the major components for the C-30HDG 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 prevents the engine from starting 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
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
make sure that the radiator is filled to the proper
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 3­inch 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. Rubber 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 peridically lubricated applying 4 or 5 drops of 30 wt. motor oil until the felt ring is moist.
MAYCO C-30HDG PUMP — OPERATION AND PARTS MANUAL — REV. #6 (04/02/12) — PAGE 23
C-30HDG PUMP — CONTROL BOX COMPONENTS
Figure 8. Pump Control Box Components
Figure 8 illustrates the location of the major components for the C-30HDG 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 engine speed. To place the engine at IDLE speed, hold the control switch to the 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 counter­clockwise to the
right
and let the engine run for 3-5
STOP position.
left
increases the
5. Pumping Control Switch – This 3-position switch controls the pumping of the pump. The with the remote control unit, the (prevents pumping), and the normal pump operation.
6. Hourmeter– Display's the number of hours the pump has been in use.
8. 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.
7. Check Engine Lamp– When lit (yellow) indicates that an engine error as occured. See Table 7 for a listing of engine diagnostic error codes.
left most
position is for use
center
position is for off
right most
position is for
4. Remote Control Input Connector – Insert the remote control input cable into this connector.
PAGE 24 — MAYCO C-30HDG PUMP — OPERATION AND PARTS MANUAL — REV. #6 (04/02/12)
C-30HDG PUMP — ENGINE COMPONENTS
Figure 9. Zenith 416 Basic Engine Components
Figure 9 illustrates the location of the basic components for the Zenith 416, 1.6 liter 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 with only manufactures 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 in the maintenance section of this manual
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.
6. Alternator – Provides power to the electrical system.
Replace with only manufactures recommended type alternator.
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 can cause the engine to run hot and overheat.
11. Control Relays – Includes a main relay, fuel pump relay and starter relay. Replace with only recommended type relays.
12. Starter Motor/Solenoid – NEVER foreign debris to come in contact with the starter motor/ solenoid.
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.
bent or broken
Operating the engine without an air filter, with a damaged air filter, or a filter in need of replacement will allow dirt to enter the engine, causing rapid engine wear.
. A damaged fan blade
allow concrete or any
MAYCO C-30HDG PUMP — OPERATION AND PARTS MANUAL — REV. #6 (04/02/12) — PAGE 25
C-30HDG PUMP — 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-flow 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 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.
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.
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.
pump mix
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.
”. The Direct-flow manifold will
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.)
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.
Admixture WRDA-79 26 oz.
Water 7.40 gal/sack
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.)
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.
Total Weight 3,906 lbs
PAGE 26 — MAYCO C-30HDG PUMP — OPERATION AND PARTS MANUAL — REV. #6 (04/02/12)
C-30HDG PUMP — HOW IT WORKS
The C-30HDG 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
piston rod, deflects with each piston stroke. This “ in conjunction with the cam profile, produces and uninterrupted smooth flow of material under average pumping conditions.
The pumping cylinder (Figure 10) 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.
, which is installed on the compensator
spring cushion
An automatic, centrifugal clutch is installed to engage and disengage the pumping action without stopping or starting the engine. The idle speed is approximately 875 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.
centrifugal clutch
is set at 1100 R.P.M. The engine
Figure 10. Pumping Cylinder
MAYCO C-30HDG PUMP — OPERATION AND PARTS MANUAL — REV. #6 (04/02/12) — PAGE 27
C-30HDG PUMP — HOW IT WORKS
The pumping piston (Figure 11) 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 11. Pumping Pistons
Figure 12 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 produce proper pre-loading of the spring for a smooth performance.
return spring
is removed or replaced for any reason, maintain the backing plate dimension (3-inches) as shown to
Figure 12. Return Spring, Compensator Spring and
Rocker Arm Interaction
PAGE 28 — MAYCO C-30HDG PUMP — OPERATION AND PARTS MANUAL — REV. #6 (04/02/12)
C-30HDG PUMP — 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.
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. ( the throttle when starting, NOT
Manually
remotely
operate
)
C. If it is necessary to wait 10 minutes or more for another
D. When pumping stiff mixes and there is waiting time
E. When the pumping job requires a stiffer mix, the follow-
WARNING - Hose Blockage Hazard
If hoses or lines are
kinked
when starting up or during the pumping cycle, the pump pressure could straighten out the kink or force out the blockage. This rapid surge of material could cause the lines to
whip
or
move
Inspect the lines at all times to prevent the above conditions
3. It is important that once the slurry procedure is completed, and you have star ted 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 water into the hopper, as this could cause separation of the concrete in the hopper.
blocked
in a manner that could cause injury to personnel.
for any reason, or if the lines are
5. Following the pump operation, proper wash out of all mate-
6. A thorough inspection of the drive components and greasing
redi-mix
driver wash too much
F. Hose sizing is very important: We strongly recommend
rials or “build-up” within the pump manifold and hoses will prevent problems when starting the next job.
of all bearings after each job will ensure adequate lubrication and service to the pump which is normally operating in wet, gritty conditions.
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.
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.
ing 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.
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.
Over-greasing any will not damage the bearing.
bearing
on your Mayco pump
B. If the
shutdown
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.
MAYCO C-30HDG PUMP — OPERATION AND PARTS MANUAL — REV. #6 (04/02/12) — PAGE 29
period exceeds 2 to 3 minutes, turn off
C-30HDG PUMP — OPERATING INFORMATION
WARNING - Hose Blockage Hazard
If you repeatedly pull the throttle all the way out and try to force your pump to push through 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 increase the engine speed to clear the blockage. Increasing the engine speed will only compound the problem.
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 or breakage of the axle and axle springs, excess strain and pressure on the hub and bearing assembly.
New Pumps
All new pumps are “ shipment. This procedure permits a thorough inspection of the entire drive system and valving under simulated full load condi­tions.
The pump owner can do the same by attaching an adaptor couple to the end of the discharge cone; e.g., the use of a standard 2 in. pipe cap with a 3/8 in. 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 in. diameter hole restriction will create sufficient back-pressure to make a thorough inspection of all moving parts.
Pumping Tips
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.
full hopper
Moving The Pump On The Job Site
water pressure tested
blockages
of concrete can cause severe damage
due to separation of
” at the factory before
2. ADMIXTURES
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 functions:
A. Pozzolith 300 – or the equivalent acts as a water
retarder and a lubricant. On a lean mix, long pushes, stiff mixes, and vertical pushes, Pozzolith 300R helps pumpability.
B. MBVR – air entraining, acts as a lubricant.
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.
3. When pumping long distance or pumping stiff mixes, you can expect a drop in volume compared to shor ter 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.
5. Damaged hoses with internal restrictions can cause block­ages.
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.
PAGE 30 — MAYCO C-30HDG PUMP — OPERATION AND PARTS MANUAL — REV. #6 (04/02/12)
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