Zenith C-30HDG User Manual

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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

publication, visit our website at:

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:

, 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

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.

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"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

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)

C-30HDG PUMP — OPERATING INFORMATION

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.

CAUTION -

When disconnecting hoses, use is under pressure!

Using a hammer, you can pound the 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. Clearing a Plugged Manifold

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.

Follow steps 7A through 7J to un-plug a clogged manifold.

DANGER -

Hose Pressure Hazard

extreme

CAUTION! The hose

Clearing A Plugged Manifold

H. After the blockage has been cleared and the pump

I. Before reconnecting hose to the reducer, start the engine

J. Shake out around 2 feet of concrete before reconnecting

8. Avoiding Setting of the Mix in the System

To avoid setting of the concrete mix in the system when waiting more than 30 minutes between concrete loads, flush the system depending on job factors (such as presence of accelerators and job site temperature) and your particular mix design.

Clearing a Mix from the System

If, for any reason, the mix should set up in the system, the following procedure is suggested:

CAUTION -

When disconnecting hoses, use hose is under pressure!

manifold has been thoroughly flushed with water, close the hinged discharged cone and lock into place.

and pump two or three shovels of concrete through the reducer. This will insure that all the blockage has been cleared.

hose to pump. After this is done, connect hose to pump and resume the pumping operation.

Hose Pressure Hazard

EXTREME CAUTION!

The

Due to pressure build-up inside the manifold, great care must be taken when clearing a plugged manifold.

A. STOP the pump. Switch OFF the engine. B. DO NOT open any of the delivery system joint clamps.

senior

C. The

least 20 feet away from the pump and turn their heads away from the manifold.

D. The operator must position himself/herself away from

the hinged side of the manifold.

E. 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.

F. After the pressure has been released, open the clamp

arm weldment and swing the hinged discharge cone open.

G. Remove blockage with a round 2-foot length of reinforc-

ing steel rod. Flush the manifolds with water. Make sure the (3” x 2”) reducer is clear of any blockage before closing the discharge cone.

operator must warn all others to stand at

1. Disconnect the hoses from the pump and wash the pump out immediately. For example: If you had 200 ft. of system out, you would disconnect each hose.

2. Reconnect the first hose and fill the hopper with water. DO NOT try to push all the concrete out of all of the hose lines at one time.

3. 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.

4. 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 observant to the pump and system, also taking into consideration the above factors affecting the mix.

MAYCO C-30HDG PUMP — OPERATION AND PARTS MANUAL — REV. #6 (04/02/12) — PAGE 31

C-30HDG PUMP — OPERATING INFORMATION

Down-Hill Pumping

Downhill pumping can be difficult on some jobs. 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. Reference the Operating Suggestions at the start of this section for slurry procedures.

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.

Valve Seats

If the volume at the end of hose starts to decrease gradually and eventually almost stops, it is quite likely that the 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 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.

steel ball

should be replaced when it starts to show

valve seats

have

Vertical Pumping

When pumping vertically up the side of a building, above 40 feet, we would recommend the installation of 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 steel 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.

When pumping vertically using 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.

It is strongly recommended that steel pipe be used on ALL vertical pumping for safety and convenience.

all hose

steel pipe

, it is recommended not

securely

Pulsation

A 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 cer tain 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.

PAGE 32 — MAYCO C-30HDG PUMP — OPERATION AND PARTS MANUAL — REV. #6 (04/02/12)

C-30HDG PUMP — OPERATING INFORMATION

Cam Roller

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 over-sized aggregates through the valving, causing it to skip.

Snap-Joint

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.

MAYCO C-30HDG PUMP — OPERATION AND PARTS MANUAL — REV. #6 (04/02/12) — PAGE 33

C-30HDG PUMP — INSPECTION

CAUTION - General Saftey Guidelines

NEVER operate the pump in a confined

area or enclosed area structure that does not provide ample

NEVER operate the pumps's engine with the engine hood removed. The possibility exists of

hands, long hair

becoming entangled with the V-belt, causing injury and bodily harm.

NEVER place hands or feet inside the while the engine is running. ALWAYS shut-down the engine before performing any kind of maintenance service on the pump.

Before Starting

free flow of air

ALWAYS wear approved

protection before operating the pump .

, and

clothing

hopper

eye

and

hearing

. ALWAYS make

Engine Oil Check

1. To check the engine oil level, place the pump on secure level ground with the engine stopped.

2. Remove the dipstick from its holder (Figure 13) and wipe it clean.

3. Check the engine oil level as shown on the dipstick (Figure 14).

Figure 13. Engine Oil Dipstick (Removal)

1. Read safety instructions at the beginning of this manual.

2. Removing any dirt and dust that might have accumulated around the engine cooling air inlet, fuel injection system.

3. Check the air filter for dirt and dust. If air filter is dirty, replace air filter with a new one as required.

4. Check fuel injection system for external dirt and dust. Clean with dry compressed air.

5. Check fastening nuts and bolts for tightness.

6. Connect Battery

7. Make sure hopper is free of dirt and foreign debris (large objects over 2-inches)

8. Make sure radiator is filled with proper amount of anti-freeze water solution (50/50).

9. Make sure all hose lines are in good condition and are working properly.

Reference manufacturer engine manual for specific servicing instructions.

4. If the engine oil level is low, add oil through the engine oil filler hole (Figure 15) with the recommended oil type (Table 3). Maximum oil capacity is 3.9 quarts (3.7 liters).

Figure 14. Engine Oil Dipstick

Figure 15. Engine Oil Filler Hole

PAGE 34 — MAYCO C-30HDG PUMP — OPERATION AND PARTS MANUAL — REV. #6 (04/02/12)

C-30HDG PUMP — INSPECTION

EPYTLIO.5ELBAT

Lubrication Box

The model C-30HDG model features a fully enclosed

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Gasoline Check

1. Remove the gasoline cap located on top of fuel tank.

lubrication box,

lubrication.

Before using your new pump, 7 gallons of SAE 30 motor oil must be added directly into the lubrication box. Visually inspect the oil in the lubrication box by making sure the oil is at the correct operating level as indicated by the dip stick (Figure 16).

Also reference the oil level decal (Figure 17) adjacent to the lubrication box.

2. Handle Fuel in a safety container. If the container does not have a spout use a funnel.

3. Visually inspect to see if fuel level is low. If fuel is low, replenish with unleaded fuel. When refueling, be sure to use a strainer for filtration. DO NOT top-off fuel. Wipe up any spilled fuel.

4. Pay attention to the fuel tank capacity when replenishing fuel. Refer to the fuel tank capacity listed in Table 5.

CAUTION -

The oil level must be level and oil cleaniness.

WARNING - EXPLOSIVE FUEL

which utilizes the

"SPLASH"

method of

Make sure the pump is on a secure level surface when checking the oil level inside the lubrication box.

Checking Lubrication Oil Levels

checked daily

to ensure adequate oil

Gasoline

is extremely flammable, and its 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

could ignite if it comes into contact with hot engine parts or 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.

DO NOT smoke while refueling, motor fuels are highly flammable and can be dangerous if mishandled.

Figure 16. Lubrication Box Dipstick

Figure 17. Lubrication Box Oil Caution Decal

MAYCO C-30HDG PUMP — OPERATION AND PARTS MANUAL — REV. #6 (04/02/12) — PAGE 35

C-30HDG PUMP — INSPECTION/STARTUP

Checking Engine Coolant Level

1. Remove the radiator cap, and check the cooling water level inside the radiator (Figure 18).

2. Maintain water/coolant level at top of radiator coils. Make sure radiator overflow bottle is filled to the proper level.

Starting

Figure 18. Radiator Coolant

Figure 19. V-Belt Deflection

CAUTION - General Saftey

DO NOT attempt to operate this concrete pump

until the Safety, General Information and Inspection sections have been read and understood.

WARNING - Burn Hazards

NEVER remove the radiator cap when the

engine is HOT! Allow the engine to cool before remove the cap.

3. Check the radiator and hoses for any signs of leakage.

4. If cooling water is dirty, flush the cooling system.

5. When using antifreeze, mix the antifreeze coolant with water. Observe the instructions on the antifreeze container. Usually a 50/50 mixture is a good choice.

6. When replacing the radiator cap, be sure to fit it securely back onto the radiator. If replaced loosely or incorrectly, the cooling water will quickly evaporate, causing the engine to overheat.)

V-Belt Deflection

1. Visually inspect the V-belt for cracks, fraying, wear or oiliness.

2. Make sure V-belt does not the bottom the pulley groove.

3. Check the V-belt tension (Figure 19) by pushing midway through the two pulleys. The V-belt deflection should be between .300 to .472 inches (8 to 12 mm).

1. Hold the throttle control switch fully to the RIGHT to set the

This built in feature protects the clutch from disengaging (slipping) during operation.

2. Place the pumping control switch (Figure 21) in the OFF

engine speed to IDLE (Figure 20).

Figure 20. Throttle Control Switch

During

pumping operations

cannot be reduced below 1300 RPM's.

position.

, the engine speed

Figure 21. Pumping Control Switch (OFF)

PAGE 36 — MAYCO C-30HDG PUMP — OPERATION AND PARTS MANUAL — REV. #6 (04/02/12)

C-30HDG PUMP — STARTUP/SHUTDOWN PROCEDURES

3. Insert the ignition key into the ignition switch (Figure 22), turn

the key to the ON position, then to the START position, release the key when the engine starts.

Figure 22. Ignition Switch

4. Let the engine run for 3-5 minutes before putting pump into

operational use. Push the choke knob in all the way.

5. Listen for any abnormal sounds. If any mechanical or electri-

cal problems exists, STOP the engine and correct the problem.

6. To begin pumping concrete. Place the pumping control

switch (Figure 23) in the ON position

2. On the control box, place the pumping control switch in the

REMOTE ON position (Figure 25)

Figure 25. Pumping Control Switch (Remote)

3. To begin pumping, place the toggle switch on the hand-held remote unit (Figure 24)in the pump ON position

Radio Remote Control Operation

The MAYCO C30HDG Concrete Pump has a remote control feature (Figure 26) that allows the pump to be radio controlled via a receiver/transmitter technique.

Contact your MAYCO representative for further information regarding radio control pumping capability.

Figure 23. Pumping Control Switch (ON)

System Shut-Down

1. Place the pumping control switch in the OFF position (Figure 21).

2. Let the engine run at idle speed for 3-5 minutes.

3. Turn the ignition key (Figure 22) to the OFF position.

4. Clean pump as referenced in the maintenance section of this manual.

Remote Control Operation

1. Connect the hand-held remote control cable (Figure 24) to the control box.

Figure 26. Handheld RadioReceiver/Transmitter

Figure 24. Handheld Remote Control Cable

MAYCO C-30HDG PUMP — OPERATION AND PARTS MANUAL — REV. #6 (04/02/12) — PAGE 37

C-30HDG PUMP — MAINTENANCE (PUMP)

Preventive Maintenance

It is extremely important to maintain this pump due to the highly abrasive nature of concrete material.

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

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

ALWAYS

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

ALWAYS

grease.

carry extra “O” rings.

grease every fitting daily. Use only premium grade

Over greasing will not damage pump.

General Clean-up Procedure

1. Ensure that there is no blockage in the hose and line (Pumping Tips, step 8) or in the manifold (Pumping Tips, step 7). If a blockage exists, clear it to ensure proper operation the next time it is used. At the end of every pour, or during 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. 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.

To avoid the possibility of separation during cleanup, 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. 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.

5. 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.

PAGE 38 — MAYCO C-30HDG PUMP — OPERATION AND PARTS MANUAL — REV. #6 (04/02/12)

C-30HDG PUMP — MAINTENANCE (PUMP)

Sponge Clean-out Procedure

This section will explain the recommended procedure for using

sponge

to clean out the

hose lines.

CAUTION - Clearing The Pump

NEVER use

the chrome finish on the pumping cylinder.

NEVER use compressed air to clean out the lines.

When using a clean-out hook to clean out the rear of the redimix truck, use a 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.

1. 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.

muriatic acid

safety chain

The pump engine should be turned OFF, as explained in General 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.

to clear the pump. Acid will dissolve

to secure the clean-out hook to

Lubrication Box

The C-30HDG model features a fully enclosed which utilizes the

Visually inspect the oil in the lubrication box (Figure 16) by making sure the oil is at the correct operating level as indicated by the dip stick. Also reference the oil level decal (Figure 17) adjacent to the lubrication box.

CAUTION -

The oil level must be level and oil cleaniness.

Piston Cup Wear

rubber piston cups

The

will require

depends on many factors, proper oil level, oil cleanliness, abrasiveness of aggregrate being pumped and material slump etc.

lubrication box,

"SPLASH"

Make sure the pump is on a secure level surface when checking the oil level inside the lubrication box.

method of lubrication.

Checking Lubrication Oil Levels

checked daily

are a natural wear component and

periodic replacement. The life of the rubber cups

to ensure adequate oil

2. Start the pump engine and pump the hopper all the way down.

3. Disconnect the hose from the pump. Fill the hopper with water and pump the remaining concrete out of the pump.

4. 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.

5. 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.

6. 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.

Repeat steps 1 through 6 a few times to ensure that the hose lines are thoroughly cleaned.

As the rubber piston cups wear, fine cement particles will accumulate in the bottom of the lubrication box. Once this cement paste reaches 1-inch in height, it is recommended that the lubrication box be drained (flushed) and cleaned and the oil replaced with new SAE 30 motor oil.

Any questions regarding the lubrication box clean-out procedure, contact the MAYCO Service Department.

IMPORTANT! To ensure maximum cup life, the oil level in the lubrication box the proper level. In addition the lubrication box must be cleaned periodically.

There are two clean-out ports located at the bottom of the lubrication box.

must be

maintained at

MAYCO C-30HDG PUMP — OPERATION AND PARTS MANUAL — REV. #6 (04/02/12) — PAGE 39

C-30HDG PUMP — MAINTENANCE (PUMP)

Crankshaft and Cam Assembly Procedure

1. Set bearing block (P/N 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.

2. Set

3. Insert bearing cone spacer (P/N EM14323) onto crankshaft

4. Place O-ring and spacer (P/N EM14302) on crankshaft. Set

5. Slide cam bushing down crankshaft and align the bushing,

6. Release pressure on the bushing, reapply pressure to bush-

7. After bushing has been fitted tightly into cam, remove from

8. Place cam bearing onto crankshaft keeping bearing loose.

9. Set crankshaft assembly into the pump box and align both

10. After crankshaft assembly is securely fastened to the pump

11. Install chain P/N EM14308. To adjust, loosen locknuts on

crankshaft

wards the top. Install spacer (P/N EM14322), O-ring (P/N EM14326) and bearing cone (P/N EM14325) onto crankshaft. Place bearing block on crankshaft until the bearing cone is riding in the bearing cup.

and inside bearing block. Install second bearing cone until it is seated inside bearing cup.

cam weldment on top of spacer. Install crankshaft key and cam key on cam bushing (P/N EM14301).

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.

ing and tighten bolts evenly to 40-50 foot pounds. Repeat procedure 3 to 4 times.

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

bearing assemblies with the pump box mountings.

box, place sprocket (P/N EM14307) onto the cam side of the crankshaft assembly. Install bushing (P/N EM14309) into sprocket. Align sprocket with sprocket on countershafts and tighten bolts.

pusher bolts and tighten chain to approximately 1/2 in. slack in the chain. Once chain is adjusted properly, tighten down locknuts.

into hydraulic press with the long end to-

Make sure the eccentric lock is facing toward the outside of the pumping unit.

Ball and Seat Replacement Procedure

1. 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.

2. 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.

3. 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.

4. 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.

5. Coat piston cup with oil and push it into 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.

6. 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.

7. 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 O-rings for slippage.

8. 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 dura-seat, fits into the bottom of the hopper.

9. 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.

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

11. Install 3 in. elbow and 3x 2 in. reducer. Fill hopper half full and check for leaks.

PAGE 40 — MAYCO C-30HDG PUMP — OPERATION AND PARTS MANUAL — REV. #6 (04/02/12)

C-30HDG PUMP — MAINTENANCE (PUMP)

Clutch Lining Replacement (For P/N EM14320 Clutch Assembly Only)

The normal lining thickness measures 3/16 of an inch. If the clutch starts to slip or make an usual noise, it may be necessary to replace the lining. Please note that the lining retaining rivets

should not be exposed

The following procedure will assist you in replacing the lining.

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

2. Cut 1/8 in. 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.

3. 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.

The clutch lining is a normal maintenance item and will require periodic replacement.

to the rotating weight.

MAYCO C-30HDG PUMP — OPERATION AND PARTS MANUAL — REV. #6 (04/02/12) — PAGE 41

C-30HDG PUMP — MAINTENANCE (PUMP)

Bearing Installation

1. Install the bearing components on the crankshaft making full contact with the back side of the crank disc as indicated the symbol #. See Figure 24 below.

2. Install the bushing in the cam weldment and slide it onto the crankshaft until contact is made with the bearing spacer.

It is important that the installed properly.

Bearing Assembly

3. Tighten the 3 on the bushing towards the bearing spacer.

allen head bolts

“A” while exerting pressure

Figure 24. Bearing/Cam Bushing Installation

PAGE 42 — MAYCO C-30HDG PUMP — OPERATION AND PARTS MANUAL — REV. #6 (04/02/12)

C-30HDG PUMP — MAINTENANCE (PUMP)

Detent Hole (3) Installation

1. After the bearing assembly has been is installed , remove the

three “dog type” allen head set screws (B) to allow detents to be drilled. See Figure 25 below.

The detent holes will prevent the bushing from sliding away from the bearing spacer when the pump is under load.

2. 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.

3. If this procedure is not followed closely the heavy loading of the bearing during pumping operation causes the Timken move the taper bushing and allow the Timken bearings to separate from the race and subsequently fail.

4. Drill (detent) the shaft under the allen set screws “B” to prevent the bushing from the sliding away from the bearing spacer when the pump is under a load.

™ cone bearings to create lateral forces which will

™ cone

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

Figure 25. Detent Holes

MAYCO C-30HDG PUMP — OPERATION AND PARTS MANUAL — REV. #6 (04/02/12) — PAGE 43

C-30HDG PUMP — MAINTENANCE (PUMP)

Figure 26. V-Belt and Drive Chain Adjustment

V-Belt And Drive Chain Adjustment

1. Loosen the pillow bearing bolts (Figure 26) 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 in. slack in the chain. It is very impor tant 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.

7. 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 in. deflection in the belts, retighten the engine mounting bolts.

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

Prior to adjusting the chain, place the lobe of the cam in the down position. The chain should have 83 rivets, Including one each, half-link and full link.

6. Lubricate the chain regularly. Note-it is advisable to carry a spare chain and master links for replacement in the field if necessary.

PAGE 44 — MAYCO C-30HDG PUMP — OPERATION AND PARTS MANUAL — REV. #6 (04/02/12)

C-30HDG PUMP — MAINTENANCE (PUMP)

Roller Chain Application

A properly selected, installed and maintained (Figure 27) 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.

Figure 27. Drive Chain

Recommendations and comments on how to get the most from your roller chain drive are given in this section. The drive chain used in the MAYCO C-30HDNI pump is manufactured by the "DIAMOND CHAIN COMPANY

Working Loads

UTS-Ultimate Tensile Strength-is the one time pull required to break the chain. 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.

drive chain

Installation and Drive Alignment

Chain and sprockets (Figure 28) 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.

Figure 28. Shaft and Drive Sprocket Alignment

The chain should be installed so the slack span is properly tensioned. To check chain tension (Figure 29), 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.

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 three-strand chain.

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.

Figure 29. Drive Chain Tension

MAYCO C-30HDG PUMP — OPERATION AND PARTS MANUAL — REV. #6 (04/02/12) — PAGE 45

C-30HDG PUMP — MAINTENANCE (PUMP)

Drive Chain Lubrication

As a chain articulates in entering and leaving a sprocket, there is 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 lubrication can help to prevent 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 (Figure 30), on the order of .003 to .005 inches. A lubricant must be thin 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.

Figure 30. Chain-Link Cross Section

PAGE 46 — MAYCO C-30HDG PUMP — OPERATION AND PARTS MANUAL — REV. #6 (04/02/12)

C-30HDG PUMP — MAINTENANCE (PUMP)

Assembling and Disassembling Drive Chain

CAUTION -

You may be chain while the pump is running. Turn OFF the engine and lock out gears and sprockets before attempting installation.

Once installed, the drive chain must be guarded to prevent personal injury or properly damage in the event the chain separates during operation. NEVER run pump with drive chain guard removed.

CAUTION -

The components of the drive 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 prevent metal parts or chips from entering your eyes and have personnel in the immediate area do likewise.

DRIVE CHAIN SAFETY

seriously injured

if you attempt to install the drive

Eyesight Hazard

safety glasses

Chain-Link 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 P/N 113 or 135. Some multiple strand chains or large pitch models will require a hammer and punch or a press to remove the pins.

Installation Of Coversides

Diamond Chain coversides are manufactured three different ways:

■

Slip Fit

■

Modified Press Fit

■

Full Press Fit

Installation of Spring Locks and Cotter-Pins

Modified

patience and tools to assemble and/or disassemble. Use vice grips, plumbers pliers or a small hammer to drive coversides onto pins.

and

Full Press Fits

require some

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.

Tips To Remember

■

Chian will break if mused or abused

■

Serious injury or property damage can result if chain is installed incorrectly.

■

Select, install, guard and maintain chain in accordance with equipment manufacturer and "Diamond Chain Company's recommendations.

■

Read chain assembly instructions before attempting to install chain on pump sprocket wheel.

■

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

MAYCO C-30HDG PUMP — OPERATION AND PARTS MANUAL — REV. #6 (04/02/12) — PAGE 47

C-30HDG PUMP — ENGINE TROUBLESHOOTING

Practically all breakdowns can be prevented by proper handling and maintenance inspections, but in the event of a breakdown, please take a remedial action following the diagnosis based on the Engine Troubleshooting (Table 6) information shown below and on the proceeding page. If the problem cannot be remedied, please leave the unit just as it is and consult our company's business office or service plant.

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PAGE 48 — MAYCO C-30HDG PUMP — OPERATION AND PARTS MANUAL — REV. #6 (04/02/12)

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C-30HDG PUMP — ENGINE TROUBLESHOOTING

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MAYCO C-30HDG PUMP — OPERATION AND PARTS MANUAL — REV. #6 (04/02/12) — PAGE 49

C-30HDG PUMP — ENGINE FAULT CODES

Malfunction Indicator Diagnostic System

The Mayco C-30HDG concrete pump features an engine malfunction indicator lamp found on the control box (Figure 32). When a malfunction in the operation of the engine is detected, the orange check engine light will illuminate.

There are 2 methods of determining an engine malfunction. The first method is to connect a computer to the test port connector, the second method is to connect a ground wire to the

6. Connect a jumper wire between the A) on the com. port A connector and chassis ground. See Figure 34.

Communication Port A connector using the check engine indicator lamp on the control box to determine the error code. The indicator lamp will flash in sequence to indicate an error code. Use the Diagnostic Error Code Table (Table 7) to troubleshoot the malfunction. The second method will be discussed in this manual. The following steps use the MAP sensor as an example so that the user may become familiar with the troubleshooting process.

Example:

1. Open hood and disconnect MAP sensor connector. See Figure 31.

Figure 34. Com. Port A Connector/Jumper

7. Close hood and place ignition key in the ON position

IGNITION SWITCH

OFF

brown/white

START

wire (pin

8. Observe check engine warning lamp flashing 3 consecutive times and repeating 3 times. This 1-1-1 sequence is defined

Figure 31. MAP Sensor Connector

as the leader code.

2. Close hood and start engine. Let engine run for 3 to 5 minutes.

3. Verify that check engine warning lamp on the control box is on (lit). See Figure 32.

T H R O T

HIG

CHECK

ENGINE

WARNING

LAMP

L E

EMERGENCY

STOP

9. The check engine warning lamp will flash in 3 separate bursts as shown below. This sequence of lamp flashing represents the MIL flash error code. See Table 7 for a complete listing of error codes. In the MAP sensor example, the error code is 127.

Figure 32. Engine Warning Lamp

4. If the check engine warning lamp is on, stop engine. Place ignition key in the OFF position. See Figure 33.

IGNITION SWITCH

OFF

START

PUMPING CONTROL

Figure 33. Ignition Key (Off)

5. Locate communication port A test connector as shown in Figure 34. Remove plastic cover so that the male connector pins are exposed.

10. To correct MAP sensor error, remove jumper wire, reconnect MAP sensor connector (See Figure 31) and restart engine. It may be necessary to restart and stop the engine a few times in order to clear the error from the check engine warning lamp. Allow engine to run 3 to 5 minutes.

Figure 35. Ignition Key (On)

Figure 36. Leader Code

Figure 37. MIL Flash Error Code

PAGE 50 — MAYCO C-30HDG PUMP — OPERATION AND PARTS MANUAL — REV. #6 (04/02/12)

C-30HDG PUMP — ENGINE FAULT CODES

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MAYCO C-30HDG PUMP — OPERATION AND PARTS MANUAL — REV. #6 (04/02/12) — PAGE 51

C-30HDG PUMP — ENGINE FAULT CODES

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PAGE 52 — MAYCO C-30HDG PUMP — OPERATION AND PARTS MANUAL — REV. #6 (04/02/12)

C-30HDG PUMP — ENGINE FAULT CODES

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MAYCO C-30HDG PUMP — OPERATION AND PARTS MANUAL — REV. #6 (04/02/12) — PAGE 53

C-30HDG PUMP — WIRING DIAGRAM (ZENITH WIRING HARNESS)

Figure 38. Zenith Fuel Injection System Wiring Diagram

PAGE 54 — MAYCO C-30HDG PUMP — OPERATION AND PARTS MANUAL — REV. #6 (04/02/12)

C-30HDNI PUMP — WIRING DIAGRAM (ZENITH WIRING HARNESS)

Figure 38. Zenith Fuel Injection System Wiring Diagram (Cont.)

MAYCO C-30HDG PUMP — OPERATION AND PARTS MANUAL — REV. #6 (04/02/12) — PAGE 55

C-30HDG PUMP — WIRING DIAGRAM

Figure 39. Wiring Diagram

PAGE 56 — MAYCO C-30HDG PUMP — OPERATION AND PARTS MANUAL — REV. #6 (04/02/12)

C-30HDG PUMP — PIN CONNECTIONS

ZPP 416, 420 & 640 CUSTOMER 16-PIN CONNECTIONS

Rev: 2 Date 02/17/2007

Connector #1 – Female

IGN. (12 VDC HOT IN RUN & CRANKING)

ALTERNATOR CHARGING TROUBLE INDICATOR LAMP

GASOLINE FUEL PUMP GROUND

GASOLINE FUEL PUMP +12VDC

STARTER REQUEST +12VDC INPUT (AUDIO CRANKING)

STARTER REQUEST +12VDC INPUT (INTERRUPT TYPE)

MALFUNCTION INDICATOR LAMP GROUND

FUEL SELECT/AUX DIG INPUT #1

ENGINE WARNING/SHUTDOWN LAMP GROUND

AUX PWM OUTPUT 5

12V CLAMPING DIODE CONNECTION FOR AUX PWM 5

TACH DRIVER

Connector #2 – Male

ACCELERATOR PEDAL POSITION B (FPP2)

ACCELORATOR PEDAL POSITION A (FPP1)

SIGNAL GROUND 1

+5V EXT 1

CAN BUS +

CAN BUS –

SIGNAL GROUND 2

+5V EXT 2

SPEED SELECT 2 (GOV2) INPUT

SPEED SELECT 1 (GOV1) INPUT

AUX DIGITAL INPUT 2

AUX DIGITAL INPUT 3

POWER GROUND

AUX PWM OUTPUT 2

AUX 5V ANALOG INPUT 1 (CONFIGURABLE PULL-UP/DOWN)

AUX 5V ANALOG INPUT 3 (PULL-UP)

MAYCO C-30HDG PUMP — OPERATION AND PARTS MANUAL — REV. #6 (04/02/12) — PAGE 57

AUX PWM OUTPUT 4

AUX 5V ANALOG INPUT 2 (CONFIGURABLE PULL UP/DOWN)

AUX 5V ANALOG INPUT 4 (PULL DOWN)

AUX 5V ANALOG INPUT 5 (PULL DOWN)

C-30HDG PUMP — WIRING DIAGRAM (TAIL LIGHTS)

Figure 40. Trailer Tail Lights Wiring Diagram

PAGE 58 — 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 59

APPENDIX — C-30HDNI C-30HDNI SLUMP TEST PROCEDURE

1. To obtain a representative sample (concrete), take several 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 (Figure 38-A) 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.

4. Fill cone another 1/3 (Figure 38-B) 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.

5. Fill cone to overflowing (Figure 38-C). 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.

Figure 41-C. Slump Test

Figure 41-B. Slump

Test (2/3 Full)

2/3 FULL

(Full-Overflow)

FULL

(OVERFLOW)

6. Remove the excess concrete (Figure 38-D) from the top of the cone, using the tamping rod as a screed.

7. Lift the cone vertically (Figure 38-E) with a slow even motion. DO NOT jar the concrete or tilt the cone during this process. ( Invert the withdrawn cone, and place it next to, but not touching the slumped concrete.

8. Lay a straight edge (Figure 38-F) 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 . The slump operation must be complete in a maximum elapsed

Figure 41-E. Slump Test

time of 1-1/2 minutes. Discard the concrete. DO NOT use it in any other tests.

BULLET POINTED

STEEL ROD

Figure 41-D. Slump Test

(Removing Excess Concrete)

(Cone Invert)

Figure 41-F. Slump Test

(Measurement)

1/2 DIAMETER

24 INCHES LONG

1/3 FULL

FOOT PIECE

Figure 41-A. Slump Test (1/3 Full)

PAGE 60 — MAYCO C-30HDG PUMP — OPERATION AND PARTS MANUAL — REV. #6 (04/02/12)

APPENDIX — C-30HDG 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.

MAYCO C-30HDG PUMP — OPERATION AND PARTS MANUAL — REV. #6 (04/02/12) — PAGE 61

APPENDIX — C-30HDG CONCRETE MIX INFORMATION

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

PAGE 62 — MAYCO C-30HDG PUMP — OPERATION AND PARTS MANUAL — REV. #6 (04/02/12)

APPENDIX — C-30HDG 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.

MAYCO C-30HDG PUMP — OPERATION AND PARTS MANUAL — REV. #6 (04/02/12) — PAGE 63

APPENDIX — RECOMMENDED SHOTCRETE SYSTEM

MAYC0

RECOMMENDED SHOTCRETE SYSTEM

1-800-30-MAYCO

-3

1/2 STANDARD

AIR HOSE

AIR COMPRESSOR

(125 TO 250 CFM)

14 15

3/4 STANDARD

AIR HOSE

Figure 42. Shotcrete System

PAGE 64 — MAYCO C-30HDG PUMP — OPERATION AND PARTS MANUAL — REV. #6 (04/02/12)

APPENDIX — RECOMMENDED SHOTCRETE SYSTEM

RECOMMENDED 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.

MAYCO C-30HDG PUMP — OPERATION AND PARTS MANUAL — REV. #6 (04/02/12) — PAGE 65

APPENDIX — RECOMMENDED SHOTCRETE ACCESSORIES

RECOMMENDED SHOTCRETE ACCESSORIES

Figure 43. Shotcrete System Accessories

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 re-assembly. DO NOT close the air valve when pumping is stopped as a continued air flow keeps the air passages clean.

PAGE 66 — MAYCO C-30HDG PUMP — OPERATION AND PARTS MANUAL — REV. #6 (04/02/12)

APPENDIX — RECOMMENDED SHOTCRETE ACCESSORIES

RECOMMENDED SHOTCRETE ACCESSORIES

NO. PART NO. PART NAME QTY. REMARKS

1 EM26107 HOPPER SCREEN 1 2 EM231011 AIR VIBRATOR 1 3 EM132 BOLT, 1/2-13X2 2 4 EM23407 AIR HOSE 1 5 EM23408 BUSHING 1 6 EM23411 VALVE 1 7 EM912073 NIPPLE 2 8 EM23409 COUPLING 1 9 EM923346 WASHER, 1/2 LOCK 2 10 EM406 NUT, HEX 1/2-13 2 11 EM24841 2"X25' RAISED HOSE

EM24844 2"X50' RAISED HOSE 12 13 14 15 16 17 18 19

20 AIR HOSE ..................................................... NOT SUPPLIED BY MAYCO

21 EM23808D NOZZLE ASSEMBLY HD ................ 1 .......... INCLUDES. ITEMS W/

EM23802 ADAPTER 1

EM23803 GUN BODY 1

EM20816 “O” RING 1

EM23804 AIR INSERT 1

EM23805 NOZZLE CLAMP 1

EM23806 NOZZLE TIP, 1-3/8" 1

EM23807 NOZZLE TIP, 1-1/4" 1

EM911076 STREET ELBOW 1

MAYCO C-30HDG PUMP — OPERATION AND PARTS MANUAL — REV. #6 (04/02/12) — PAGE 67

EXPLANATION OF CODE IN REMARKS COLUMN

The following section explains the different symbols and remarks used in the Parts section of this manual. Use the help numbers found on the back page of the manual if there are any questions.

NOTICE

The contents and part numbers listed in the parts section are subject to change without notice. Multiquip does not guarantee the availability of the parts listed.

SAMPLE PARTS LIST

NO. PART NO. PART NAME QTY. REMARKS

1 12345 BOLT ......................1 .....INCLUDES ITEMS W/%

2% WASHER, 1/4 IN. ...........NOT SOLD SEPARATELY

2% 12347 WASHER, 3/8 IN. ...1 .....MQ-45T ONLY

3 12348 HOSE ..................A/R ...MAKE LOCALLY

4 12349 BEARING ..............1 .....S/N 2345B AND ABOVE

NO. Column

Unique Symbols — All items with same unique

symbol

QTY. Column

Numbers Used — Item quantity can be indicated by a

number, a blank entry, or A/R.

A/R (As Required) is generally used for hoses or other parts that are sold in bulk and cut to length.

A blank entry generally indicates that the item is not sold separately. Other entries will be clariﬁed in the “Remarks” Column.

REMARKS Column

Some of the most common notes found in the “Remarks” Column are listed below. Other additional notes needed to describe the item can also be shown.

Assembly/Kit — All items on the parts list with the same unique symbol will be included when this item is purchased.

Indicated by:

“INCLUDES ITEMS W/(unique symbol)”

(@, #, +, %, or >) in the number column belong to the same assembly or kit, which is indicated by a note in the “Remarks” column.

Duplicate Item Numbers — Duplicate numbers indicate multiple part numbers, which are in effect for the same general item, such as different size saw blade guards in use or a part that has been updated on newer versions of the same machine.

NOTICE

When ordering a part that has more than one item number listed, check the remarks column for help in determining the proper part to order.

PART NO. Column

Numbers Used — Part numbers can be indicated by a

number, a blank entry, or TBD.

TBD (To Be Determined) is generally used to show a part that has not been assigned a formal part number at the time of publication.

A blank entry generally indicates that the item is not sold separately or is not sold by Multiquip. Other entries will be clariﬁed in the “Remarks” Column.

Serial Number Break — Used to list an effective serial number range where a particular part is used.

Indicated by:

“S/N XXXXX AND BELOW” “S/N XXXX AND ABOVE” “S/N XXXX TO S/N XXX”

Speciﬁc Model Number Use — Indicates that the part is used only with the speciﬁc model number or model number variant listed. It can also be used to show a part is NOT used on a speciﬁc model or model number variant.

Indicated by:

“XXXXX ONLY” “NOT USED ON XXXX”

“Make/Obtain Locally” — Indicates that the part can be purchased at any hardware shop or made out of available items. Examples include battery cables, shims, and certain washers and nuts.

“Not Sold Separately” — Indicates that an item cannot be purchased as a separate item and is either part of an assembly/kit that can be purchased, or is not available for sale through Multiquip.

PAGE 68 — MAYCO C-30HDG PUMP — OPERATION AND PARTS MANUAL — REV. #6 (04/02/12)

C-30HDG PUMP — SUGGESTED SPARE PARTS

C-30HDG CONCRETE PUMP

W/ ZENITH FUEL INJECTION SYSTEM

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

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

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

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

4 ....... EM289041 .................... 3" GASKETS

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

8 ....... 22401M7714 ................. SPARK PLUG

30 ...... EM98057A .................... "SLICK PACK"

............................................... HOSE PRIMING AGENT

C-30HDG CONCRETE PUMP

W/ ZENITH FUEL INJECTION SYSTEM

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

6 ....... EM14315 ...................... V-BELT

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

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

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

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

6 ....... EM20763 ...................... FUEL FILTER

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

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

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

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

10 ...... EM289041 .................... 3" GASKET

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

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

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

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

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

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

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

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

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

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

1 ....... EM14320 ...................... CLUTCH

60 ...... EM98057A .................... "SLICK PACK"

............................................... HOSE PRIMING AGENT

MANIFOLD

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

MAYCO C-30HDG PUMP — OPERATION AND PARTS MANUAL — REV. #6 (04/02/12) — PAGE 69

C-30HDG PUMP — NAMEPLATE AND DECALS

PAGE 70 — MAYCO C-30HDG PUMP — OPERATION AND PARTS MANUAL — REV. #6 (04/02/12)

C-30HDG PUMP — NAMEPLATE AND DECALS

NAME PLATE AND DECALS

NO PART NO PART NAME QTY. REMARKS

2 3 4 5 6

7 DECAL, NAME PLATE ............................. 1 ........... CONTACT MQ PARTS DEPT. W/

10 EM514274 KIT, DECAL .............................................. 1 ........... INCLUDES ITEMS W/

DCL152 DECAL, CAUTION OIL LEVEL 1 EM932 DECAL, CAUTION, MANIFOLD 1

EM1028 DECAL, MULTIQUIP MAYCO 2

508594 DECAL, CAUTION READ MANUAL 2

EM517019 DECAL, C-30HDG 2

EM513165 DECAL, MAINTENANCE 1

............................................................................... MODEL AND SERIAL NUMBER.

98022 DECAL, WARNING 1 34536 DECAL, OWNER'S MANUAL 1

MAYCO C-30HDG PUMP — OPERATION AND PARTS MANUAL — REV. #6 (04/02/12) — PAGE 71

C-30HDG PUMP — COMPENSATOR PISTON ROD ASSY.

COMPENSATOR PISTON ROD ASSY.

PAGE 72 — MAYCO C-30HDG PUMP — OPERATION AND PARTS MANUAL — REV. #6 (04/02/12)

C-30HDG PUMP — COMPENSATOR PISTON ROD ASSY.

COMPENSATOR PISTON ROD ASSY.

NO. PART NO. PART NAME QTY. REMARKS

1 EM14805 ROD END ................................... 1 ........... INCLUDES ITEMS W/+

1A+ EM148053 BUSHING 1 2 EM968446 NUT HEX, 3/4”-10 GR5 2 3 EM14332 ROD SPRING GUIDE 3/4” 1 4 EM14331 SPRING BACKING PLATE 1 5 EM14333 SPRING RETURN 1 6 EM14806 PISTON GUIDE ASSY. 1 7 EM505490 FITTING 1 8 9 10 11 12 13 EM916001 FITTING 2 14 EM510266 SCREW, HHC 1/2-13X3 1 15 EM621 WASHER 2 16 492584 NUT LOCK 1/2” DIA. 1 17 EM14335 PISTON ROD 1 18 EM14336 PISTON GUIDE 1 19 EM505489 FITTING 1 20 EM14334 COMPENSATOR SPRING 1 21 EM18409 O-RING 1 22 EM98032 PLATE, OILER 1 23 EM14407 O-RING, OILER PLATE 1 24 EM14410 RING & FELT HOLDER 1 25 EM14408 BRONZE RING 1 26 EM14411 PISTON CUP-BLACK 1 26 EM98051 PISTON CUP-ORANGE 1 27 EM14412 BUSHING 1 1/4 CRS 1 28 EM18409 O-RING 1” 2 29 EM14413 FACE PLATE 1

30 EM18800HD PUMPING CYLINDER ................ 1 ............ 2-1/2" LIP SLEEVE

31 EM26525 O-RING, CYLINDER BOX 1 32 EM968446 NUT HEX, 3/4-10 3 33 EM16493 FELT RING 1 34 EM148053 BUSHING 1

35 EM20328TKIT BEARING KIT ............................ 1 ............ INCLUDES ITEMS W/

EM903163 BEARING CUP 1

EM20814 BEARING BUSHING 1

EM20813 SPACER 1

EM903162 BEARING CONE 2

EM20816 O-RING 2

MAYCO C-30HDG PUMP — OPERATION AND PARTS MANUAL — REV. #6 (04/02/12) — PAGE 73

C-30HDG PUMP — CONNECTING ROD - DRIVE SIDE ASSY.

CONNECTING ROD - DRIVE SIDE ASSY.

PAGE 74 — MAYCO C-30HDG PUMP — OPERATION AND PARTS MANUAL — REV. #6 (04/02/12)

C-30HDG PUMP — CONNECTING ROD - DRIVE SIDE ASSY.

CONNECTING ROD - DRIVE SIDE ASSY.

NO. PART NO. PART NAME QTY. REMARKS

7 EM505490 FITTING 1 8 9 10 11 12 21 EM18409 O-RING 1 22 EM98032 PLATE, OILER 1 23 EM14407 O-RING, OILER PLATE 1 24 EM14408 BRONZE RING 1 25 EM14410 RING AND FELT HOLDER 1 26 EM14411 PISTON CUP-BLACK 1 26 EM98051 PISTON CUP-ORANGE 1 27 EM14412 BUSHING 1 1/4 CRS 1 28 EM18409 O-RING 1” 2 29 EM14413 FACE PLATE 1

30 EM14807HD CONCRETE CYLINDER ............. 1 ............ 3-3/4 IN. LIP SLEEVE

32 EM968446 NUT HEX, 3/4-10 3 33 EM14808 PISTON ROD ASSY. 1 34 EM16493 FELT RING 1

35 EM20328TKIT BEARING KIT ............................ 1 ............ INCLUDES ITEMS W/

EM903163 BEARING CUP 1

EM20814 BEARING BUSHING 1

EM20813 SPACER 1

EM903162 BEARING CONE 2

EM20816 O-RING 2

MAYCO C-30HDG PUMP — OPERATION AND PARTS MANUAL — REV. #6 (04/02/12) — PAGE 75

ROCKER ASSY.

C-30HDG PUMP — ROCKER ASSY.

LUBRICATION

POINT

LUBRICATION

POINT

LUBRICATION

POINT

PAR T O F

FRAME

KIT

LUBRICATION

POINT

NOTES:

A. LONG STROKE SETTING.

HIGHER VOLUME, LOWER PSI. B. STANDARD SETTING, NORMAL. C. SHORT STROKE SETTING.

REDUCED VOLUME, HIGHER PSI.

SEE CRANKSHAFT ASSEMBLY

PAGE 76 — MAYCO C-30HDG PUMP — OPERATION AND PARTS MANUAL — REV. #6 (04/02/12)

LUBRICATION

POINT

C-30HDG PUMP — ROCKER ASSY.

ROCKER ASSY.

NO. PART NO. PART NAME QTY. REMARKS

1 EM14329 SHAFT ROCKER ARM 1 2 EM14116 JOURNAL BLOCK 1 3 EM963180 SCREW, HHC 3/4”-10X5 2 4 EM923350 WASHER LOCK 3/4” SPRING STEEL 2

5 EM14846 CAM ROCKER ARM ..................................... 1 ......... INCLUDES ITEMS W/

6 EM133 BOLT 1”-14X2” HEX HEAD 1 7 EM603 WASHER 1” LOCK 1 8 EM916001 ZERK FITTING 1 9 EM903092 BEARING ASSY. 1 10 EM20347 BEARING SPACER 2 11 EM402434 BEARING BUSHING 1 12 EM20344 SPECIAL BOLT 1 13 EM916001 ZERK FITTING 1 14 EM417 NUT FLEX LOCK 1 15 EM402456 OILER FELT 2 16 EM607 WASHER, FLAT 5/8” 1 17 EM20349 OILER PLUG, PLASTIC 1 19 EM969038 NUT STOP REG. 3/4”-10 1 20% EM903163 BEARING CUP 1 21% EM20814 BEARING BUSHING 1 22% EM20813 SPACER 1 23% EM903162 BEARING CONE 2 24% EM20816 O-RING 2 25 EM105 BOLT 1”-14X6” HEX HEAD 1 27#+ EM203262 BRONZE BUSHING 4 28 EM20364 CONNECTING ROD 1 30 EM702 SCREW ALLEN HEAD 3/8”-16X3/4” 1 31 EM505490 ZERK FITTING 1

35 EM14328 ROCKER ARM ASSY. ................................... 1 ......... INCLUDES ITEM W/#

36 EM402996 SEAL PLATE 1 37 EM20336 O-RING 1 38 EM903176 BEARING 1 40 EM20338 SPACER 1 41 EM923348 WASHER LOCK 5/8 1 42 EM503982 BOLT 1/2-13X5 1

43 EM98043 FORGED CRANKSHAFT 1 44 EM417 NUT, LOCK 3/4"-10 2 45 EM202 BOLT, HEX 1-8 X 6 LG. 1

46 EM20328TKIT BEARING KIT ...................................................... 1 .......... INCLUDES ITEMS W/%

47 EM104 HHCS 5/8-11 X 2" G5 1

MAYCO C-30HDG PUMP — OPERATION AND PARTS MANUAL — REV. #6 (04/02/12) — PAGE 77

COUNTERSHAFT ASSY.

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C-30HDG PUMP — COUNTER-SHAFT ASSY.

LUBRICATION

POINT

NOTES:

SEE CLUTCH ASSEMBLY

PAGES 84 AND 85.

SEE CRANKCASE ASSEMBLY,

PAGES 74 AND 75,

FRAME

LUBRICATION

POINT

PAR T O F

FRAME

MASTER

LINK

HALF

LINK

PAGE 78 — MAYCO C-30HDG PUMP — OPERATION AND PARTS MANUAL — REV. #6 (04/02/12)

C-30HDG PUMP — COUNTER-SHAFT ASSY.

COUNTER-SHAFT ASSY.

NO. PART NO. PART NAME QTY. REMARKS

1 EM513073 COUNTER SHAFT 1 2 EM14311 CAM BEARING 2 3 EM124 BOLT HEX 1/2 X 1-3/4 2 4 EM1621 WASHER 5” 2 5 EM923346 WASHER, LOCK1/2” 2 6 EM968011 NUT HEX, 1/2-13 2 7 EM916001 FITTING 1 8 EM14316 KEY WAY 3/8”X2.5” 1 9 EM14314 BUSHING, PULLEY 1 10 EM14313 PULLEY 1 11 EM14315 BELT, DOUBLE 1 12 EM143111 SET COLLAR 1 21 EM14318 SPROCKET, 13 TOOTH 1 22 EM14319 BUSHING 1 55 EM14307 SPROCKET 60 TEETH 1 57 EM1702 SCREW ALLEN HEAD 3/8”-16X3/4” 1 58 EM703 SET SCREW 3/8”-16X3/8” 1 59 EM14308 CHAIN W/MASTER LINK 1 60 EM26314 LINK MASTER 1 61 EM26313 HALF LINK 1

MAYCO C-30HDG PUMP — OPERATION AND PARTS MANUAL — REV. #6 (04/02/12) — PAGE 79

CRANKSHAFT ASSY.

C-30HDG PUMP — CRANKSHAFT ASSY.

KIT

LUBRICATION

POINT

LUBRICATION

POINT

NOTES:

SEE ROCKER ARM ASSEMBLY

ITEM 43 FOR ASSOCIATED CRANKSHAFT COMPONENTS.

SEE COUNTER-SHAFT ASSEMBLY,

ITEM 55

PAGE 80 — MAYCO C-30HDG PUMP — OPERATION AND PARTS MANUAL — REV. #6 (04/02/12)

C-30HDG PUMP — CRANKSHAFT ASSY.

CRANKSHAFT ASSY.

NO. PART NO. PART NAME QTY. REMARKS

23 24 25 EM505490 ZERK FITTING 1 26 EM129 SCREW, HHC 3/4-10X8-1/2 2 27 EM492628 LOCK WASHER 3/4 2 28 EM968446 NUT HEX, 3/4-10 GR5 4 29 30 31 32 33 34 35 38 EM903176 BEARING 1 40 EM402996 SEAL PLATE 1 41 EM923348 WASHER, LOCK 5/8" 2 43 44 45 46 48 49 50 51 EM128 BOLT 5/8-11X4” HEX HEAD 2 52 EM620 WASHER, SPECIAL 5/8” 2 54 EM968013 NUT HEX 5/8-11 4 55 56

57 EM98043K CRANKSHAFT FORGE ASSEMBLY ............ 1......... INCLUDES ITEM W/

EM14303 BEARING BLOCK 1

EM702 SCREW, ALLEN HEAD 3/8-16X3/4 6

EM14324 CUP BEARING 1

EM14323 SPACER BEARING CONE 1

EM14325 CONE BEARING 2

EM14326 O-RING 2

EM14322 SPACER 1

EM98043 CRANKSHAFT, FORGED 1

EM14306 KEY CRANKSHAFT 2

EM14302 SPACER, CAM BUSHING 1

EM14300 CAM ASSY. 1

EM14301 BUSHING, CAM 1

EM703 SCREW ALLEN HEAD 3/8-16X3/8 6

EM175 BOLT 3/8-16X1-1/4 6

EM14304 BEARING-CAM COMPLETE 1

EM916001 ZERK FITTING 1

EM14307 SPROCKET 60 TEETH 1

EM14309 BUSHING 1

MAYCO C-30HDG PUMP — OPERATION AND PARTS MANUAL — REV. #6 (04/02/12) — PAGE 81

MANIFOLD ASSY.

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ACCESSORIES

C-30HDG PUMP — MANIFOLD ASSY.

PAR T O F

FRAME

PAR T O F

FRAME

PAGE 82 — MAYCO C-30HDG PUMP — OPERATION AND PARTS MANUAL — REV. #6 (04/02/12)

C-30HDG PUMP — MANIFOLD ASSY.

MANIFOLD ASSY.

NO. PART NO. PART NAME QTY. REMARKS

1 EM23946 ELBOW 3”X90 DEG.HD 1 2 EM28004DD REDUCER 3X2X36 HD 1 3 EM2C0B BALL 2” SPONGE 2 4 EM28904 COUPLING 3” HD *CF* 2 5 EM18409 O-RING 1” 4 6 EM14843 UPPER DURASEAT 1 7 EM18801 O-RING 6 8 EM18804 BALL 4-1/2” 1 9 EM14801 MANIFOLD T ASSY. 1 11 EM136 PIN BALL STOP 3/4-16 x 8 3 12 EM18409 O-RING 4 13 EM618 WASHER SPECIAL 4 14 EM968266 NUT JAM HEX 3/4-16 4 15 EM104 BOLT 5/8-11X2” HEX HEAD 3 16 EM923348 WASHER LOCK 5/8 SPRING 3 17 EM505882 WASHER, 5/8 3 18 EM14842 SEAT DURA LOWER 1 19 EM14818 BALL 4” 1 21 EM14819A MANIFOLD ASSY. EASY OPEN 1 23 EM18409 O-RING 2 24 EM618 WASHER SPECIAL 2 26 EM137 TEE-BOLT 3/4-10X14” 2 27 EM619 WASHER 3/4” 2 28 EM968446 NUT HEX 3/4”-10 GR5 2 30 EM14850 EXHAUST GATE “H/D” 1 31 EM963180 CAPSCREW 3/4-10X5 HEX HD G8 1 32 EM969038 NUT STOP REG.3/4-10 2 33 EM14845 ARM CLAMP 1 34 EM135 BOLT 1-1/4” -12X7” HEX HD. 1 35 EM14810 SPRING 1 36 EM451 NUT 1-1/4” -12 LOCK 1 37 EM160 BOLT 3/8-16X3/4” 1 38 EM509329 SCREW HHC 3/4-10X6 1

MAYCO C-30HDG PUMP — OPERATION AND PARTS MANUAL — REV. #6 (04/02/12) — PAGE 83

FRAME ASSY.

C-30HDG PUMP — FRAME ASSY.

PAGE 84 — MAYCO C-30HDG PUMP — OPERATION AND PARTS MANUAL — REV. #6 (04/02/12)

C-30HDG PUMP — FRAME ASSY.

FRAME ASSY.

NO. PART NO. PART NAME QTY. REMARKS

1 EM513085 FRAME ASSEMBLY 1 2 EM70186 JACK STAND, REAR 1 3 EM744 CLEVIS PIN 1/2” X 4” 1 4 EM745 HAIR PIN C 5/8- 3/4” 1 5 EM14600A AXLE, ASSEMBLY 1 7 501299 WASHER THICK 1” 2 8 491689 KEY COTTER 1/8 X 2 2 10 EM492396 SCREW HHC 1/2- 13 X 2 4 11 EM621 WASHER .5” 4 12 EM406 NUT LOCK 1/2” DIA. 4 13 EM511418 FENDER RIGHT-SIDE 1 14 981635 BOLT, HHC 1/2- 13 X 3/4 6 15 6109180 WASHER LOCK 1/2” 6 16 EM512251 COVER 1 17 EM512252 COVER 1 18 EM512253 COVER 1 19 EM512250 COVER 1 20 EM492309 SCREW, HHC 16 21 0166 A WASHER, LOCK 3/8” 24 22 EM512263 ROD 1 23 EM507895 PLUG, 2 1/2 NPT 2 26 29228 HITCH, TONGUE 2" 1 27 EM969023 NUT, HEX 5/8" NC 2 28 EM507658 SCREW, HHC 5/8" NC 4-1/2 G5 2 29 EM509947 LINK, QUICK 2 30 EM14165 BOLT EYE 2 31 EM619 WASHER 3/4” WILLIAM 2 32 EM968002 NUT COUPLING 3/4- 10 2 33 EM505121 SCREW 3/4”- 10 X 3 GR.5 2 34 EM969038 NUT STOP REG. 3/4- 10 2 35 EM513078 COVER, CHASSIS BOTTOM 1 36 10136 WASHER, FLAT 3/8 8 37 EM492264 HHCS. 3/8" NC X 1" 8 38 EM929028 HOOD REST, STEEL 2 39 492363 SCREW HHC 5/16- 18 X 3/4” 4 40 EM923343 WASHER LOCK 5/16” 4 41 EM265361 BRACKET LIGHT 2 42 EM26536 TAIL LIGHT 2 43 491010 HOOD FASTENER, RUBBER 2 44 EM513087 FENDER LEFT-SIDE 1 45 EM25610 JACK STAND, FRONT 1

MAYCO C-30HDG PUMP — OPERATION AND PARTS MANUAL — REV. #6 (04/02/12) — PAGE 85

AXLE ASSY.

C-30HDG PUMP — AXLE ASSY.

PAGE 86 — MAYCO C-30HDG PUMP — OPERATION AND PARTS MANUAL — REV. #6 (04/02/12)

C-30HDG PUMP — AXLE ASSY.

AXLE ASSY.

NO. PART NO. PART NAME QTY. REMARKS

1 EM26518 CAP 14” CHROME 2

2 EM26615A TIRE ASSY. ................................ 2 ........... INCLUDES ITEMS W/

5# EM26306 DUST COVER 2 6# EM968481 CASTLE NUT 2 7 EM705 PIN, COTTER 3/16X1 1/2 2 8# EM26329 WASHER 2 9# EM903113 OUTER BEARING 2 10# EM903012 OUTER CUP 2 11# EM26519 NUT 12 12# EM20612 STUD 12 13# EM26300 HUB 2 14# EM903169 INNER CUP 2 15# EM903168 INNER BEARING 2 16# EM26305 GREASE SEAL 2

17% EM20601 HUB ASSEMBLY ........................ 2 ........... INCLUDES ITEMS W/#

18% EM14600 AXLE 1

19 EM14600A AXLE WITH HUBS INSTALLED ..... 1 .......... INCLUDES ITEMS W/%

WHEEL ....................................... 2 ........... CANNOT BE PURCHASED SEPARATELY

TIRE 14" ..................................... 2 ........... CANNOT BE PURCHASED SEPARATELY

MAYCO C-30HDG PUMP — OPERATION AND PARTS MANUAL — REV. #6 (04/02/12) — PAGE 87

C-30HDG PUMP — MUFFLER, AIR FILTER, AND STOP SWITCH ASSY.

MUFFLER, AIR FILTER AND STOP SWITCH ASSY.

195

462

184

461

184

448

446

135

208

112

132

204

212

132

137

210

133

136

135

137

134

103

104

107

184

106

102

460

104

208

204

202

133

140

236

206

NOTES:

1 STOP SWITCH MOUNTING

HARDWARE IS INCLUDED WITH ITEM 5.

2 CLAMP IS INCLUDED

WITH ITEM 1.

PAGE 88 — MAYCO C-30HDG PUMP — OPERATION AND PARTS MANUAL — REV. #6 (04/02/12)

C-30HDG PUMP — MUFFLER, AIR FILTER, AND STOP SWITCH ASSY.

MUFFLER, AIR FILTER AND STOP SWITCH ASSY.

NO. PART NO. PART NAME QTY. REMARKS

1 EM98076 FILTER, AIR 1 2 EM98162 PRECLEANER, AIR FILTER 1 3 ZE1 ELEMENT, AIR FILTER 1 4 EM491873 GLAND CONNECTOR 1 5 EM14217 STOP SWITCH, ENGINE COVER 1

6 ZPPC6741620 CATALYTIC CONVERTER ........................................ 1.......... INCLUDED W/ENGINE

7 ZPPC14667 GASKET................................................................... 2.......... INCLUDED W/ENGINE

102 492363 BOLT, 5/16" DIA NC X 3/4" G5 3 103 2105164 NUT, LOCK 5/16" 1 104 EM923023 WASHER FLAT 5/16" 3 106 2105164 NUT 5/16" 2 107 EM516995 PANEL, FILTER SUPPORT 1

112 EM513102 FLEX HOSE, AIR CLEANER 2" ............................... 1.......... JUNE 2007 AND BELOW

112 EM517690 FLEX HOSE, AIR CLEANER 2", 29.7" .................... 1.......... JULY 2007 AND ABOVE

132 EM513110 SHOCK MOUNT 8 133 EM923057 WASHER 1/4" 8 134 EM98078 CLAMP 2 135 2101402 WASHER SPRING 1/4" 8 136 517293 MUFFLER 1 137 EM968435 NUT HEX 1/4-20 8 140 EM517292 EXHAUST PIPE 1

184 EM513126 CLAMP ..................................................................... 2.......... JUNE 2007 AND BELOW

184 EM513126 CLAMP ..................................................................... 4.......... JULY 2007 AND ABOVE

195 EM516996 BRACKET 1 202 3019092 WASHER FLAT 3/8" 2 204 0166 A WASHER LOCK 3/8" MED 6 206 EM963610 CAPSCREW 3/8" NC X 1-1/4" G8 2 208 1456 NUT HEX FINISH 3/8-16 6 210 492378 BOLT HHSC G-5 4 212 EM504679 WASHER FLAT 3/8" 8 236 EM515458 SUPPORT FRONT 2 446 19633 BUSHING, RUBBER FUEL 1 448 12008 FITTING, 90° 1 460 EM505831 GASKET 1

461 EM517679 SLEEVE ................................................................... 1.......... JULY 2007 AND ABOVE

462 EM517687 HOSE, 8" .................................................................. 1.......... JULY 2007 AND ABOVE

MAYCO C-30HDG PUMP — OPERATION AND PARTS MANUAL — REV. #6 (04/02/12) — PAGE 89

CLUTCH ASSY.

C-30HDG PUMP — CLUTCH ASSY.

PAGE 90 — MAYCO C-30HDG PUMP — OPERATION AND PARTS MANUAL — REV. #6 (04/02/12)

C-30HDG PUMP — CLUTCH ASSY.

CLUTCH ASSY.

NO. PART NO. PART NAME QTY. REMARKS

1 2 3 4 5 6 8 9 10 11 12 13 0166A WASHER, LOCK 3/8” 6 14 EM517015 SHAFT STUB (FLANGE), ENGINE 1 15 EM26348 KEY 1

16 EM14320 CLUTCH COMPLETE ASSEMBLY ............. 1 ............. INCLUDES ITEMS W/

492395 SCREW, HHC 1/2- 13X1-3/4” 1

EM923346 WASHER, LOCK 1/2” 1

EM621 WASHER, FLAT 1/2” SPECIAL 1

EM26321 ROTOR ASSEMBLY 1

EM918050 CLUTCH SPRING 2

EM26310 CLUTCH LINING 1

EM902204 CLUTCH BEARING 2

EM926066 RETAINING RING 2

EM926053 RETAINING RING 1

EM508342 SCREW, HHC M8X25 PI.25 6

EM26322 CLUTCH HOUSING W/LINING 1

MAYCO C-30HDG PUMP — OPERATION AND PARTS MANUAL — REV. #6 (04/02/12) — PAGE 91

C-30HDG PUMP — ENGINE MOUNTING BRACKETS ASSY.

ENGINE MOUNTING BRACKETS ASSY.

PAGE 92 — MAYCO C-30HDG PUMP — OPERATION AND PARTS MANUAL — REV. #6 (04/02/12)

C-30HDG PUMP — ENGINE MOUNTING BRACKETS ASSY.

ENGINE MOUNTING BRACKETS ASSY.

NO. PART NO. PART NAME QTY. REMARKS

1 EM517379 SUPPORT BRACKET, RIGHT 1 2 EM517418 SUPPORT BRACKET, LEFT 1 3 20900059 SPACER, 20 OD X 11 ID X 32 LONG 1 4 20900063 SPACER, 76 X 30 X 6.35 2 5 21000205 BRACKET, ECU MOUNT 1 7 64700072 PLAIN WASHER, 10MM 4 8 64700073 HELICAL SPRING LOCK WASHER, 10MM 4 9 64700079 PLAIN WASHER, 8MM 1 10 64700080 HELICAL SPRING LOCK WASHER, 8MM 1 13 64900022 HEX SERRATED FLANGE CAP SCREW, M8-1.25 X 20 2 14 64900083 HEX CAP SCREW, M10-1.25X35 2 15 64900160 HEX CAP SCREW, M10-1.25X30 2 18 64900205 HEX CAP SCREW, M8/1.25 X 60 1 20 EM516977 ENGINE, HYUNDAI ZENITH C-30 1 30 EM516981 BRACKET RISER 2 32 EM513204 BOLT 1/2" NC X 5" 2 34 6109180 WASHER, LOCK 1/2" 6 44 6109170 WASHER, FLAT 1/2" 14 46 6109160 HEX NUT, 1/2-13 14 47 492580 NUT, 1/2" 2 48 EM505123 BOLT HEX 1/2 X 2-1/2" 2 49 EM513089 THREADED PIECE 2 50 EM517487 SUPPORT BRACKET, REAR 1

51 BOLT ...................................................................................... 2............. INCLUDED W/ENGINE

52 WASHER ............................................................................... 2 ............. INCLUDED W/ENGINE

53 WASHER ............................................................................... 2 ............. INCLUDED W/ENGINE

54 NUT ........................................................................................ 2............. INCLUDED W/ENGINE

322 EM506886 BOLT M8X20 1 324 EM923343 WASHER LOCK 5/16" 1 432 EM513094 BOLT, 1/2" NC X 1-3/4" 4 330 EM517024 CLUTCH GUARD 1 380 EM517351 GUARD 1

MAYCO C-30HDG PUMP — OPERATION AND PARTS MANUAL — REV. #6 (04/02/12) — PAGE 93

C-30HDG PUMP — RADIATOR, MOUNTING BRACKET AND HOSES ASSY.

RADIATOR, BRACKET AND HOSES ASSY.

PAGE 94 — MAYCO C-30HDG PUMP — OPERATION AND PARTS MANUAL — REV. #6 (04/02/12)

C-30HDG PUMP — RADIATOR, MOUNTING BRACKET AND HOSES ASSY.

RADIATOR, BRACKET AND HOSES ASSY.

NO. PART NO. PART NAME QTY. REMARKS

1 20800072 BRACKET, TOP MOUNT 1 2 21000161 BRACKET, TUBE SUPPORT 1 3 62410120 CONNECTOR, STRAIGHT 410 X 32 DIA 2 4 64700072 PLAIN WASHER, 10 MM 1 5 64700073 HELICAL SPRING LOCK WASHER, 12MM 1 6 64700098 WASHER, PLAIN 12MM X 23.7MM 2 7 64700126 HELICAL SPRING LOCK WASHER, 12MM 2 8 64800164 NUT, LOCK, FLANGE, M6-1 4 9 64900002 HEX CAP SCREW, M12-1.25 X 30 2 10 64900026 HEX SERRATED FLANGE CAP SCREW, M6-1 X 20 4 11 64900035 HEX SERRATED FLANGE CAP SCREW, M10-1.25 X 20 3 12 64900083 HEX CAP SCREW, M10-1.25 X 35 1 13 64900174 HEX SERRATED FLANGE CAP SCREW, M8-1.25 X 16 1 14 65500001 ISOLATOR, 32 X32, M8-1.25 1 15 68800001 CLAMP, HOSE, WORM-DRIVE 8 16 68800018 CLAMP, TUBE/HOSE, LOOP/OFFSET 4 17 68900360 HOSE, 20R4, DIA 32, HYUNDAI 1.6 TOP REAR 1 18 68900359 HOSE, 20R4, DIA 32, HYUNDAI 1.6 LOWER REAR 1 19 68900361 HOSE, 20R4, DIA 32, HYUNDAI 1.6 TOP FRONT 1 20 68900362 HOSE, 20R4, DIA 32, HYUNDAI 1.6 FRONT BOTTOM 1 21 492356 BOLT, 1/4" X 3/4" 2 22 2101402 WASHER SPRING 1/4" 2 23 EM513116 CLAMP 1/2" 2 24 EM514536 HOSE 1 25 22000184 BRACKET, CROSS 1 26 65500002 ISOLATOR, 46.4MM, 51.21MM, 1/2-13 2 27 64700096 LARGE OD PLAIN WASHER, 1/2 X 2 X 1/8 2 28 64900182 HEX CAP SCREW, 1/2 - 13 X 2-1/2 2 29 64800059 HEX SERRATED FLANGE NUT, M10-1.5 2 30 64900173 HEX SERRATED FLANGE CAP SCREW, M10-1.5X25 2

MAYCO C-30HDG PUMP — OPERATION AND PARTS MANUAL — REV. #6 (04/02/12) — PAGE 95

CONTROL BOX ASSY.

C-30HDG PUMP — CONTROL BOX ASSY.

PAGE 96 — MAYCO C-30HDG PUMP — OPERATION AND PARTS MANUAL — REV. #6 (04/02/12)

C-30HDG PUMP — CONTROL BOX ASSY.

CONTROL BOX ASSY.

NO. PART NO. PART NAME QTY. REMARKS

1 EM517174 FRONT PANEL OVERLAY 1 3 EM98036 SWITCH, THROTTLE CONTROL 1

6 EM517176 RED PILOT LENS DIA 5/8" .................................. 1 ........... INCLUDES ITEMS W/#

7# 12 VDC BULB 2 8 10958 IGNITION SWITCH 1 8A EM508239 CONNECTOR, PLASTIC 1 9 11078 IGNITION SWITCH KEY 1 10 EM40711 SWITCH, PUMPING CONTROL 1 11 EM517184 CONTROL BOX 1 12 EM26789 RECEPTACLE (REMOTE) 1 13 EM18706 HOURMETER 1 14 492356 BOLT, HEX 1/4 IN. x 3/4 IN. 5 15 EM515466 SUPPORT, ZENITH CONTROL PANEL 1 16 492596 WASHER, FLAT 1/4 IN. 5 17 492581 NUT, HEX 1/4 IN. 5 18 EM508451 NUT, LOCK 1/4 IN. 6 19 EM515455 SIDE SUPPORT, ZENITH CONTROL PANEL 1 20 EM513110 BUSHING, 1/4- 20 RUBBER MUFFLER 3

21 EM517177 EMERGENCY STOP BUTTON ............................ 1 .......... INCLUDES ITEMS W/%

22% ORANGE PILOT LENS DIA 5/8" 1 23 EM517186 CONTACT BLOCK, EMERGENCY SWITCH 1

MAYCO C-30HDG PUMP — OPERATION AND PARTS MANUAL — REV. #6 (04/02/12) — PAGE 97

BATTERY ASSY.

C-30HDG PUMP — BATTERY ASSY.

PAGE 98 — MAYCO C-30HDG PUMP — OPERATION AND PARTS MANUAL — REV. #6 (04/02/12)

C-30HDG PUMP — BATTERY ASSY.

BATTERY ASSY.

NO. PART NO. PART NAME QTY. REMARKS

1 EM515122 CABLE, POSITIVE BATTERY 1 2 EM506266 COVER, POSITIVE TERMINAL 1 3 10318 BOX, BATTERY 1 4 EM492541 NUT, HEX 5/16- 18 1 5 EM923023 WASHER, FLAT 5/16 1 6 EM923343 WASHER, LOCK 5/16 1 7 EM515113 CABLE, NEGATIVE BATTERY 1 8 EM505624 COVER, NEGATIVE TERMINAL 1 9 EM491344 BATTERY, 12 VOLT 1

MAYCO C-30HDG PUMP — OPERATION AND PARTS MANUAL — REV. #6 (04/02/12) — PAGE 99

FUEL TANK ASSY.

C-30HDG PUMP — FUEL TANK ASSY.

PAGE 100 — MAYCO C-30HDG PUMP — OPERATION AND PARTS MANUAL — REV. #6 (04/02/12)

Zenith C-30HDG User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual