MULTIQUIP MAYCO C30HDGA Operation Manual Download

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OPERATION MANUAL

THIS MANUAL MUST ACCOMPANY THE EQUIPMENT AT ALL TIMES.

Revision #1 (09/09/19)

SERIES

MODEL C30HDGA

CONCRETE PUMP

(ZENITH 416 GAMMA GASOLINE ENGINE)

Summary of Contents for MAYCO C30HDGA

Page 1: ...publication or associated parts manual visit our website at www multiquip com OPERATION MANUAL THIS MANUAL MUST ACCOMPANY THE EQUIPMENT AT ALL TIMES Revision 1 09 09 19 SERIES MODEL C30HDGA CONCRETE P...

Page 2: ...PAGE 2 MAYCO C30HDGA CONCRETE PUMP OPERATION MANUAL REV 1 09 09 19 PROPOSITION 65 WARNING...

Page 3: ...se 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 revie...

Page 4: ...nals 13 General Information 14 16 Components Pump 18 19 Components Control Box 20 Components Engine 21 Inspection 22 24 Startup Shutdown 25 Operation 26 30 Maintenance 31 39 Trailer Maintenance 40 41...

Page 5: ...GER WARNING CAUTION or NOTICE SAFETY SYMBOLS DANGER Indicates a hazardous situation which if not avoided WILL result in DEATH or SERIOUS INJURY WARNING Indicates a hazardous situation which if not avo...

Page 6: ...n of the nearest phone or keep a phone on the job site Also know the phone numbers of the nearest ambulance doctor and fire department This information will be invaluable in the case of an emergency P...

Page 7: ...pump s emergency stop switch The purpose of this test is to shut down the engine in the event of an emergency Multiquip strongly encourages the operator to take the safety training courses offered by...

Page 8: ...uel cap until it clicks Slowly open fuel cap to release pressure BATTERY SAFETY DANGER DO NOT drop the battery There is a possibility that the battery will explode DO NOT expose the battery to open fl...

Page 9: ...ing of the towing vehicle are rated equal to or greater than the trailer gross vehicle weight rating ALWAYS inspect the hitch and coupling for wear NEVER tow a trailer with defective hitches couplings...

Page 10: ...l other metal parts be sent to a recycling center Metal recycling involves the collection of metal from discarded products and its transformation into raw materials to use in manufacturing a new produ...

Page 11: ...slump line size used and job site conditions Table 2 Engine Specifications Model ZENITH 416 GAMMA Type 4 stroke overhead valve single cylinder horizontal shaft gasoline engine Bore Stroke 3 032 in 3...

Page 12: ...ERATION MANUAL REV 1 09 09 19 DIMENSIONS Table 3 Pump Dimensions Reference Letter Dimensions in mm A 76 1930 B 14 5 368 C 16 406 D 161 4089 E 63 5 1612 F 59 5 1511 C 30HDGA MAYC0 A B C E F D 145 IN 3...

Page 13: ...NUAL REV 1 09 09 19 PAGE 13 IMPORTANT HAND SIGNALS Figure 1 Operation Hand Signals CHUTE UP CHUTE DOWN STOP START PUMP SPEED UP SLOW PUMP DOWN STOP PUMP LITTLE BIT ADD WATER 4 GALLONS ALL DONE CLEAN U...

Page 14: ...rrect 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 NOTICE If jamming conditions in the pum...

Page 15: ...ston is pumping the material out to the nozzle and causing ball B to seat preventing the material from returning to the pumping cylinder intake GENERAL INFORMATION An automatic centrifugal clutch is i...

Page 16: ...pring 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...

Page 17: ...MAYCO C30HDGA CONCRETE PUMP OPERATION MANUAL REV 1 09 09 19 PAGE 17 NOTES...

Page 18: ...PAGE 18 MAYCO C30HDGA CONCRETE PUMP OPERATION MANUAL REV 1 09 09 19 Figure 5 Pump Components 1 3 5 10 6 7 8 9 12 13 14 27 17 21 23 20 11 22 2 4 18 19 15 M A Y C 0 C 30HDGA 24 25 26 16 COMPONENTS PUMP...

Page 19: ...ds approximately 11 gallons 42 liters DO NOT top off fuel Wipe up any spilled fuel immediately 12 Tow End Jack Stand Use this jack stand to level and support the pump 13 Tow Hitch Coupler Requires a 2...

Page 20: ...p 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 st...

Page 21: ...he H marking on the dipstick NEVER run engine with low oil 6 Alternator Provides power to the electrical system Replace only with manufacturer s recommended type alternator 7 Oil Filter Replace this o...

Page 22: ...wn the engine before performing any kind of maintenance service on the pump INSPECTION FUEL CHECK 1 Remove the gasoline cap located on top of fuel tank 2 Handle Fuel in a safety container If the conta...

Page 23: ...r Lower SAE 10W 10 LUBRICATION BOX The C30HDGA features a fully enclosed lubrication box which utilizes the SPLASH method of lubrication Before using your new pump 7 gallons of SAE 30 motor oil must b...

Page 24: ...overheat WARNING If adding coolant antifreeze mix to the radiator DO NOT remove the radiator cap until the unit has completely cooled The possibility of hot coolant exists which can cause severe burn...

Page 25: ...mation General Information and Inspection sections have been read and understood NOTICE During pumping operations the engine speed should not be reduced below 1300 RPMs to prevent the clutch from dise...

Page 26: ...the blockage This rapid surge of material could cause the lines to whip or move in a manner that could cause injury to personnel Inspect the lines at all times to prevent the above conditions c It is...

Page 27: ...th a full hopper of concrete can cause severe damage or bending of the axle and axle springs excess strain and pressure on the hub and bearing assembly Concrete starts setting by drying up through a c...

Page 28: ...er pressure DANGER Due to pressure build up inside the manifold great care must be taken when clearing a plugged manifold at least 20 feet away from the pump and turn their heads away from the manifol...

Page 29: ...ecessary 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...

Page 30: ...used 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 af...

Page 31: ...easing will not damage pump NOTICE To avoid the possibility of separation during clean up do not pump the concrete below the inlet ball in the hopper It is best to leave approximately 3 to 4 inches of...

Page 32: ...must be checked daily to ensure adequate oil level and oil cleanliness CRANKSHAFTANDCAMASSEMBLYPROCEDURE 1 Set bearing block P N EM14303 into hydraulic press Place bearing cup into bearing block and...

Page 33: ...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 p...

Page 34: ...the crank disc as indicated the symbol See Figure 23 below 2 Install the bushing in the cam weldment and slide it onto the crankshaft until contact is made with the bearing spacer 3 Tighten the 3 alle...

Page 35: ...sliding laterally NOTICE The detent holes will prevent the bushing from sliding away from the bearing spacer when the pump is under load 3 If this procedure is not followed closely the heavy loading o...

Page 36: ...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 whi...

Page 37: ...in 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 chai...

Page 38: ...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 prov...

Page 39: ...e metal chips to break off from the chain or the tools used resulting in personal injury During all stages of chain disassembly and assembly wear safety glasses to prevent metal parts or chips from en...

Page 40: ...t been used for an extended amount of time have the bearings inspected and packed more frequently at least every six months and prior to use Follow the steps below to disassemble the wheel hub and ser...

Page 41: ...ure of the trailer structure and can cause serious injury or death DO NOT repair cracked or broken welds unless you have a certified welder perform the repair If not have the welds repaired by your de...

Page 42: ...imes the passing distance without the trailer Shift your automatic transmission into a lower gear for city driving ALWAYS use lower gears for climbing and descending grades DO NOT ride the brakes whil...

Page 43: ...information for the use of your trailer Again be sure your hitch and tow vehicle are rated for the Gross Vehicle Weight Rating of your trailer WARNING Driving too fast for severe road conditions can r...

Page 44: ...as the area to the rear of it WARNING Improper electrical connection between the tow vehicle and the trailer will result in inoperable lights and can lead to collision Before each tow check that the t...

Page 45: ...nded mirrors on a tow vehicle except while a trailer is actually being towed In this situation detachable extended mirrors are necessary Check with your dealer or the appropriate state agency for mirr...

Page 46: ...l is too small too large is underrated is loose or is worn the trailer can come loose from the tow vehicle and may cause death or serious injury THE TOW VEHICLE HITCH AND BALL MUST HAVE A RATED TOWING...

Page 47: ...y the hitch Raise the jackstand to a height where it will not interfere with the road 2 INCH TRAILER COUPLER 2 INCH BALL TOW VEHICLE If the coupler cannot be secured to the hitch ball do not tow the t...

Page 48: ...rable lights and electric brakes and can lead to collision Before each tow Check that the taillights brake lights and turn signals work Figure E Pintle Hitch Coupler A pintle hitch trailer may be fitt...

Page 49: ...t in death or serious injury Before coupling trailer inspect the pintle hitch hook for wear corrosion and cracks Replace worn or damaged pintle hitch hook CouplingTrailer toTow Vehicle Pintle Coupler...

Page 50: ...que wrench to tighten the lug nuts If you do not have a torque wrench use a lug wrench from your tow vehicle and tighten the nuts as much as you can Then have a service garage or trailer dealer tighte...

Page 51: ...law M S The M S or M S indicates that the tire has some mud and snow capability Most radial tires have these markings hence they have some mud and snow capability Speed Rating The speed rating denote...

Page 52: ...ormation indicates the maximum load and tire pressure when the tire is used as a single Load Range This information identifies the tire s load carrying capabilities and its inflation limits Tire Safet...

Page 53: ...e may cause pieces of the rim to explode break off with great force and cause serious eye or bodily injury Wheels Bearings and Lug Nuts Check wheel bearings jack trailer and check wheels for side to s...

Page 54: ...14 20 25 50 60 90 120 15 20 25 50 60 90 120 16 20 25 50 60 90 120 Lights and Signals Before each tow check the trailer taillights stoplights turn signals and any clearance lights for proper operation...

Page 55: ...MAYCO C30HDGA CONCRETE PUMP OPERATION MANUAL REV 1 09 09 19 PAGE 55 TRAILER GUIDELINES Figure J Trailer to Tow Vehicle Wiring Diagram...

Page 56: ...led Reduce oil level Normal slurry buildup increasing oil level Cleanout lubrication box Broken chain links Over stressed Remove delivery system blockage Adjust excessive chain slack deflection Chain...

Page 57: ...nut etc At low temperatures engine will not start Engine oil too thick Refill engine crankcase with correct type of oil for winter environment Defective battery Replace battery Engine fires but stops...

Page 58: ...1 Open hood and disconnect MAP sensor connector See Figure 33 Figure 33 MAP Sensor Connector 2 Close hood and start engine Let engine run for 3 to 5 minutes 3 Verify that check engine warning lamp on...

Page 59: ...3 separate bursts as shown below This sequence of lamp flashing represents the MIL flash error code Figure 39 See Table 7 for a complete listing of error codes In the MAP sensor example the error cod...

Page 60: ...ignal No Activity Yes 134 16 Front O2 sensor heater control fault Yes 135 17 Closed loop LPG A F is too lean Yes 151 18 Closed loop LPG A F is too rich Yes 152 19 Post Cat O2 Signal No Activity Yes 15...

Page 61: ...s 315 54 Knock Retard at Limit Yes 325 55 Knock1 2 excessive signa Yes 326 56 Knock1 2 sensor open Yes 327 57 CRANK Sync Loss Yes 335 58 CRANK signal noise Yes 336 59 No CRANK signal Yes 337 60 FPP1 l...

Page 62: ...LPG Adaptive learn A F is too lean Yes 161 95 LPG Adaptive learn A F is too rich Yes 162 96 NG Adaptive learn A F is too lean Yes 163 97 NG Adaptive learn A F is too rich Yes 164 98 EPR delivery press...

Page 63: ...9 AUX 5V ANALOG INPUT 5 open or high Yes 563 130 AUX 5V ANALOG INPUT 5 low Yes 564 131 Envirotech receipt lost No 1601 132 Watchdog processor blocked outputs RTI 1 Yes 712 133 Microprocessor failure R...

Page 64: ...er 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...

Page 65: ...MAYCO C30HDGA CONCRETE PUMP OPERATION MANUAL REV 1 09 09 19 PAGE 65 APPENDIX CONCRETE MIX INFORMATION A S T M STANDARD SPECIFICATION FOR GRADING AGGREGATE...

Page 66: ...the entire cross section of the layer Figure O Slump Test 2 3 Full 5 Fill cone to overflowing Figure P Rod this layer 25 times with rod penetrating into but not through the second layer Distribute ro...

Page 67: ...T 16 AWG BLK CHASSIS GND 25 AMP FUSE ALTERNATOR 12V DC BATTERY STARTER FUEL PUMP 16 AWG WHT GRN YEL 16 AWG 16 AWG BLU 16 AWG RED 10 AWG RED 16 AWG PNK 16 AWG PNK BLK BLK RED 16 AWG TAN BRN TAN BLK WIR...

Page 68: ...PAGE 68 MAYCO C30HDGA CONCRETE PUMP OPERATION MANUAL REV 1 09 09 19 ELECTRICAL COMPONENT LOCATOR CONTROL PANEL REAR VIEW PUMP HOOD NOT SHOWN FOR CLARITY B C D E F G H I A L M P Q...

Page 69: ...MAYCO C30HDGA CONCRETE PUMP OPERATION MANUAL REV 1 09 09 19 PAGE 69 ELECTRICAL COMPONENT LOCATOR K N O J...

Page 70: ...tered trademarks of Multiquip Inc and may not be used reproduced or altered without written permission All other trademarks are the property of their respective owners and used with permission This ma...

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