EZG 38 Special Pump User manual

38 Special Pump
Owner's Manual
HP38 Trailer Mounted
HP38SM Skid Mounted
HP38SS Skid Steer
Serial Number __________________
Before using this equipment,
study and understand entire
Owner’s Manual.
EZG Manufacturing
405 Watertown Road
Waterford, Ohio 45786
[phone] or 1-800-417-9272
Fax [phone] www.ezgmfg.com
38 Special Pump
EZG Manufacturing
1-800-417-9272

Introduction ................................................................................................................................................................3
General Information ..................................................................................................................................................4
About This Manual .....................................................................................................................................................4
Safety Information ......................................................................................................................................................4
Safety Precautions......... ............................................................................................................................................5
Proposition 65 Warning..............................................................................................................................................7
Controls & Switches ..................................................................................................................................................8
Towing.....................................................................................................................................................................10
Pre-Operation Checks..............................................................................................................................................11
Operations...............................................................................................................................................................20
Maintenance ............................................................................................................................................................21
Rotor and Stator Pump Adjustments .......................................................................................................................25
Warranty .................................................................................................................................................................27
Registration.............................................................................................................................................................28
Rotor-Stator Replacement......................................................................................................................................26
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Rev000 5/24/2022 2
TABLE OF CONTENTS

INTRODUCTIONINTRODUCTION
The 38 Special Pump is a self-contained, portable, robust machine built to deliver grout, mortar, or concrete on the job
site. The HP38SS model is ruggedly built and can be transported via skid steer. The HP38SS is powered utilizing the
skid steer hydraulics. The HP38SM is mounted on a sturdy frame complete with four outrigger legs and a 37HP
Kohler engine. Additionally, the HP38 is equipped with a hitch, a drop leg jack, safety chains, single axle and
protected rear lighting. The HP38SM and HP38 units are equipped with a rear-mounted tool box for storage of
clamps, tools, and clean out fittings.
On the HP38SM and HP38 models, a 37HP Kohler ECH980 gas engine powers the hydraulic pump, driving a single auger
for outstanding pumping capabilities. The 38 Special Pump handles up to 3/8-in. diameter aggregate, including pea
gravel, and is ideal for filling block walls. The hopper is equipped with a 3 inch pipe wing nut expanding plug to facilitate
quick and efficient cleanup.
The well-designed operator control panel includes pressure gauge, a control panel for speed adjustment and forward and
reverse operations, a switch for the optional vibrator motor (available option on HP38SM and HP38 only), and a tiny-tach.
The E-Stop is located on the face of the electrical box inside the enclosure and, the hopper grate has an safety switch
that shuts the machine down when the grate is lifted.
Before operating the 38 Special Pump, carefully read and understand the information contained in this manual. The
manual provides basic guidelines for operator safety, proper operation, and maintenance of the 38 Special Pump. To
prevent injury or death, conduct routine maintenance on the 38 Special Pump, do not operate outside
of recommended use, and always be aware of the surroundings. Store this manual in the manual canister, mounted on
the inside of the engine enclosure, for quick reference of operating, cleaning, and maintenance procedures.
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GENERAL INFORMATION
ABOUT THIS MANUAL
SAFETY INFORMATION
This symbol, either used alone or with a signal word, is used to call your attention
to instructions involving your safety and/or the safety of others. Failure to follow
these instructions will likely result in personal injury or death.
This signal word is used to identify a hazard which, if not avoided, will result in
death or serious injury.
This signal word is used to identify a hazard which, if not avoided, could result in
death or serious injury.
This signal word is used to identify a hazard which, if not avoided, could result in
minor or moderate injury.
This signal word is used to identify a hazard which, if not avoided, could result in
property or equipment damage. It also may be used for special instructions
related to performance, maintenance or general items.
Illustrations throughout this manual are representative and may show details or components that may not be
the same as your machine. Continuing machine design improvements may cause changes not included in this
manual. The information in this document is subject to change without any prior notice.
This manual is provided with the 38 Special Pump to inform the equipment owner/operator how to safely operate
the machine and become aware of hazards. It also contains important information regarding set up, operation,
maintenance, and repair procedures. It is the responsibility of the equipment owner/operator to make sure anyone
who operates this machine understands all safety warnings. If you do not understand any items in this manual,
please contact the dealer where this product was purchased or the manufacturer at the number listed throughout
this manual. If you have any suggestions about how to make this manual easier to understand, contact the
manufacturer. Keep this manual available for reference wherever this piece of equipment is being used and make
it available to any operators.
The following safety symbols and signal words will be used throughout this manual and on the product, for your
safety and the safety of others, please become familiar with their meaning and heed their warnings.
To prevent serious injury or death, thoroughly read and understand all aspects of this manual. Ensure safety
practices discussed in this chapter are put into practice when operating the 38 Special Pump. This chapter is
NOT all-inclusive. It is the responsibility of each operator to abide by all other safety precautions implemented
by the company, owner of the equipment, state, federal and local government.
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NOTICE
CAUTION
WARNING
DANGER

SAFETY PRECAUTIONS
Required Personal Protective Equipment (PPE)
The use of PPE is critical to safe operation and well-being of the operator. The following PPE and
information (this list is not all-inclusive) should be used in the safe operation of the 38 Special Pump:
• Jewelry removed (especially necklaces and rings)
• Long hair tied back
• Close-fitting work clothes that do not hinder movement
• Safety glasses with side shields, or goggles
• Hearing protection
• Safety-toed footwear
• Occupational Safety and Health Administration (OSHA)-approved hard hats
• National Institute for Occupational Safety and Health (NIOSH)-approved ventilation masks when dust is
present
• Protective gloves
• Rubber boots and rubber gloves when performing clean out procedures
General
•Make sure anyone operating the 38 Special Skid Steer, Skid Mounted, or Trailer Pump is thoroughly familiar
and understand its operation. Keep all unauthorized and untrained personnel, especially children, away from
the machine.
•For your safety and the safety of others, replace any missing or damaged warning decals by contacting the
manufacturer at 1-800-417-9272.
•Never operate machine with the safety grate, guards, or safety devices removed or open. Do not alter any
safety guards.
•Be sure any clothing you wear does not have strings, fringes, or other external tightening means that could
be caught in moving parts.
•Keep all body parts, clothing, jewelry, and solid objects away from all moving parts.
•Never perform any work on the machine while it is running. Before working on or cleaning the unit, turn the
ignition key off and disconnect the negative battery cable.
•Never operate the machine when under the influence of alcohol, drugs, or medications.
•Do not use the 38 Special concrete pump for anything other than its designed purpose of masonry grout,
SCC( Self-Consolidating Concrete), small diameter (up to 3/8-in.) media (pea gravel), shotcrete, slurry, and
light-wweight concrete.
•Mixes with crushed aggregate are not recommended and may cause material separation.
•Stay clear of moving parts while the machine is in operation.
•Operate machine only in a properly vented environment.
•Wear a mask and avoid breathing dust produced while using the machine. Dust may contain crystalline silica
and may cause serious health problems.
•Always know the location of nearest fire extinguishers, first aid kit, and phone with first-responder contact
numbers in case of emergency.
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Towing
• Ensure the outrigger legs are pinned and locked in the stowage position before traveling. If the locking device
is damaged or worn, it should be repaired immediately and the unit must not be driven until the outrigger legs
can be positively locked.
• The 38 Special Pump is supplied with a 2-5/16" ball hitch connection. Verify correct hitch before connecting to
the HP38.
• Safety chains must be used with HP38 when unit is in tow.
• Insure tow vehicle and hitch have a rated GCWR, GTW, and tongue weight capacity to handle HP38.
• Alway chock wheels of HP38 when not coupled to a tow vehicle.
Model Empty Weight Tongue Weight
HP38SS
Model Tire Size Tire Pressure
HP38 ST225/75R15 65 psi (245 kPa)
SAFETY PRECAUTIONS
Model Empty Weight Tongue Weight
HP38SM N/A
Model Empty Weight Tongue Weight
HP38 2234 lbs. (1013 kg) 237 lbs. (107.5 kg)
N/A
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• Before operation, inspect all hoses, fasteners, bolts, and welds for nicks, cracks, cuts, damage, wear, or
looseness before each use. Repair as needed.
• Always wear approved PPE, including glasses, hearing protection, hard hats, and ventilation masks when
operating the machine.
• Avoid contact with hot hydraulic oil.
• Allow system to cool before performing any repairs or service, such as adding fuel, oil, or coolant.
• Use only factory authorized parts.
• Used lubricants such as engine oil, hydraulic oil, and hazardous waste must be taken to an authorized
disposal or recycling center.
• The 38 Special Pump must be stable before operating the machine. Level the machine if placed on a slope
or uneven terrain. Failure to comply may result in personal injury or equipment damage.
California - Proposition 65 Warning
Engine exhaust and some of its constituents, and some dust created by power sanding,
sawing, grinding, drilling, and other construction activities contains chemicals known to the
State of California to cause cancer, birth defects and other reproductive harm. Some examples of these
chemicals are:
Lead from lead based paints - Crystalline silica from bricks -Cement and other masonry products -Arsenic and
chromium from chemically treated lumber
Your risk from these exposures varies, depending on how often you do this type of work. To
reduce your exposure to these chemicals: ALWAYS work in a well ventilated area, and work
with approved safety equipment, such as dust masks that are specially designed to filter out microscopic
particles.
SAFETY PRECAUTIONS
Hydraulic System
• The hydraulic system is under pressure and oil may be hot.
• Always allow the machine to cool completely before performing service.
• Always relieve pressure in the hydraulic system before performing service.
• Always use appropriate safety equipment and clothing to protect exposed skin and eyes from high pressure
oil.
• Tighten all connections to proper specifications before applying pressure.
• Never use bare hands to check for leaks. Oil under pressure can penetrate the skin, and can cause
gangrene within a few hours if not properly removed. Use a piece of cardboard to check for leaks.
•Inspect all hoses and fittings for signs of damage, wear scrapes, kinks, or cracking. Replace hoses if any of
these conditions are found. It is recommended to replace all hydraulic hoses every 5 years.
Electrical System
• Always disconnect the negative (-) before servicing, removing, or installing electrical components.
• Always disconnect the negative terminal first and positive terminal last. Connect positive
terminal first and negative terminal last. Use care when dealing with live circuits to prevent
arcing. Arcing may result in death or serious injury.
• Use care to prevent arcing when working on live circuits or components. Arcing can cause component
damage and may ignite flammable materials.
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Pump Control Panel
“Forward” is a maintained switch that will run the rotor / stator pump in the pumping direction, the
indicator light will illuminate during operation.
“Reverse” is a spring return position and will allow the pump to reverse whilst the switch is operated. The
indicator will illuminate during operation.
The graduated rotary knob controls the speed at which the pump rotates during operation and can be
adjusted during operation.
System pressure gauge, reading pressure of the motor system during rotation.
The picture below shows the vibrator motor option. The vibrator switch is located on the fuel tank
side of the engine enclosure and operates the vibrator motor mounted on the hinged grate on top of
the pumping hopper. This is used to assist grading the material through the grate. Do not operate with
engine stopped. Operating the vibrator motor with the engine off will deplete the battery.
CONTROLS AND SWITCHES
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Engine Ignition switch and starter switch
In the “RUN” position the ignition is “ON” and the engine ready to run. In the “RUN” position all other
switches become operable and the hydraulic cooling fan will operate (not independently switched). Do not
leave the switch in the “RUN” position with the engine stopped.
The “START” position is a spring return position. When twisted clockwise it will engage the engine starter.
When released it will disengage.
NOTE: The engine has power generation abilities to cover the operation of both the cooling fan and
vibrator while running. When not running the battery will drain rapidly. It is strongly advised that all
switches be turned OFF when the engine is not running.
Engine Choke lever
Move the lever to the right to operate the choke “ON”, left to turn “OFF”
Engine Throttle lever
To increase engine speed slide the lever to the left. To decrease slide the lever to the right.
CONTROLS AND SWITCHES
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Trailer checks
The unit is a highway registered, tow-able machine. It is fitted with DOT approved tires, lights, and
2-5/16” ball coupling hitch.
Ensure ALL parts of the pump and trailer are secured. ALL lids secured. ALL tools, hoses etc. either
stowed or secured. Check the correct operation of all lighting.
The single axle is rated @ 3500 LB and does not have brakes. The electrical connections to the tow
vehicle are via a standard 4-Pin type connector plug.
The 2-5/16” channel style coupler is bolted to the tongue assembly and must be pinned closed when
coupled to the tow vehicle. The hitch can be raised and lowered to suit tow ball height using the different
hole positions provide in the tongue assembly.
It is suggested that the unit be placed as close as is practicably possible to the discharge location so that
excessive pumping distances can be avoided, helping to minimize the burden on the machine.
The unit should be leveled using the tongue jack prior to operation of the engine. A slight rise from tongue
to pump is acceptable to help with draining the hopper.
TOWING
4-Pin connector
Channel Style
Coupler
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Drive system
Engine exhaust and ventilation
The engine fan cowl and the heat exchanger opening must be free of ALL obstructions. The fans must be
free to rotate and draw air at all times to ensure that the motor and hydraulic fluid are correctly cooled.
Pay attention to the engine exhaust flow toward the right side of the engine enclosure as it will be hot
and contain exhaust fumes.
Prior to operation ALL fluid levels should be checked and be in good order.
PRE-OPERATION CHECKS
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Engine oil level
Check using the dip stick situated at the rear of the engine (looking from the operator controls). Filling is
carried out through the filler cap.
Hydraulic fluid
Hydraulic oil level is checked though the sight tube from the outside of the machine.
Filling access is on top of the enclosure located to the rear of the left side
DAILY PRE-OPERATION CHECKS
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Hydraulic fluid filling via the filling cap with built in strainer (shown with enclosure top removed).
Fuel level
Fuel level is checked by visually inspecting the tank via the filler opening.
Warning - Do not drain fuel system completely of fuel.
Danger – Do not fill while the engine is running.
Danger – Do not fill while the engine is hot.
DAILY PRE-OPERATION CHECKS
View shown with 8 gallon tank. 16 gallon tank available.
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Battery
Check all battery connections for security and being free of corrosion.
Cooling fan
The cooling fan operates whenever the unit is operational. Due to the low volume of hydraulic oil in the
system correct operation of the fan is critical. Ensure that the vent and the fan are clear of all obstructions.
The cooling fan exhaust is diverted through the top of the enclosure via a heat shroud.
DAILY PRE-OPERATION CHECKS
Keep this area clear of dirt and debris. Heat Shield
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Pumping unit
Ensure that the pumping unit is correctly secured to the front of the material hopper and all nuts tight and
secure.
Pay attention to the clamp nuts installed either side of the stator unit. Make sure they are tightened and
pinned securely.
NOTICE! Never run rotor stator dry.
Check that the drive shaft is correctly engaged into the UJ and that the socket is engaged over the head of
the rotor.
Check that the fasteners that hold the hydraulic motor to its mounting plate and the plate to the
hopper are secure.
PRE-OPERATION CHECKS
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Check that the vibrator grate is in the lowered position, resting on its rubber “bumper” feet.
Rubber / Poly bumper shown.
Ensure that ALL fasteners are present, in good condition and tightened securely prior to any operation.
DAILY PRE-OPERATION CHECKS
Shown with optional vibrator motor.
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The pre-start pressure test check is a crucial part of pre-operation checks and must be
performed daily before pump operations can begin. This test is to ensure the correct operation
of the rotor-stator and to prevent unnecessary wear on the rotor-stator.
Daily Pre-operation Pressure Test
x Start the engine and let idle.
x Securely install the pressure test rig on the output flange.
x Shut the ball valve on the pressure test rig.
x Fill the hopper to a water level that is approximately 1" above the inner outlet opening. Add
approximately 1 tablespoon of a mild dish soap for every gallon of water. This provides a level of
lubrication for the dry rotor and stator making it easier to break free without damage.
x Slowly adjust the throttle lever increasing the engine revs to maximum.
x Set the speed control on the pump control panel to approx. 50%, then push the toggle switch to
the “FWD” position and observe the auger rotating inside the hopper in the forward direction.
The forward direction can be verified by briefly and quickly opening and closing the ball valve on
the pressure test rig to ensure water from the hopper is being pumped out of the unit.
x With the ball valve closed observe the psi indicated on the pressure test rig gauge. 150 psi is
the recommended operating range. If the indicated psi is below 150 then adjustments to the
stator housing clamp is necessary.
Stator Housing Clamp Adjustment
Step 1: Remove stator cover.
Step 2: With the engine running as described in the previous section loosen the bolts
indicated by the number 3. Start at one end and tighten the adjusting bolts as
indicated by the number 1 in the picture below. Tighten stator housing bolts evenly
to adjust the pressure on the pressure test rig. 1/4 to 1/2 turn each at a time is a
good place to start.
Step 3: Observe the pressure on the gauge. If psi is below 150 then repeat step 1.
NOTE: Nuts and bolts adjusted during step 1 may become loose as the they are tightened
along the length of the stator housing clamp. These need to be re-tightened (snug)
before repeating step 1.
Step 4: Once 150 psi is observed, tighten the bolts indicated by the number 2 in the picture below. These bolts
should be made snug before tightening to match step 1.
Step 5: Tighten the bolts as indicated by the number 3 in the picture below. These are set bolts and
should be tightened slightly pass snug. This will prevent the stator housing clamp from
changing without adding additional pressure.
Do not overtighten adjustment bolts. If the engine is noticed “bogging down” during the
adjustment procedure, then the rotor-stator is becoming too tight to operate efficiently. If bogging
down is noticed during the adjustment procedure or 150 psi cannot be achieved the rotor-stator
needs to be replaced.
3 3 3
1 1 2121 1 1
DAILY PRE-OPERATION CHECKS
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!! IMPORTANT PROCEDURE !!

Shut Down
Step 1: Turn off pump and reduce engine RPM to idle for 3-5 minutes.
Step 2: Turn off engine.
Step 3: Open ball valve on test rig to drain. Remove expansion plug to drain hopper.
Step 4: Remove test rig from outlet.
Step 5: Replace expansion plug in hopper.
DAILY PRE-OPERATION CHECKS
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Section 4 – Machine operation
Ensure that the unit is clear of bystanders and other possible hazards before starting.
Startup
Place the engine choke lever in the “ON” position.
Choke is not required for a warm engine.
Note - slide lever to the right to operate or close the choke. Slide to the left to stop or open the choke.
Throttle / accelerator lever Ignition / starting key
•Slide the throttle lever to the right to the slowest position. Start the engine using the ignition starter
key. Once running, progressively open the choke lever by sliding to the left until the engine runs
without hesitation. Let the engine warm up for a few minutes.
•For troubleshooting the engine start up, refer to the engine user manual supplied.
Shut Down
When shutting down, move the switch on the pump control panel to the middle “off” position then
slow the engine to idle using the throttle lever sliding to the right. Leave the engine idle for a few
minutes prior to turning off using the ignition key set to the “off” position.
OPERATIONS
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The vibrator grate / safety cover is used to both protect the operator and to assist in the grading of the
material passing into the pumping hopper. The grate will prevent items larger in size than the rotor / stator
can process. The vibrator grate must be in the lowered position during operation.
The vibrator grate hinges upwards and swings past vertical to allow for unobstructed access to the hopper.
OPERATIONS
Shown with optional vibrator motor.
•If access is required into the hopper, then turn off the engine before lifting the grate. Pump can be
disassembled by removing the clamping nuts facilitating easier clean up.
•The 38 Special Pump is supplied with an adjustable stator. The sleeve can be tightened to bring
working pressure back to normal range as the stator wears. This should be done evenly along the
length and in small increments. Over-tightening the stator will cause premature wear and heat up
material.
•Always check hoses and cords for wear.
•The unit runs at high pressures and temperatures. Use caution when moving or touching parts of
the unit.
•Check the condition of the Universal joint seal tube. Look for signs of wear or cuts on the tube.
•Check that all fasteners are all secure.
•Grease drive shaft seal daily with water resistant, corrosion inhibited grease via the grease fitting /
Zerk in the motor flange.
•For starting the pump, ensure that the throttle is at maximum and direction control is set to
“FWD”.
•Do not let hopper run dry while pump is running.
•To stop machine Move the Pump Control Panel switch to the center position.
•If a hose becomes plugged while pumping, stop the machine, then reverse the driveshaft direction
on pump to relieve line pressure using the Pump Control Panel switch set to “REV”.
•Never point a hose towards personnel when pump is working.
•When cleaning the pump, do not remove the safety grate while pump is running. Wash out hopper
with water and let it run out of the hose. When the hopper is clean, run foam balls through hose
with clean water. Then wipe down with a damp rag.
•Hopper draining can be assisted by the removal of the drain plug from the lower section of the
hopper.
General notes for operation
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