MQ Multiquip MAYCO C-30HDNI User manual

PARTS AND OPERATION MANUAL
Concrete Pump
Model C-30HDNI
(FUEL INJECTION)
Revision #0 (05/15/03)
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PAGE 2 — MAYCO C-30HDNI PUMP — OPERATION AND PARTS MANUAL — REV. #0 (05/15/03)
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PAGE 4 — MAYCO C-30HDNI PUMP — OPERATION AND PARTS MANUAL — REV. #0 (05/15/03)
Proposition 65 Warning ...........................................2
Here's how to get help ............................................3
Table of contents..................................................... 4
Parts ordering procedures ......................................5
MQ-MAYCO C-30HDNI
CONCRETE PUMP
Pump Specifications................................................. 6
Engine Specifications............................................... 7
Pump Dimensions .................................................... 8
Safety Message Alert Symbols .........................10-11
Rules For Safe Operation .................................12-13
Operation And Safety Decals ................................. 14
Important Hand Signals ......................................... 15
Pump Components ...........................................16-17
Control Box Components ....................................... 18
Engine Components .............................................. 19
General Information ............................................... 20
How ItWorks .....................................................21-22
Operating Information .......................................23-27
Inspection..........................................................28-30
Initial Start-Up ........................................................ 31
Towing Guidelines .............................................32-33
Trailer Safety Guidelines ...................................34-36
Maintenance (Pump) ........................................37-45
Engine Troubleshooting.....................................46-47
Malfunction Indicator Diagnostic Error Codes ......48-51
Component Location (EFI Wiring Harness) ........... 52
Wiring Diagram (EFI Wiring Harness)....................53
Wiring Diagram ......................................................54
Wiring Diagram (Trailer Lights) .............................. 55
Concrete Mix Information..................................57-59
Recommended Shotcrete System ....................60-61
Recommended Shotcrete Accessories.............62-63
Slump Test Procedure ............................................ 64
Explanation Of codes In Remarks Column............ 66
Suggested Spare Parts.......................................... 67
TABLE OF CONTENTS
Specification and part
numberaresubjectto change
without notice.
NOTE
PARTS ILLUSTRATIONS
Nameplate and Decals......................................68-69
Compensator Piston Rod Assy. (Compensator)70-71
Compensator Piston Rod Assy. (Primary).........72-73
Rocker Assy.......................................................74-75
Countershaft Assy. ............................................76-77
Crankshaft Assy. ...............................................78-79
Manifold Assy.....................................................80-81
Frame Assy........................................................82-83
AxleAssy. ..........................................................84-85
Muffler, Air filter And Stop Switch Assy..............86-87
Clutch Assy .......................................................88-89
Radiator And Engine Mounting Bracket Assy. ..90-91
Radiator, Mounting And Hoses Assy. ................92-93
Control Box Mounting Bracket Assy. .................94-95
Control Box Assy. ..............................................96-97
Battery Assy. .....................................................98-99
FuelTank Assy. .............................................100-101
Hopper Assy..................................................102-103
Hood Assy. ....................................................104-105
Lubrication Panel Assy. .................................106-107
Control Cable Assy........................................108-109
EFI Gasoline Fuel System ............................110-111
PARTS ILLUSTRATIONS (NISSAN ENGINE)
Cylinder Block And Oil Pan Assy. ..................112-113
Cylinder Head And Valve Cover Assy............114-115
Crankcase Ventilation Assy. ..........................116-117
Piston, Crankshaft And Flywheel Assy. .........118-119
Camshaft And Valve Mechanism Assy. .........120-121
Manifold Assy.................................................122-123
Oil Pump Assy. ..............................................124-125
Exhaust Tube and Muffler Assy. ....................126-127
Water Pump Assy. .........................................128-129
Ignition System Assy. ....................................130-131
Distributor Assy. ............................................132-133
Alternator Assy. .............................................134-135
Terms and Conditions Of Sale — Parts ...............136
Mayco Pump Warranty ......................................... 137
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PAGE 6 — MAYCO C-30HDNI PUMP — OPERATION AND PARTS MANUAL — REV. #0 (05/15/03)
C-30HDNI PUMP — PUMP SPECIFICATIONS
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MAYCO C-30HDNI PUMP — OPERATION AND PARTS MANUAL — REV. #0 (05/15/03) — PAGE 7
C-30HDNI PUMP — ENGINE SPECIFICATIONS
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PAGE 8 — MAYCO C-30HDNI PUMP — OPERATION AND PARTS MANUAL — REV. #0 (05/15/03)
C-30HDNI PUMP — PUMP DIMENSIONS
Figure 3. C-30HDNI Concrete Pump Dimensions
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PAGE 10 — MAYCO C-30HDNI PUMP — OPERATION AND PARTS MANUAL — REV. #0 (05/15/03)
C-30HDNI PUMP — SAFETY MESSAGE ALERT SYMBOLS
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.
FORYOUR SAFETY ANDTHE SAFETY OF OTHERS!
This Owner's Manual has been
developed to provide complete
instructionsforthesafeand efficient
operation of the Multiquip
Model C-30HDNI Concrete Pump.
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.
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
theoperator, andareprecededbyoneofthree words: DANGER,
WARNING, or CAUTION.
DANGER: You WILL be KILLED or
SERIOUSLY injured if you do not follow
directions.
WARNING: You CAN be KILLED or
SERIOUSLY injured if you do not follow
directions.
CAUTION: You CAN be injured if you
do not follow directions.
HAZARD SYMBOLS
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 structure that does not
provide ample free flow air.
Potential hazards associated with this concrete pump operation
will be referenced with Hazard Symbols which appear
throughout this manual, and will be referenced in conjunction
with Safety Message Alert Symbols.
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.
Explosive Fuel
Lethal Exhaust Gases
Burn Hazards
Enginecomponents cangenerateextreme heat.
To prevent burns, DO NOT touch these areas
while the engine is running or immediately after
operations. Neveroperatetheenginewithheat
shields or heat guards removed.
Rotating Parts
NEVER operate equipment with covers, or
guards removed. Keep fingers, hands, hair and
clothing away from all moving parts to prevent
injury.
NOTE
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MAYCO C-30HDNI PUMP — OPERATION AND PARTS MANUAL — REV. #0 (05/15/03) — PAGE 11
Accidental Starting
C-30HDNI PUMP — SAFETY MESSAGE ALERT SYMBOLS
ALWAYS place the engine ON/OFF switch in
the OFF position, and remove the ignition key
when the pump is not in use.
Respiratory Hazard
ALWAYS wear approved respiratory
protection.
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.
ALWAYS wear approved eye and hearing
protection.
Sight and Hearing hazard
This concrete pump, other property,
or the surrounding environment
could be damaged if you do not
follow instructions.
NOTE
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PAGE 12 — MAYCO C-30HDNI PUMP — OPERATION AND PARTS MANUAL — REV. #0 (05/15/03)
C-30HDNI PUMP — RULES FOR SAFE OPERATION
■ ALWAYS refuelina well-ventilated area, away fromsparks
andopenflames.
■ ALWAYS useextremecautionwhenworkingwithflammable
liquids.Whenrefueling,stop theengineandallowittocool.
DO NOT smoke around or near the machine. Fire or
explosioncouldresultfromfuelvapors,oriffuelisspilledon
ahot engine.
■ NEVERoperatetheconcretepumpin
an explosive atmosphere or near
combustiblematerials.Anexplosionor
firecould result causingsevere
bodily
harmor even death.
■ Topping-off to filler portisdangerous,asittendstospillfuel.
■ ALWAYS stored the pump in a clean, dry location out of the
reach of children.
■ NEVER Run engine without air cleaner. Severe engine
damage may occur.
■ NEVER leave the pump unattended, turn off engine.
■ CAUTION must always be observed while servicing this
pump. Rotating parts can cause injury if contacted.
■ DO NOT leave pump with engine running. Use chock blocks
if parking pump on a grade.
■ NEVERtouchthehotexhaustmanifold,
mufflerorcylinder.Allowthesepartsto
coolbeforeservicingengineorpump.
■ The engine of this pump
requiresanadequatefree
flowofcoolingair. NEVER
operate the pump in any
enclosed or narrow area
where free flow of the air
isrestricted.Iftheairflow
is restricted it will cause
serious damage to the
pumporengineandmaycauseinjurytopeopleandproperty.
Rememberthe pump's enginegivesoffDEADLY gases.
■ HighTemperatures – Allowtheenginetocoolbeforeadding
fuelorperformingserviceandmaintenancefunctions.Contact
with
hot componentscan cause serious burns.
CAUTION:Failure to follow instructions in this manual
maylead to seriousinjury or evendeath!This
equipment is to be operated by trained and
qualified personnel only! This equipment is
forindustrialuse only.
The following safety guidelines should always be used when
operatingthe MAYCOC-30HDNIConcrete Pump:
GENERAL SAFETY
■ DO NOT operate or service this equipment before
readingthisentiremanual.
■ This equipment should not be operated by
personsunder 18 years ofage.
■ NEVER operate this equipment without proper
protectiveclothing, shatterproof glasses,steel-
toedbootsandother protectivedevicesrequired
by the job. ALWAYS wear slip resistant safety
shoesorboots.
■ NEVERoperatethisequipmentwhennotfeeling
wellduetofatigue, illness or takingmedicine.
■ NEVER operate this equipment under the
influenceor drugs oralcohol.
■ NEVER use accessories or attachments, which are not
recommended by Multiquip for this equipment. Damage to
theequipmentand/or injury to usermayresult.
■ Manufacturedoesnotassumeresponsibilityforanyaccident
duetoequipment modifications.
■ Whenever necessary, replace nameplate, operation and
safetydecalswhentheybecomedifficultread.
■ ALWAYS wear proper respiratory (mask), hearing and eye
protectionequipmentwhen operating the pump.
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MAYCO C-30HDNI PUMP — OPERATION AND PARTS MANUAL — REV. #0 (05/15/03) — PAGE 13
C-30HDNI PUMP — RULES FOR SAFE OPERATION
■ ALWAYS useextremecarewhenoperatingnearobstructions,
onslippery surfaces, grades andsideslopes.
■ Unauthorized equipment modifications will void all
warranties.
■ Refer to the Engine Owner's Manual for engine technical
questions or information.
■ Beforestart-up,checkthehopperandremoveallobstructions.
■ Keepallhandsout ofthehopperwhentheengine isrunning.
■ DO NOT operate the pump with the hood open.
■ Replace any worn or damaged pump components
immediately.
■ ALWAYS turn the engine OFF before performing must be
beforeperformingmaintenance.
■ ALWAYS make sure pump is correctly secured to the
trailer.Check all supports attaching the pump to the trailer
andmakesuretheyaretight.
■ ALWAYSmakesure that the pump's trailerisplacedonsolid
level ground so that it cannot slide or shift around,
endangeringworkers.Placeblocksunderthetrailer'sbumper
tomake it level (preventstipping),and use a chockedblock
underneath the wheels to prevent rolling. Also keep the
immediateareafreeofbystanders.
■ Beforetowing,check thehitchandsecurethesafety chainto
thetowingvehicle.Also check for proper tirepressure.
■ Tow only with a vehicle and hitch rated to tow a 2,950 lbs.
(1,338Kg)load.
■ If pump is equipped with ball hitch coupler, use only a 2”all
steelballrated foraminimumof5000 lbs.Usea1”hardened
steel pull pin, if the pump is equipped with a pin hitch.
■ ALWAYS check the machine for loosened threads or bolts
beforestarting.
■ 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
■ Acopyof thismanualshallaccompanythepumpatalltimes.
■ DO NOT use worn out hoses or couplings;inspect daily.
■ DONOTdisconnectthehosecouplingsornozzlewhilethey
are under pressure. Relieve the pressure by manually
swingingtheclamparmlatchhandleto thefirstopenposition
attheexhaustcone outlet.
■ ThepumpshouldNEVERbe towed in excessof45MPH(or
lessdepending on roadconditions).
■ If hose lines are blocked for any reason, or if the lines are
kinked whenstartinguporduring pumping cycle, the pump
pressure could straighten out the kink or force out the
blockage.Thisrapid surge ofmaterial could cause thelines
to
move or whip in a manner that could cause injury to
personnel.
■ Inspectthe hose lines atalltimes
■ DO NOT tow the pump with thehopper full of material.
■ DO NOT towthe pump with thehosesattached.
■ High Temperatures – Always stop engine and allow the
engine to cool before adding fuel, oil or performing service
and maintenance functions. Contact with
hot components
cancauseserious burns.
■ NEVER disconnect any "emergency or safety devices" .
Thesedevices are intendedfor operatorsafety.Disconnection
of these devices can cause severe injury, bodily harm or
even death! Disconnection of any of these devices will void
all warranties.
Emergencies
■ ALWAYSknowthelocationofthenearest fire extinguisher
and firstaidkit .Know thelocationofthenearesttelephone.
Also know the phone numbers of the nearest
ambulance ,
doctor and fire department . This information will be
invaluable in the case of an emergency.
Maintenance Safety
■ NEVER lubricate components or attempt service on a
runningmachine.
■ ALWAYS allow the machine a proper amount of time to
coolbeforeservicing.
■ Keepthe machinery inproperrunning condition.
■ Fixdamagetothemachineimmediatelyandalwaysreplace
brokenparts.
■ Dispose of hazardous waste properly. Examples of
potentially hazardous waste are used motor oil, fuel and
fuelfilters.
■ DO NOT use food or plastic containers to dispose of
hazardouswaste.
■ DO NOT pour waste, oil or fuel directly onto the ground,
downa drain orinto any watersource.
Lifting
■ Thepumphas an operating weightofapproximately2,950
lbs.(1,338 Kg). Use liftingequipment capable of liftingthis
weight.
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PAGE 14 — MAYCO C-30HDNI PUMP — OPERATION AND PARTS MANUAL — REV. #0 (05/15/03)
Figure 1. Operation and Safety Decals
C-30HDNI PUMP — OPERATION AND SAFETY DECALS
Figure 1 display's the operation and safety decals as they appear on the concrete pump, should any of these decals become
da magedorunreadable,contactDiscount-Equipment forareplacementset.
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MAYCO C-30HDNI PUMP — OPERATION AND PARTS MANUAL — REV. #0 (05/15/03) — PAGE 15
C-30HDNI PUMP — IMPORTANT HAND SIGNALS
Figure 2. Operation Hand Signals
Figure2 display's thebasichand signals commonlyused in concrete pumpingoperations.
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PAGE 16 — MAYCO C-30HDNI PUMP — OPERATION AND PARTS MANUAL — REV. #0 (05/15/03)
C-30HDNI PUMP — PUMP COMPONENTS
Figure 4. Major Pump Components
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MAYCO C-30HDNI PUMP — OPERATION AND PARTS MANUAL — REV. #0 (05/15/03) — PAGE 17
C-30HDNI PUMP — PUMP COMPONENTS
Figure 4 illustrates the location of the major components
for the C-30HDNI 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" reducertoelbow.
2. Discharge Cone Safety Latch – When towing of the
pumpisrequired,
ALWAYS securethedischargeconeto
latchlocatedonthe manifold.
3. Rear Running Lights – ALWAYS check and make sure
both the right and left running lights are functioning
correctlybeforetowingthepump.
4. Hopper – Concrete from a Redi-Mix truck is poured into
this hopper.The hopper can hold 6.0 cu. ft of concrete.
NEVER puthandsor any other partsofyoubodyinto the
hopper.
5. Safety Grill –Thesafetygrillshouldbelockedatalltimes
when the pump is being towed. Under normal working
conditions,raise and place thesafety grill on thesupport
hookswhich are located onsplashguard.
6. Shaft PulleyV-Belt –
ALWAYS inspectthe driveshaft
V-belt for wear and alignment. A defective or misaligned
V-belt can wear prematurely and adversely affect the
performanceofthepump.Replacewithonlymanufactures
recommendedtypeV-belt.
7. Distributor–
NEVER allowconcrete,wateroranyforeign
debristo come in contactwiththedistributor.
8. Compartment Hood –
NEVER operate the pump with
thehoodremoved. Installedonthepumpframe isasafety
inter-lockdevicewhich prevents the enginefromstarting
if the hood is removed or in the up position (open).
9. Hood Fastener – Whenthe hood is in the down position,
securetherubberlatchto this fastener.
10. Hood Lift Handle – Grip this handle, pull upward then
backtoraisethecompartment hood.
11. Control Box – Contains the mechanical and electrical
components required to run the pump. Below is a list of
thosecomponents:
■ ThrottleControl
■ LowOil Pressure Indicator
■ BatteryChargeIndicator
■ WaterTemperature Indicator
■ IgnitionSwitch
■ RemoteConnector
12. Radiator/Cap – Fillwitha water/anti-freeze type solution
as recommended in the maintenance section of this
manual.
ALWAYS make sure that the radiator is filled to
theproper operating level before startingtheengine.
13. FuelTank/Cap – Fill with unleaded fuel.Fuel tank (cell)
holds approximately 11 gallons (42 liters). DO NOT top
offfuel. Wipe up anyspilled fuel immediately
14. Tow End Jack Stand – Use this jack stand to level
and support the pump.
15. Tow Hitch Coupler – Requires a 2-inch ball hitch or a
3-inch pintle. Capable of towing 5,000 lbs. (
16. Safety Chain – ALWAYS attach safety chain to the
towing vehicle. NEVER! tow the pump with the safety
chain unattached.
17. Engine Stop Device–Thisdevicewillpreventthestarting
of the engine when the compartment hood is in the
up
position. The compartment hood must be in the down
positionin order for theengineto start.
18. Grease Port Console–Thisconsoleallowsfortheremote
lubricationofcomponents on the pump.
19. Access Door –There arefouraccessdoorsonthe pump.
Remove these door to gain access to drive and piston
assemblieswhenmaintenance is required.
20. Drive Chain – Keep this chain properly lubricated and
alignedatalltimes. Lubricatethischainasspecifiedinthe
maintenancesectionofthis maintenance.
21. Rubber Latch – Secure this rubber latch to the hood
fastenerwhenever the pumpisin use orbeingtowed.
22. Tires Ply–Thetire ply (layers) numberisrated in letters;
Thistrailer uses 4-ply tires.
23. Chock Blocks – Place these blocks (not included as
part of your concrete pump package) under each trailer
wheel to prevent rolling.
24. Pump End Jack Stand – Use this jack stand to level
and support the pump.
25. Discharge Cone Release Lever – secures the
discharge cone to the "Y" manifold; also relieves
manifold pressure.
26. Documentation Box – Contains engine and pump
operation, parts and maintenance information.
27. 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.
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PAGE 18 — MAYCO C-30HDNI PUMP — OPERATION AND PARTS MANUAL — REV. #0 (05/15/03)
C-30HDNI PUMP — CONTROL BOX COMPONENTS
Figure 5. Pump Control Box Components
1. Throttle Control Knob – This is a variable speed type
control.Turningthecontrolknob
clockwise increasesthe
enginespeed.ToplacetheengineatIDLEspeed, turnthe
controlknob fully
counter-clockwise and let the engine
runfor3-5minutes.
2. Trouble Indicator LED– Thisisadiagnosticfeatureonthe
C-30HDNI to assist the operator with identifying problems
thatoccurwiththefuelinjectionsystem(SeeTable7).
3. Oil Pressure Indicator Lamp – In the event of low oil in
the engine crankcase or low oil pressure, the oil "
Oil
Pressure Lamp
" indicator will be lit. STOP the engine
immediatelyifthis lampislit.
NEVER runtheengine when
thislamp is on.
4. Battery Charge Indicator Lamp – Indicates if the
electrical system is charging properly. If the "
Battery
Charge
Indicator Lamp " is lit, this is an indication that
thecharging system ismalfunctioning.
STOP the engine
andremedy the electrical chargingproblem.
Figure 5 illustrates the location of the major
components for the C-30HDNI Control Box.The
function of each component is described below:
5. WaterTemperature Lamp – In the event of high engine
water temperature (220 degrees Fahrenheit), this lamp
willbelit.
STOP theengineimmediatelyifthislampcomes
on.
NEVER run the engine whenthislamp is on.
6. Ignition Switch – Inserttheignition keyhere tostart the
engine.Turn the key clockwise to the
ON position, then
continue turning clockwise to the
START position and
release. To stop the engine turn the key fully counter-
clockwiseto the
STOP position.
7. Remote Control Input Connector – Insert the remote
controlinput cableintothis connector.
8. Pumping Control Switch – This 3-position switch
controlsthepumping of the pump.The
left most position
isforusewiththe remote control unit, the
center position
is for normal pumping operation, and the
right most
position(OFF) prevents pumping.
9. Hourmeter–Display'sthenumberofhoursthepump has
been in use.
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MAYCO C-30HDNI PUMP — OPERATION AND PARTS MANUAL — REV. #0 (05/15/03) — PAGE 19
C-30HDNI PUMP — ENGINE COMPONENTS
2
1
5
8
4
6
7
3
910
12
13
14
11
Figure 6. Nissan Model A15 Basic Engine Components
Operatingtheenginewithoutanair
filter, with a damaged air filter, or a
filter in need of replacement will
allow dirt to enter the engine,
causing rapid engine wear.
7. Cooling Fan Blades – Make sure that the blades of the
coolingfanarenot
bentorbroken .Adamagedfanblade
cancause the enginetorun hot andoverheat.
8. Crankcase Drain Plug – Remove this plug to drain
engineoilfromthecrankcase.Replacewithrecommended
engineoil as specified inthe maintenance section ofthis
manual.
9. Fuel Pump/Fuel Filter – Replace or clean thefuelpump
orfuelfilterasspecifiedin the maintenance sectionofthis
manual.
10. Distributor –
NEVER allowconcreteoranyforeigndebris
tocomeincontactwith the distributor.
11. Spark Plug – Provides spark to the ignition system. Set
sparkpluggapto0.6-0.7 mm (0.028 - 0.031inch).Clean
sparkplug once aweek.
12. Dipstick – Removethisdipsticktodetermineif engine oil
islow.Maintain oil levelatthe "H "markingonthedipstick.
NEVER run engine with low oil.
13. Oil Filler PortCap – Removethiscapto add engine oil to
thecrankcase.Fillwithrecommendedtypeoilasspecified
inthe maintenance section ofthismanual
14. Fuel Injection System–
ALWAYS keep dirt, dust, and
anyforeigndebrisfromenteringthefuelinjectionsystem.
Clean the fuel injection system as recommended in the
maintenancesectionofthis manual.
TOPVIEW
FRONTVIEW
Figure 6 illustrates the location of the basic components
for the NISSAN A-15 Engine. The function of each
component is described below:
1. Oil Filter – Replace this filter as recommended in the
maintenancesectionof this manual
2. Oil Pressure Switch – In the event of low oil level, this
switchwill shutdown theengine.
3. Starter Motor/Solenoid –
NEVER allowconcreteorany
foreign debris to come in contact with the starter motor/
solenoid.
4. FanV-Belt –
ALWAYS make sure thatV-belt is properly
tensioned. AlooseordefectiveV-beltcanadverselyaffect
theperformanceofthepump.
5. Alternator – Provides power to the electrical system.
Replace with only manufactures recommended type
alternator.
6. AirCleaner –Preventsdirt andotherdebrisfromentering
the fuel system. Remove wing-nut on top of air filter
cannister to gain access to filter element. Replace with
onlymanufactures recommended type air cleaner.
NOTE
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PAGE 20 — MAYCO C-30HDNI PUMP — OPERATION AND PARTS MANUAL — REV. #0 (05/15/03)
C-30HDNI PUMP — GENERAL INFORMATION
The following operating principles and operating suggestions
shouldprovehelpfulinthesuccessfuloperationofyourconcrete
pump.Yournew“small line”concrete pump has been designed
to give you many years of service when operated properly.A
studyofthefollowingparagraphsis important to the successful
operationof yournew Direct-flowConcretePlacer.
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
toprevent havingto replace these itemsduring a pour.
Experiencehasprovedthat inconsistency of batchedconcrete
mixesand frequent movingofthe line requirestheoperator 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.
PUMPMIXGUIDELINES
When ordering concrete, be certain to advise the concrete
supplierthatyourequirea“
pumpmix ”.TheDirect-flowmanifold
willpumpawidevarietyofmaterials,butcertainbasicprinciples
mustbefollowed to assure successfulpumping,asfollows:
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
separationand jamming inthemanifold while pumping under
pressure.
If this condition develops, check with your concrete suppliers
engineers and get their recommendations for supplementing
thelackof thefines.The use oflocallyacceptedad-mixesmay
be required. (For example, Pozzolith, Bentonite Clay,
Plastiments,etc.)Whenproperly prescribed,additivesformthe
plastic paste sometimes necessary to hold the cement and
aggregatetogether.
Asageneralrule,theuseofapproximatelysixsacksofcement,
70%washedconcretesandand30%#4 pea gravel per yardof
concretewillresultinapumpablemix.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
variousmixesinyourareatodeterminethedegreeof versatility
oftheDirect-flowPump.
Uniform gradation of the washed concrete sand and the 1/2”
minusaggregatealongwithsufficientcementcontentandwater
areimportanttoa successful pump operation.
A recommended pumpable mix design would be 70% sand
and30%aggregate-cementcontenttobeaminimumof6 sacks.
(564lbs.)
SAMPLE DESIGN MIX-3000 PSI 3/8" SLUMP 4"- 5"
TypeIICement 6.49sack/cu. yd 611 lbs.
Sand Sat.Surf.Dry 2000lbs.
#4 Gravel Sat.Surf.Dry 864lbs.
#3 Gravel Sat.Surf.Dry 0 lbs.
Water 48 Gallons 400 lbs.
Total Weight 3,906lbs
AdmixtureWRDA-79 26oz.
Water7.40gal/sack
Test laboratory data has proven in many areas that the above
mix guidelines have produced concrete rated at 3000 psi (28
daytest) and upwards of5000psi with anincreasein cement.
In some areas where the gradation of sand and rock is ideal
andsufficientcementisusedalongwithadmixtures,theMayco
smalllineconcretepumpwillhandleuptoa50-50ratioofsand
androck.
When the mix is designed for wet gunning applications, it is
normaltoincreasethecement(upto7.5or8sacks)andchange
thesand to rock ratioto 85% sand and15%rock.
The Mayco concrete pump will valve efficiently when using
cellular-foamconcretemixes upwards of 70lbs.percubic foot
wet density. (Below 70 lbs. materials (roof decks) the valving
becomesinefficient.)
Yourlocalsandandrockengineers
will give you the S.S.D. weights of
sandandrockrequiredinyourlocal
areawhichwillyieldonecubicyard
pertheaboverecommendation.
If jamming conditions in the pump
orhose occur foranyreason at all,
donotattempttousemorepowerto
correctthecondition.Determinethe
cause of jamming, correct it and
resume pumping. Trying to force
material through under jammed conditions may result in
damagetothedrivesystem,thusvoidinganywarrantyservices.
NOTE
NOTE
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MAYCO C-30HDNI PUMP — OPERATION AND PARTS MANUAL — REV. #0 (05/15/03) — PAGE 21
C-30HDNI PUMP — HOW ITWORKS
The MAYCO concrete pump has one main pumping piston
which is valved by means of two ball checks. (A inlet, and B
outlet.)
The secondary piston is used as a compensator piston to
smooth out the pulsations of a single piston action.Note:The
compensator will not start operating until material is pumped
into the line and back pressure develops.
The
compensator spring , which is installed on the
compensatorpiston rod, deflectswitheach piston stroke.This
“
springcushion ”,inconjunction withthecamprofile,produces
and uninterrupted smooth flow of material under average
pumpingconditions.
The pumping cylinder (Figure 7) retracts drawing the material
pasttheball(A)and filling the cylinder.Thecompensatorpiston
ispumpingthematerial out tothenozzleandcausingball(B)to
seat preventing the material from returning to the pumping
cylinderintake.
An automatic, centrifugal clutch is installed to engage and
disengagethe pumping action withoutstoppingor starting the
engine.The
centrifugalclutch isset at1100R.P.M.Theengine
idlespeed is approximately875R.P.M.;therefore,theclutchis
completely disengaged at idle. The throttle settings while
pumpingshouldalways maintainanengineR.P.M.high enough
topreventtheclutchfromslipping and burning theclutchlining.
Thereturnspringwhichisinstalledontherockerarm,isinstalled
to eliminate shock and stress between the cam roller and the
camweldmentwhenthepumpisinoperation.Ifthereturnspring
is removed or replaced for any reason, maintain the backing
plate dimension of 3” as shown on Figure 3, to produce the
properpre-loadingof the springforasmooth performance.
Figure 7. Pumping Cylinder
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PAGE 22 — MAYCO C-30HDNI PUMP — OPERATION AND PARTS MANUAL — REV. #0 (05/15/03)
Figure9showstherelationshipbetweenthereturnspring, the
compensator spring and the rocker arm to maintain a smooth
performance.DO NOT tightenthebolt(Item 1) completely,the
rodend must be abletomove.
The pumping piston (Figure 8) is forcing the material past ball
(B)andoutto thenozzle,alsoseatingballA sothatthematerial
will not flow back to the hopper. This action also fills the
compensatingpistonforthenextstroke.
Figure 8. Pumping Pistons
Figure 9. Return Spring, Compensator Spring and
Rocker Arm Interaction
C-30HDNI PUMP — HOW ITWORKS
The return spring is installed to eliminate shock and stress
betweenthecamrollerand the cam weldment when thepump
isin operation. Ifthe
return spring isremoved or replacedfor
any reason, maintain the backing plate dimension (3-inches)
as shown to produce proper pre-loading of the spring for a
smoothperformance.
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