REED ROCK MASTER A30HP User manual

REED ROCK MASTER A30HP
TRAILER CONCRETE PUMP
MAINT
PAGE 00
PREVENTATIVE MAINTENANCE
How good is any of the equipment you own? It is only as good as it is MAINTAINED. Even the
finest equipment manufactured requires attention and care. The 05 MODEL A30HP is no
different. A good well planned and carried out preventative maintenance program will enhance
a properly operating unit as well as the safety of those operating and using the equipment.
It is very important to establish a good maintenance program. Costly repairs and loss of
revenue can often be avoided by planning ahead, setting a regular schedule and exercising
good preventative maintenance techniques.
The following section is offered as a guide and depicts a start for developing your own
preventative maintenance program for the MODEL A30HP concrete pump. The program is
depicted and broken into sections of INSPECTION and LUBRICATION.
All points noted herein regarding the maintenance
and checks are not intended to replace any local or
regional regulations which may pertain to this type of
equipment. It should also be noted that the list and
schedule is not considered to be inclusive. Interval
times may vary due to the climate and/or conditions
associated with the location area in which the
equipment will be used.
It is your responsibility to always insure that the
applicable safety precautions are strictly observed
when performing the inspections and maintenance
checks. Make certain any components that are found
to be defective are replaced or those in need of
adjustments or repair are corrected before operating
the machine.
REVISION:

REED ROCK MASTER A30HP
TRAILER CONCRETE PUMP
MAINT
PAGE 01
SCHEDULED INSPECTION
The main purpose of accomplishing scheduled inspections is to identify and detect any
potential malfunction before it can expand into a major problem. The list presented herein
should be inspected and checked on a regular basis. In so doing, it will help ensure a good,
safe unit performance.
1. TRAILER
•Frame integrity, visually check welds, cracks
•Torsion axle secure
•Wheels and tires, lug nuts tight, tire inflation
•Electric brakes, breakaway switch connected
•Front jack stand handle turns easily, smoothly
•Manual jacks slide freely, lock pins in place
•Lighting good condition operational
2. ENGINE
•Inspect mountings, bolts, brackets
•Oil level proper, any leaks
•Fuel system, tank mounting, filter condition, leaks, damaged lines
•Battery hold down, condition, tightness of cables
•Key switch, indicator lights operable
•Throttle control functional
•Air cleaner and muffler securely mounted
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REED ROCK MASTER A30HP
TRAILER CONCRETE PUMP
MAINT
PAGE 02
3. PUMP CELL
•Visually check for structural damage, cracked welds
•Hydraulic drive cylinders in good condition, secure, no leakage
•Material cylinders secure, tie rods tight
•Water box structurally sound, clean, cover in place
•S-tube shift mechanism structurally sound, all pins and retainers in place
•Hydraulic shift cylinders in good condition
•Bearing housing, seals etc. in good condition
•Hydraulic hoses secure no leaks
4. HOPPER ASSEMBLY
•Visually check for structural damage, cracked welds
•S-tube secure, in good condition
•Check condition of wear plate, wear ring, seals
•Check connection of S-tube to outlet, seals, bearing
•Hopper drain is functional
5. MAIN CONTROL
•Control box in good condition, not damaged
•All toggles in good condition, stay in position or momentarily return to center
•Control identification in good condition, legible
•Gauges in good condition
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REED ROCK MASTER A30HP
TRAILER CONCRETE PUMP
MAINT
PAGE 03
6. REMOTE CONTROL
•Control console in good condition, not damaged
•Switch in good condition
•Umbilical cord in good condition, no cuts, securely mounted to box
7. HYDRAULIC SYSTEM
•Hydraulic tank securely mounted, covers tight
•Filler cap and strainer in place, level sight gauge in proper condition
•Check filter condition indicators
•Hydraulic oil cooler securely mounted, connections tight
•Check accumulator condition, mounting brackets & clamps
•Hydraulic fluid to proper level and clean
•All hoses and tubing secure, no leaks
REVISION:

REED ROCK MASTER A30HP
TRAILER CONCRETE PUMP
MAINT
PAGE 04
LUBRICATION
The MODEL A30HP concrete pump is equipped with several components that because of the
application require frequent lubrication. These areas involve the S-tube shifting mechanism,
swing components, the shift and outlet bearings and agitator. To insure the economical service
and the long life of these components, grease fittings are installed at each point.
Rapid wear and probable component breakdown will
result if the unit is operated with inadequate
lubrication. Follow the recommended interval and if
need be increase the interval when above normal
usage takes place.
LUBE POINT LOCATION
•Swing Tube Shift
•Quantity 1 at cylinder barrel pivot
•Quantity 1 at bell crank
•Quantity 2 at swing tube shaft bearing housing
•Swing Tube Outlet
•Quantity 2 on outlet bearing housing
Recommended Lubricant: GENERAL PURPOSE GREASE, SHELL ALVANIA EPLFH2 or
EQUAL
Recommended Interval: DAILY, BEFORE START-UP AND AS REQUIRED DURING
OPERATION
LUBRICANT AND INTERVAL
The lubricant that is recommended is generally the best choice, however, should this lubricant
be unavailable in your area, consult your local supplier for an equivalent.
REVISION:

REED ROCK MASTER A30HP
TRAILER CONCRETE PUMP
MAINT
PAGE 05
REVISION:

REED ROCK MASTER A30HP
TRAILER CONCRETE PUMP
MAINT
PAGE 06
On the same basis, recommended lubrication intervals are based on normal use, in normal
environmental conditions. User is CAUTIONED to adjust the lubrication interval accordingly to
meet each individual condition and usage If the swing tube bearing housings become
extremely hot or lubricant becomes a liquid and oozes out around the bearing or seal, the area
should be relubricated.
If the MODEL A30HP has been stored or exposed to environmental conditions of extreme low
humidity, high dust level, elevated temperatures or heavy rainfall, lubrication of components
may be required more frequently than under normal conditions.
External non-bearing surfaces should be wiped
clean of extruded or spilled surplus grease and oil
with a clean, but lint free cloth to prevent damaging
dust and abrasive accumulation on lubricant wet
surfaces.
REVISION:

REED ROCK MASTER A30HP
TRAILER CONCRETE PUMP
MAINT
PAGE 07
HYDRAULIC SYSTEM MAINTENANCE
The REED MODEL A30HP utilizes a diesel engine as the main source of power, which drives
the main hydraulic pump. The hydraulic pump is used to supply the flow and develop the
necessary pressure to operate the concrete pump. As with any operational system, it is only as
good as it is maintained. The hydraulic system is a critical system and it is for this reason that
it is IMPORTANT that it receive extra care and good maintenance. This section is offered to
alert you and guide you in maintaining the hydraulic system.
CONTAMINATION is the downfall of most hydraulic
systems and a major contributor leading to system
malfunctions. Extreme care must be exercised to
prevent dirt from entering the system. Make it a
habit to ALWAYS cap or plug open ports and
hydraulic lines.
RETURN FILTER
HYDRAULIC OIL TANK
FUEL TANK
GEAR PUMP
REVISION:

REED ROCK MASTER A30HP
TRAILER CONCRETE PUMP
MAINT
PAGE 08
HYDRAULIC TANK
The hydraulic tank has a capacity of 40 GALS (190L) and is located just forward of the hopper.
It is equipped with a filler breather unit, access cover. A sight gauge is installed on the left side
of the tank and is used to determine the fluid level inside the tank. The tank is also equipped
with drain valve.
Filtration is by a return line filter located on the front of the tank. An oil cooler is adjacent to the
engine cooling unit. This cooler is used to cool the oil prior to entering the tank.
SYSTEM MAINTENANCE ITEMS
The following are specific items for care and maintenance of the hydraulic system.
•FLUID LEVEL Check level daily with sight gauge provided.
Maintain level at full mark. Add through filter.
•TANK BREATHER Clean every 50 hours of operation. Remove from
tank, clean with solvent and air blow dry.
•RETURN LINE FILTER One (1) 10-micron filter; change after first 50
Hours of operation. Thereafter change every
150 hours of operation or when condition
gauge indicates to do so.
•HYDRAULIC TANK Change oil in tank every 1000 hours of operation
or yearly whichever comes first.
After fluid loss for any reason, filter replacement,
component removal etc., sufficient fluid must be
added to properly maintain required level in tank.
HYDRAULIC FLUID
The MODEL A30HP utilizes in its hydraulic system a fluid manufactured by the SHELL OIL
CO. and is designated as TELLUS #46. It is to be used in ambient temperatures of 39 - 90°F
(4 - 32°C). The normal fluid temperature will range from 100 - 167°F (38 - 75°C).
REVISION:

REED ROCK MASTER A30HP
TRAILER CONCRETE PUMP
MAINT
PAGE 09
For ambient temperatures of 90°F (32°C) and above use fluid designated as a ISO rating of
68. Use ISO 32 for ambient temperatures of 32°F (4°C) and below.
USE ONLY SHELL TELLUS 46 or equal hydraulic fluid and
NEVER MIX with other type fluids. Always use a CLEAN
fluid. Using impure or other type of fluids not specified will
contaminate the hydraulic system and can lead to eventual
system malfunction or damage and possibly deteriorate the
hydraulic seals.
ADDING HYDRAULIC FLUID
As previously indicated, a hydraulic systems worst enemy is CONTAMINATION. Exercise
extreme care when adding fluid to the hydraulic tank.
•To prevent any dirt or water from entering the hydraulic tank, thoroughly clean area
around top of filter.
•Use fresh clean hydraulic fluid. If a hand pump is used to transfer the fluid, check that
pump filter is clean. If pouring of fluid from a container, pour it through a fine wire mesh
screen, 200 mesh or finer.
Do not use a cloth for straining fluid as lint is harmful to
the hydraulic system.
FILTER SERVICING
The purpose of installing hydraulic filters in the system is to provide a means of continuous
hydraulic fluid filtration in an effort to prevent recirculation of abrasive solids which will cause
rapid wear of component breakdown.
REVISION:

REED ROCK MASTER A30HP
TRAILER CONCRETE PUMP
MAINT
PAGE 10
FILTER INDICATOR
FILTER HOUSING
GASKET
CHECK VALVE
The MODEL A30HP hydraulic filter system consist of a return filter located on tank’s side. The
filter is equipped with a condition indicator gauge which should be checked periodically and the
element changed when gauge reads 25PSI or higher..
To service/change the filter elements, the following is offered:
•Shut off machine. On pump circuit allow accumulator system to depressurize
•Wipe clean any dirt and grime from around filter housing.
•Remove the four (4) bolts holding on top plate of filter.
•There is a check valve in the filter housing, so the only oil lost will be that in the housing.
•Carefully remove cover so as not to damage the gasket.
•Remove element and discard.
•Replace with new element and replace cover.
•Start up machine and observe for leakage.
DO NOT ATTEMPT TO WASH OUT FILTER ELEMENT.
These are disposable types and more harm can be
done than it is worth.
REVISION:

REED ROCK MASTER A30HP
TRAILER CONCRETE PUMP
MAINT
PAGE 11
CLEANING THE HYDRAULIC TANK
The hydraulic tank should be drained and cleaned after 1000 hours of operation or yearly
whichever comes first. This will assist in keeping the systems clean and in proper condition.
To accomplish this the following is offered.
•Shut off machine. On pump circuit allow accumulator system to depressurize
Place a suitable size container under the hydraulic tank drain fitting located at back of
tank facing the hopper. NOTE: The tank has a capacity of 40gals (160 L). Make sure
your drain container is large enough. Remove drain plug.
•Remove the access cover on the hydraulic tank being careful not to damage the gasket
•After tank has drained, flush the inside of the hydraulic tank with clean solvent and wipe
clean with lint free cloths. DO NOT USE PAPER TOWELS. Remove any particles from
tank bottom.
•Install the tank drain plug and access cover with gasket
•Clean the filler breather with solvent and air blow dry
•Change the hydraulic system filter element (see previous page)
•Refill the hydraulic tank with new CLEAN hydraulic fluid, SHELL TELLUS 46
•Start machine and check for leaks
RETURN FILTER
HYDRAULIC OIL TANK
HOPPER REF
REVISION:

REED ROCK MASTER A30HP
TRAILER CONCRETE PUMP
MAINT
PAGE 12
DESCRIPTION OF HYDRAULIC SYSTEM
The hydraulic system of the MODEL A30HP consists of two separate circuits and although
integrated, each is designed to perform a particular function within the operation of the concrete
pump. The two circuits utilized are:
•Main Pump Circuit - It controls the function for operation of the hydraulic drive cylinder
and material cylinders.
•S-tube Shift Circuit - It controls the function for operation of shifting the S-tube from one
material cylinder to the other during concrete pumping.
For the purpose of making the operation of each circuit easier to understand, they are being
described separately.
SPECIFICS – PRESSURES
•Main System Max. Pressure = 3000 PSI (207 Bar)
•Main System Relief Pressure = 3000 PSI (207 Bar)
•S-tube Shift System Relief Pressure = 2300 PSI (159 Bar)
•Accumulator Pre-Charge Pressure = 900 PSI ( 62 Bar)
SYSTEM FILTRATION
The hydraulic tank has a capacity of 40 gals (160L) of SHELL TELLUS #46 hydraulic fluid.
The system return fluid must pass through a 10-micron filter element before returning to the
tank and after passing through the oil cooler.
MAIN PUMP CIRCUIT (Refer To Hydraulic Schematic)
The MODEL A30HP is designed to pump concrete like material from the hopper to the
placement site. To accomplish this requires the use of two (2) material cylinders that are driven
by two (2) hydraulic cylinders and the material pumping action is the result of the two cylinders
operating or stroking on an alternate basis. In other words, when one cylinder is retracting it is
drawing into the material cylinder tube the material from the hopper. The other cylinder, which
has its material cylinder already full, is extending. This causes the material to be pushed
through the swing tube and out into the delivery line.
REVISION:

REED ROCK MASTER A30HP
TRAILER CONCRETE PUMP
MAINT
PAGE 13
This action continually takes place. This is the purpose of the MAIN PUMP circuit, to provide
the hydraulic power for this operation.
The MAIN PUMP CIRCUIT is of the OPEN LOOP type. Meaning, that the hydraulic pump
directs the fluid to one hydraulic cylinder to extend and the oil from the retracting cylinder is
directed back to the tank.
HYDRAULIC TANK REF
HYDRAULIC GEAR PUMP MAIN HYDRAULIC PUMP
ENGINE REF
To meet the volume and pressure requirements of the main pump circuit a hydraulic pump is
used. The MODEL A30 uses a gear type pump, while the MODEL A30HP uses a piston type
load-sensing hydraulic pump.
In the case of the MODEL A30HP, the VOLUME OUTPUT works as a function of R.P.M..
The main hydraulic pump is driven directly by the Perkins diesel engine. When the engine is
started and running and the PUMP switch is in the OFF position, the oil is directed through the
main valve back to tank through the cooler. This condition exists regardless of whether the
engine is at idle or maximum RPM.
REVISION:

REED ROCK MASTER A30HP
TRAILER CONCRETE PUMP
MAINT
PAGE 14
The main pump circuit is equipped with a manifold block installed at the HEAD side of the drive
cylinders. This manifold is drilled and ported to accommodate the relief valve, check valve, and
the pilot operated cycle valve. The cycle valve is a directional spool valve with electro hydraulic
solenoid operation. Its purpose is to direct the flow of oil to one or the other hydraulic drive
cylinders.
The pump will produce flow in proportion to the amount by which the RPM has been raised.
Since the PUMP switch is OFF, the flow from the hydraulic pump is directed to the cycling
valve, however, it is not needed and thus returns to the hydraulic tank by way of the cooler.
To energize the cycling circuit, the PUMP switch must be ON. When this is done, an electrical
signal is generated which in turn energizes the coils of the main cycling pilot valve, which also
activates the swing tube shift circuit. (Described later)
Where, how, and why is this electrical signal generated?
It was previously noted that the material pumping action is the result of the two material
cylinders cycling on an alternate basis. This alternating cycling is controlled by an electrical
signal that is generated at the end of each material cylinder’s suction, (retraction stroke).
A proximity sensor, one for each material cylinder, is installed in the flush box. As the piston
coupler passes under the proximity sensor, it generates an electrical signal that is sent to the
Can-Bus logic controller. The controller is a REED proprietary solid state device, designed to
control the alternating action of the material cylinders and in turn the movement of the swing
tube. The signal from the controller is used to energize the coils of the main cycling pilot valve.
CIRCUIT OPERATIONAL SEQUENCE
In the operational sequence of the MAIN PUMP CIRCUIT and with the engine started and
throttle adjusted, the main pump is idling. When the PUMP switch is placed ON, the hydraulic
drive cylinders begin to cycle. The cylinder to receive the flow from the hydraulic pump via the
cycling valve, is the cylinder whose coupler has triggered the proximity sensor while in the
retracted position and is ready to extend. At full extension the other cylinder is totally retracted
and the coupler activates the proximity sensor which via the Can-Bus logic controller, shifts the
pilot valve spool, allowing the oil to pilot the main cartridge, which sends oil to the head side of
retracted cylinder. This alternating cycling takes place continuously until the PUMP switch is
turned OFF.
It can be noted in the schematic and the diagram below that the main pressure and flow is only
directed to one side of the hydraulic drive cylinder. In this instance, it is directed to the barrel
or piston side of the cylinder.
REVISION:

REED ROCK MASTER A30HP
TRAILER CONCRETE PUMP
MAINT
PAGE 15
The hydraulic drive cylinders are identical and because only one cylinder is pressurized at a
time, a means is required to assist in the retraction of the opposite cylinder. This is
accomplished by connecting the rod sides of the cylinders together. In so doing, the hydraulic
fluid that exists in the rod side of the extending cylinder (CYL A) is transferred and directed to
the rod side of the other cylinder (CYL B) causing it to retract. The oil in the barrel of CYL B is
then forced out and has a free flow through the cycling valve back to the hydraulic tank or
return system.
With this arrangement of connecting the two cylinders together, it is possible for various
reasons, such as leakage around the piston seals that more oil exists on the rod side of the
cylinder than is required. When this condition exists, some hydraulic oil remains at the rod end
of the cylinder being extended while the other cylinder is fully retracted. As a result the cylinder
cannot be totally extended and thus it SHORT STROKES which will also happen eventually to
the other cylinder.
This condition can be corrected by actuating the STROKE CHANGE switch on the electrical
control box to the change position and HOLD, whichever cylinder is extending is forced down,
until the extended cylinder is fully bottomed out. Hydraulically, this is accomplished by use of
the check valves installed on both cylinders. By holding the STROKE CHANGE switch, you
have interrupted the cycle and are forcing more oil into the barrel of the extending cylinder.
This oil is then directed by means of the check valve at the rod end of the extending cylinder,
putting more oil on the rod side which is then transferred to the rod side of OTHER CYL. Since
that cavity is full, pressure is built up in the rod side of OTHER CYL, which unseats the barrel
side check valve forcing the excess oil back to the tank. Once the extending cylinder is at full
stroke, regular operation can continue.
REVISION:

REED ROCK MASTER A30HP
TRAILER CONCRETE PUMP
MAINT
PAGE 16
In addition to piston leakage, a SHORT STROKE
condition may result from incorrect proximity
sensor location or leaking check valves.
As protection to the MAIN PUMP CIRCUIT against excessive pressure, a relief valve has been
installed and is set to open at 3000 PSI, main system pressure. Thus when the system
pressure reaches 3000 PSI, the relief valve opens directing the oil back to the tank.
S-TUBE SHIFT CIRCUIT (Refer to Hydraulic Schematic)
In the foregoing description of the Main Pump Circuit, we learned that the hydraulic drive
cylinders operate on an alternating basis causing the material cylinders to do the same. Since
there is only one outlet for the pumping material, a means is required to transfer the material
from the material cylinder to the outlet and into the delivery line. To accomplish this a
component referred to as the swing tube or “S” - tube is installed in the hopper. Since there
are two material cylinders and one S-tube, the S-tube must be shifted from one material
cylinder to the other, whichever one is loaded with the pumping material. Thus the
incorporation of the, S-TUBE SHIFT CIRCUIT.
The S-tube shift hydraulic circuit is of the UNLOADING CIRCUIT type, meaning that when the
PILOT control valve is in the NEUTRAL position electrically non operational (unactuated), the
UNLOADING CIRCUIT passages of the valves are open, allowing the hydraulic fluid to return
to the tank. With the engine running the hydraulic pump is operating, producing a flow of oil
which, with no control energized, will pass through the UNLOADING CIRCUIT on its way back
to tank.
THE ACCUMULATOR AND CYL. ARE FULLY
CHARGED AND READY TO WORK WHEN THE “E”
STOP CURCUIT IS DEACTIVATED!!!
To meet the flow and pressure requirements of the shift circuit, one section of a tandem pump
is used. The TANDEM HYDRAULIC PUMP is of the gear pump design, having a fixed
displacement meaning it is designed to constantly produce the same displacement at pre-set
maximum engine RPM. The tandem gear pump is direct connected to the engine. In addition
to the hydraulic pump, the swing tube shift circuit consists of an unloader manifold, an
accumulator. The following is offered to describe the function of each in the system.
REVISION:

REED ROCK MASTER A30HP
TRAILER CONCRETE PUMP
MAINT
PAGE 17
SHIFT CIRCUIT MANIFOLD
Like the main hydraulic circuit, the shift circuit is incorporated into the manifold block. This
block is flange mounted to the drive cylinders. It contains a shift cartridge, relief cartridge, (2)
two solenoid valve cartridge, and unloading valve cartridge. The directional cartridge valve is
mounted in the block. Each of these components is designed to perform a particular function in
the swing circuit as explained in the following descriptions:
CYCLING VALVE (SV1)/Y1/Y2
TEST PORT (M1) ACCUMULATOR (S)
REVERSE VALVE (SV2) UNLOADER VALVE (UV1)
SOLENOID VALVE CARTRIDGE (SV4)
MAIN SHIFT CARTRIDGE (DCEC)
SOLENOID VALVE CARTRIDGE (SV3)
RELIEF CARTRIDGE (RPGC)
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TRAILER CONCRETE PUMP
MAINT
PAGE 18
•RELIEF CARTRIDGE - This cartridge is located on the top side of the manifold block
and is used to protect the system from excessive pressure and to limit the amount of
pressure being applied to the accumulator and is set at 2300 PSI (158 Bar)
•DIRECTIONAL CARTRIDGE –This cartridge is used to direct the flow of oil from the
accumulator to one or the other end of the shift cylinder based on the hydraulic signal it
receives from the cycling valve as is the main cycle cartridge.
•UNLOADER VALVE - This cartridge is used to divert the pump flow from going to the
accumulator once its capacity has been reached, directing it back to tank. It becomes
operational when the differential setting has been reached (Working value).
REVERSE VALVE (Y3)
ACCUMULATOR (S)
CYCLING VALVE
CHECK VALVE (CXFA) HIGH PRESSURE TEST PORT (M2)
DIRECTIONAL CARTRIDGE (RVEA)
DRIVE CYLINDER FLANGE MOUNT
MANIFOLD BLOCK
SWING TUBE SHIFT CARTRIDGE (DCDD)
TEST PORT (M)
REVISION:

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TRAILER CONCRETE PUMP
MAINT
PAGE 19
•SOLENOID VALVE CARTRIDGE – (Y4 Refer to the schematic) Referred to as a dump
valve, it is designed into the shift circuit as a SAFETY VALVE. Its purpose is to
automatically relieve the pressure in the accumulator through an orifice. The valve is
controlled by, the Can-Bus logic controller, the valve OPENS when the “E” Stop switch is
PUSHED IN. This prevents the unintentional shifting of the S-tube when the pump is in
an “E” Stop condition.
•SOLENOID VALVE CARTRIDGE- (Y5 Refer to the schematic) The second valve is also
used as a dump valve and is used to direct pilot flow back to the tank when the PUMP
ON SWITCH is off.
ACCUMULATOR
REVISION: