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Multiquip C-30HDNI Automobile Parts User Manual

1. 00 RAD DDH 5 MAYCO C 30HDNI PRECISION PUMP OPERATION AND PARTS MANUAL REV 7 04 03 12 PAGE 83 C 30HDNI PRECISION AXLE ASSY AXLE ASSY NOTES TORQUE LUG NUTS PER LUG NUT TORQUE TABLE REFERENCED IN THIS MANUAL FOR AXLE MOUNTING HARDWARE SEE FRAME ASSY PAGE 84 MAYCO C 30HDNI PRECISION PUMP OPERATION AND PARTS MANUAL REV 7 04 03 12 C 30HDNI PRECISION AXLE ASSY AXLE ASSY NO PARTNO PART NAME QTY REMARKS 1 EM26518 CAP 14 CHROME 2 2 26615 TIRE ASSY INCLUDES ITEMS W 3x WHEEL M 2 spass CANNOT BE PURCHASED SEPARATELY 4 TRE 11 c EE CANNOT BE PURCHASED SEPARATELY 5 26306 DUST COVER 2 968481 CASTLE NUT 2 7 705 PIN COTTER 3 16 1 1 2 2 8 26329 WASHER 2 9 903113 OUTER BEARING 2 10 903012 OUTER CUP 2 11 26519 NUT 12 12 20612 STUD 12 134 26300 HUB 2 144 903169 INNER CUP 2 15 903168 INNER BEARING 2 16 26305 GREASE SEAL 2 17 EM20601 HUB ASSEMBLY INCLUDES ITEMS W 18 14600 AXLE 1 19 14600 AXLE WITH HUBS INSTALLED 1 INCLUDES ITEMS W MAYCO C 30HDNI PRECISION PUMP OPERATION AND PARTS MANUAL REV 7 04 03 12 PAGE 85 C 30HDNI
2. eee 6 Engine Specifications aan 6 Pump Dimensions a 7 Safety Message Alert Symbols 8 9 Rules for Safe Operation 10 12 Towing Guidelines 14 15 Trailer Safety Guidelines 16 18 Operation And Safety Decals 20 Important Hand Signals 21 Pump Components acci 22 23 Control Box Components a 24 Engine Components 25 General Information 26 How AG 27 28 Operating Information 29 33 Inspection 34 36 Startup Shutdown Procedures 37 Maintenance 38 47 Engine Troubleshooting 48 49 Malfunction Indicator Diagnostic Error Codes 50 53 Component Location EFI Wiring Harness 54 Wiring Diagram EFI Wiring Harness 55 Wining sui conici tute 56 Wiring Diagram Trailer Lights 57 Appendix Slump Test Procedure 58 Concrete Mix Information 59 61 Recommended Shotcrete System 62 63 Recommended Shotcrete Accessories
3. p 5 39 e lt C 30HDNI PUMP RADIATOR MOUNTING BRACKET AND HOSES ASSY RADIATOR BRACKET AND HOSES ASSY NO PARTNO 1 513116 2 2101402 3 492268 4 EM20427 5 EM64900014 6 EM94700071 7 EM64700070 8 506208 9 EM21000092 10 EM68800003 11 EM65508003 12 EM64800155 13 EM98079 14 EM98080 15 EM98072 16 EM69300001 17 EM21000091 18 EM64900101 PART NAME CLAMP 1 2 HOSE WASHER FLAT 1 4 HHCS 1 4 3 4 HOSE OVERFLOW HHCS 3 8 16 x 7 8 WASHER LOCK 3 8 WASHER FLAT 375 x 0734 x 065 CLAMP HOSE BRACKET UPPER RADIATOR CLAMP HOSE WORM DRIVE ISOLATOR NUT HEX 3 8 16 RADIATOR HOSE UPPER RADIATOR HOSE LOWER RADIATOR CAP RADIATOR 13 PS1 BRACKET UPPER RADIATOR 5 8 1 25 X 20 REMARKS ISOLATOR MOUNT MAYCO C 30HDNI PRECISION PUMP OPERATION AND PARTS MANUAL REV 7 04 03 12 PAGE 93 C 30HDNI PRECISION PUMP CONTROL BOX ASSY CONTROL BOX ASSY NOTES INCLUDED WITH ITEM 6 PILOT LAMP ASSY P N 513099 INCLUDED WITH ITEM 13 HOUR METER P N 506222 INCLUDED WITH ITEM 10 PUMPING CONTROL SWITCH P N 40711 INCLUDED WITH ITEM 8 IGNITION SWITCH P N 506267 INCLUDED WITH ITEM 12 FT PI UG 26789 3 THROTTLE OIL WATER PRESSURE BATTERY TEMPERATURE ENGINE HOURS IGNITION SWITCH OFF ON START PUMPING CON
4. MUFFLER AIR FILTER AND STOP SWITCH ASSY MUFFLER AIR FILTER AND STOP SWITCH ASSY NOTES HARDWARE IS INCLUDED WITH ITEM 11 AIR FILTER SUPPORT BRACKET IS INCLUDED WITH ITEM 1 STOP SWITCH MOUNTING HARDWARE IS INCLUDED WITH ITEM 19 PAGE 86 C 30HDNI PRECISION PUMP OPERATION AND PARTS MANUAL REV 7 04 03 12 C 30HDNI PUMP MUFFLER AIR FILTER AND STOP SWITCH ASSY MUFFLER AIR FILTER AND STOP SWITCH ASSY NO PARTNO PART NAME QTY REMARKS 1 EM98076 FILTER AIR 1 98168 PRECLEANER AIR FILTER 1 2 492364 SCREW HHC 5 16 18 X 1 2 3 EM513126 CLAMP AIR INTAKE 2 4 EM513102 FLEX HOSE AIR CLEANER 1 17 5 LENGTH 1 3 4 DIA 5 513106 PANEL FILTER SUPPORT 1 6 EM492897 WASHER FLAT 5 16 2 7 492582 NUT NYLOC 5 16 18 2 8 EM963610 HHCS 3 8 X1 G5 2 9 0166A WASHER LOCK 2 10 3019092 WASHER FLAT 2 11 506257 U BOLT 2 12 513111 FLEX TUBING MUFFLER jp 10 LENGTH 1 1 2 DIA 13 513110 BUSHING 1 4 20 RUBBER MUFFLER 4 14 EM923057 WASHER FLAT 1 4 2 15 2101402 WASHER LOCK 1 4 2 16 TBD NUT 4 17 98078 CLAMP 6 MUFFLER 2 18 515598 MUFFLER 1 19 EM14217 STOP SWITCH ENGINE COVER 1 20 EM491873 GLAND CONNECTOR 1 21 ZE1 ELEMENT AIR FILTER 1 C 30HDNI PRECISION PUMP OPERATION AND PARTS MANUAL REV 7 04 03 12 PAGE 87 C 30HDNI PRECISION CLUTCH ASSY C
5. EM26313 HALF LINK 212225 EM26314 5 EM14334 COMPENSATOR SPRING 2 14408 BRONZE RING 2 EM903092 CAM ROLLER BEARING 2 EM14315 V BELT 2 14842 LOWER SEAT 2 EM14843 UPPER SEAT 2 EM26310 CLUTCH LINING 10 EM18409 O RING 2 20763 FUEL FILTER 2 20328 BEARING 1 EM28004DD REDUCER 3 X 2 23946 3 ELBOW gt 28904 3 CLAMP 2711 289041 3 GASKETS Mee 14159 5 652 22401M7714 SPARK PLUG 1520855400 ELEMENT OIL 11920H9915 V BELT GOVERNOR 2215723G15 ROTOR ASSY ENGINE Lig 2211577 11 SIGNAL ROTOR SET 1 2202005111 TRANSISTOR IGN UNIT 2202305110 SEAT SYNK 1 2216278 10 ASSY DIST W POINT ASSY 1172077702 0 V BELT FAN Part number on this Suggested Spare Parts List may super cede replace the P N shown in the text page
6. lt a a a lt N p 5 39 e lt a C 30HDNI PRECISION FRAME 55 FRAME ASSY NO PARTNO PART NAME 1 EM513085 FRAME ASSEMBLY 2 70186 JACK STAND REAR 3 EM744 CLEVIS PIN 1 2 X 4 4 745 HAIR PIN 5 8 3 4 5 14600 AXLE ASSEMBLY 7 501299 WASHER THICK 1 8 491689 KEY COTTER 1 8 X 2 10 EM492396 SCREW HHC 1 2 13 X 2 11 EM621 WASHER 5 12 EM406 NUT LOCK 1 2 DIA 13 511418 FENDER RIGHT SIDE 14 981635 BOLT HHC 1 2 13 X 3 4 15 6109180 WASHER LOCK 1 2 16 EM512251 COVER 17 EM512252 COVER 18 EM512253 COVER 19 EM512250 COVER 20 EM492309 SCREW HHC 21 0166 WASHER LOCK 3 8 22 EM512263 ROD 23 EM507895 PLUG 2 1 2 NPT 26 29228 HITCH TONGUE 2 27 EM969023 NUT HEX 5 8 NC 28 EM507658 SCREW 5 8 NC 4 1 2 G5 29 EM509947 LINK QUICK 30 EM14165 BOLT EYE 31 EM619 WASHER 3 4 WILLIAM 32 EM968002 NUT COUPLING 3 4 10 33 EM505121 SCREW 3 4 10 X 3 GR 5 34 969038 NUT STOP REG 3 4 10 35 EM513078 COVER CHASSIS BOTTOM 36 10136 WASHER FLAT 3 8 37 492264 HHCS 3 8 1 38 929028 HOOD REST STEEL 39 492363 SCREW 5 16 18 3 4 40 EM923343 WASHER LOCK 5 16 41 EM265361 BRACKET LIGHT 42 EM26536 TAIL LIGHT 43 491010 HOOD FASTENER RUBBER 44 EM513087 FENDER LEFT SIDE 45 25610 JACK STAND FRONT lt
7. CHECK the tire air pressure on both the towing vehicle and the trailer Also check the tire tread wear on both vehicles ALWAYS make sure the trailer section of the pump is equipped with a Safety Chain ALWAYS attach trailer s safety chain to frame of towing vehicle ALWAYS make sure that the vehicle and trailer directional backup brake and trailer lights are connected properly and are working properly Remember in most cases the maximum speed unless otherwise posted for highway towing is 45 MPH however before towing your pump check your local state and county vehicle towing requirements Recommended off road towing is not to exceed 10 MPH or less depending on type of terrain Place chocked blocks underneath wheel to prevent rolling while parked Depending on soil conditions and location it may be necessary to place support blocks underneath the trailer s bumper to prevent tipping while parked Inflate tires to correct pressure inspect tires for cuts and excessive wear See Table 3 Tire Wear Troubleshooting Check wheel mounting lug nuts with a torque wrench Torque wheel lug nuts as described in the Lug Nut Torque Requirements Table 5 Make sure brakes are synchronized and functioning properly Check tightness of suspension hardware nuts and bolts Avoid sudden stops and starts This can cause skidding or jackknifing Smooth gradual starts and stops will improve gas m
8. PISTON ROD 1 65 EM26788 REMOTE SWITCH 1 903176 CONN ROD BEARING 1 14305 CRANKSHAFT 2 14807 PUMP CYLINDER 2 uns 18800 COMPENSATOR CYLINDER EM14320 CLUTCH 24 22401M7714 SPARK PLUG 12 1520855400 ELEMENT OIL disces 11920H9915 V BELT GOVERNOR 2215723G15 ASSY ENGINE 2211577A11 SIGNAL ROTOR SET 2202005111 TRANSISTOR IGN UNIT 3 22023G5110 SEAT SYNK 2216278 10 ASSY DIST W POINT 55 3 1172077702 FAN C 30HDNI PRECISION OPERATION AND PARTS MANUAL REV 7 04 03 12 PAGE 67 AND DECALS C 30HDNI PRECISION PUMP N DQ gt 5 5 D wz 22 NO SSN NR EN q gt 43 aT 2227 UD pe gt Lu lt lt 7 an lt a a a z o 25 cp e lt lt C 30HDNI PRECISION NAMEPLATE AND
9. REMOTE CONTROL CABLE ASSY NOTES 8 INCLUDED WITH ITEM 1 A CORD ASSY ITEM 9 INCLUDES ITEMS WITHIN DASHED LINES PAGE 106 MAYCO C 30HDNI PRECISION PUMP OPERATION AND PARTS MANUAL REV 7 04 03 12 C 30HDNI PRECISION REMOTE CONTROL CABLE ASSY REMOTE CONTROL CABLE ASSY NO PARTNO PART NAME QTY REMARKS 1 16753 JUNCTION BOX 1 2 EM16754 SWITCH MICRO 1 3 EM16756 GUARD SWITCH ALUMINUM 1 4 EM491897 CONNECTOR 3 16 RING 2 5 EM26791 GRIP CORD SEAL 1 26790 25 1 7 26793 ADAPTER CORD GRIP 1 2 1 8 EM26792 ADAPTER CORD 100 FT 1 9 EM26788 REMOTE W 25 CORD ONLY d ncn INCLUDES ITEMS W MAYCO C 30HDNI PRECISION PUMP OPERATION AND PARTS MANUAL REV 7 04 03 12 PAGE 107 C 30HDNI PRECISION PUMP EFI GASOLINE FUEL SYSTEM ASSY EFI GASOLINE FUEL SYSTEM ASSY PAGE 108 MAYCO C 30HDNI PRECISION PUMP OPERATION AND PARTS MANUAL REV 87 04 03 12 C 30HDNI PRECISION PUMP EFI GASOLINE FUEL SYSTEM ASSY EFI GASOLINE FUEL SYSTEM ASSY NO PARTNO PART NAME QTY REMARKS 1 7642010 15 GAS ONLY WIRING HARNESS 1 2 P9397 EFI CONTROLLER SOFTWARE 1 USER SPECIFIC EEE EE CONTACT PRECISION GOVERNORS 4 P3395 1 4 20 ACORN NUT NICKEL 2 5 P3241 1 4 WASHER 4 6 P2559 AIR TEMP SENSOR 1 7 P3363 3 8 NPT 5
10. OPERATION AND PARTS MANUAL 4 4 MULTIQUIP MAYCO SERIES MODEL C 30HDNI CONCRETE PUMP PRECISION FUEL INJECTION UP TO S N 240601 Revision 7 04 03 12 To find the latest revision of this publication visit our website at www multiquip com THIS MANUAL MUST ACCOMPANY THE EQUIPMENT AT ALLTIMES PROPOSITION 65 WARNING CALIFORNIA Proposition 65 Warning Engine exhaust and some of its constituents are known to the State of California to cause cancer birth defects and other reproductive harm PAGE 2 MAYCO C 30HDNI PRECISION PUMP OPERATION AND PARTS MANUAL REV 47 04 03 12 SILICOSIS RESPIRATORY WARNINGS SILICOSIS WARNING Grinding cutting drilling of masonry concrete metal and other materials with silica in their composition may give off dust or mists containing crystalline silica Silica is basic component of sand quartz brick clay granite and numerous other minerals and rocks Repeated and or substantial inhalation of airborne crystalline silica can cause serious or fatal respiratory diseases including silicosis In addition California and some other authorities have listed respirable crystalline silica as substance known to cause cancer When cutting such materials always follow the respiratory precautions mentioned above RESPIRATORY HAZARDS Grinding cutting drilling of masonry concrete metal and other materials can generate dust mists and fumes containing
11. One location should have 1 s in the odd numbered bits and the other has 18 in the even numbered bit positions Error Code 52 indicates that the Analog to Digital A D converter in the ECM is faulty This converter reads sensors e g TPS O sensor etc and converts thier analog voltage output to a dignital number for use by the ECM If the A D converter fails the ECM sets this code Defective ECM Conditions for displaying this error code are AD Converter has failed to properly read a sensor after 5 attempts PAGE 52 MAYCO C 30HDNI PRECISION PUMP OPERATION AND PARTS MANUAL REV 7 04 03 12 C 30HDNI PUMP MALFUNCTION INDICATOR DIAGNOSTIC ERROR CODES TABLE 7 MALFUNCTION INDICATOR DIAGNOSTIC ERROR CODES Continued DESCRIPTION OF ERROR POSSIBLE CAUSES OF ERROR Error Code 53 indicates that Oil Pressure Level is low Low Oil level Conditions for displaying this error code are Bad Oil Pump Oil Pressure Level signal has grounded after the engine has been running for 10 seconds Error Code 61 indicates that the LP solenoid relay output is faulty Conditions for displaying this error code are is commanding the LP solenoid relay output or OFF Electrical feedback to the ECM indicates any one of the following faults short circuit fault over current fault over voltage fault or an open circuit fault Error Code 62 indicates that the Fuel Pump relay output is faulty
12. WEIGHT GOVERNOR SIGNAL ROTOR SET COUPLING SET PLATE ASSEMBLY BREAKER ROTOR ASSEMBLY CAP ASSEMBLY POINT ASSEMBLY CARBON O RING LEAD WIRE PACKING BOLT PICK UP KIT CONTROL ASSEMBLY VAC TERMINAL ASSEMBLY SCREW KIT QTY REMARKS 1 o c o c lA c INCLUDES ITEMS W INCLUDES ITEMS W INCLUDES ITEMS 15 NISSAN ENGINE ALTERNATOR ASSY ALTERNATOR ASSY PAGE 132 C 30HDNI PRECISION PUMP OPERATION AND PARTS MANUAL REV 7 04 03 12 15 NISSAN ENGINE ALTERNATOR ASSY ALTERNATOR ASSY NO PARTNO PART NAME QTY REMARKS 1 11710H7201 BRACKET ALTERNATOR 1 2 1171321001 SHIM ALTERNATOR AR 3 11715H7201 BAR ADJ ALTERNATOR 1 4 1172077702 BELT FAN 1 6 081810301A BOLT 2 4 0812082062 BOLT 1 8 081710351A BOLT 1 9 081310421A BOLT 1 10 089151381A WASHER 2 11 089151401A WASHER 2 12 089154381A WASHER PLAIN 2 5 23300G5110 ALTERNATOR 1 MAYCO C 30HDNI PRECISION PUMP OPERATION AND PARTS MANUAL REV 7 04 03 12 PAGE 133 TERMS AND CONDITIONS OF SALE PARTS PAYMENT TERMS Terms of payment for parts are net 30 days FREIGHT POLICY All parts orders will be shipped collect or prepaid with the charges added to the invoice All shipments are F O B point of origin Multiquip s responsibility ceases when sign
13. use food or plastic containers to dispose of hazardous waste DO NOT pour waste oil fuel directly onto the ground down a drain or into any water source ting nat 0 FIRSTAID KIT The pump has an operating weight of approximately 2 950 Ibs 1 338 Kg Use lifting equipment capable of lifting this weight PAGE 12 C 30HDNI PRECISION OPERATION AND PARTS MANUAL REV 7 04 03 12 5 C 30HDNI PRECISION AND PARTS MANUAL REV 7 04 03 12 PAGE 13 C 30HDNI PRECISION PUMP TOWING GUIDELINES Towing Safety Precautions A CAUTION Local Towing Regulations Check with your county or state safety towing regulations department before towing your concrete pump To reduce the possibility of an accident while transporting the pump on public roads always make sure that the trailer and the towing vehicle are in good operating condition and both units are mechanically sound The following list of suggestions should be used when towing the pump Make sure that the hitch and coupling of the towing vehicle are rated equal to or greater than the trailer gross vehicle weight rating GVWR ALWAYS inspect the hitch and coupling for wear NEVER tow the light tower s trailer with defective hitches couplings chains etc
14. 04 03 12 A15 NISSAN ENGINE IGNITION SYSTEM ASSY IGNITION SYSTEM ASSY NO PARTNO PART NAME QTY REMARKS 1 22401 7714 PLUG SPARK STD 4 2 2243110560 RING HT CABLE 1 3 22450Y4000 CABLE ASSEMBLY COIL TO DIST 1 4 2245195000 CABLE ASSEMBLY 1 1 5 22452H5000 CABLE ASSEMBLY 2 1 6 22453 5000 CABLE ASSEMBLY 3 1 7 22454 5000 CABLE ASSEMBLY 4 1 9 2401790004 CONN WIRE 1 13 2246252A60 COIL IGNITION 1 C 30HDNI PRECISION PUMP OPERATION AND PARTS MANUAL REV 7 04 03 12 PAGE 129 DISTRIBUTOR ASSY A15 NISSAN ENGINE DISTRIBUTOR ASSY E gt a gt lt CD lt o lt CC LU gt gt o e 25 39 gt 2 lt 15 NISSAN ENGINE DISTRIBUTOR ASSY DISTRIBUTOR ASSY NO PART C 30HDNI PRECISION OPERATION AND PARTS MANUAL REV 7 04 03 12 PAGE 131 22100G5110 0143600191 0143600221 22020G5111 22023G5110 2210414615 22108G5110 22109G5110 2211577A11 22119M5610 2213677A11 2215723G15 2216278A10 22165M5610 2218071200 22183G5111 2218523G15 2220122010 2222977A11 22301G5110 22309H5010 22750 0110 DISTRIBUTOR ASSEMBLY SCREW SCREW TRANSISTER IGNITION UNIT SEAT SYNK SCREW 4 X 8 SHAFT ASSEMBLY
15. 62 Conditions for displaying this error code are is commanding the Fuel Pump relay output ON or OFF Electrical feedback to the ECM indicates any one of the following faults Defective short circuit fault over current fault over voltage fault an open circuit fault Open circuit wiring connected Short circuit in relay circuit Error Code 63 indicates that the Dual Fuel relay output is faulty Voltage level above 28V Conditions for displaying this error code are is commanding the Dual Fuel relay outputON or OFF Electrical feedback to the ECM indicates any one of the following faults short circuit current current fault over voltage fault or an open circuit fault Error Code 64 indicates that the Ignition Power relay output is faulty Conditions for displaying this error code are is commanding the Ignition Power relay outputON or OFF Electrical feedback to the ECM indicates any one of the following faults short circuit current current fault over voltage fault or an open circuit fault MAYCO C 30HDNI PRECISION PUMP OPERATION AND PARTS MANUAL REV 7 04 03 12 PAGE 53 C 30HDNI LOCATION EFI WIRING 55 TABLE 8 EFI SYSTEM COMONPONENTS 11 6 Memel Pop 3 its ese Senor 7 _ e PAG
16. 818 Gy Rd 8 ENGINE AIR TEMP FUEL INJECTOR Figure 32 EFI Wiring Diagram C 30HDNI PRECISION PUMP OPERATION AND PARTS MANUAL REV 47 04 03 12 PAGE 55 C 30HDNI PRECISION PUMP WIRING DIAGRAM BLK 12 AWG RI RED RED RED RED 12 AWG 12AWG 12AWG 12AWG 12AWG FUEL SOLENOID OIL BATTERY WATER HOUR PRESSURE CHARGE TEMP METER E EE CHASSIS 12 AWG BLK BLK 12 AWG 12 AWG 7 WHITE 85 PUNIRE 85 5518 RELAY FUEL INJECTION COIL 1 oii PRESSURE WATER TEMP SEE PAGE 50 SENSOR BLACK 86 SENSOR CONNECT TO 14 WIRE CHASSIS WHTIE BLUE GROUND FUEL INJEGTION ECM CONNECTOR SEE PAGE 50 REMOTE CONNECTOR EEE CONTROL BOX PUMPING CONTROL T ON SWITCH EEUU NS O OPEN PUMPING FE CLOSED IDLE RED 12 VDC 12 AWG 1 6 WIRE WHITE BLACK RED FUEL INJECTION ECM CONNECTOR SEE PAGE 50 RED 12 AWG K1 COMMON HOOD SAFETY NO C NNECTION SWITCH 1 ty 12 AWG CLOSED IGNITION FUEL INJECTION SWITCH ECM CONNECTOR REAR VIEW SEE PAGE 50 REAR VIEW PUMPING CONTROL SWITCH SW1 BLK 10 AWG pue ON REMOTE ON RED TO RED 10 AWG BLK TO 4 REL
17. After manifolds are tight check O rings for slippage Insertseatinto frame hole directly above the T manifold The seat orifice shouldfitinsidethe frame itself then the seat sits on top of the orifice On the dura seat set the big end of the seatintheframe The seat orthe small partofthe dura seat fits into the bottom of the hopper After tightening the manifold bolts and inserting the seats in place setthe hopper overthe seat and align the bolt holes Tighten bolts check O ring and seat for alignment Check exhaust gate for wear install and align gate onto Y manifold Insert O ring into exhaust gate flange and close gate Lock down lever and adjust clamp arm Install3in elbowand3x2in reducer Fill hopper halffulland check for leaks PAGE 40 MAYCO C 30HDNI PRECISION PUMP OPERATION AND PARTS MANUAL REV 7 04 03 12 C 30HDNI PRECISION MAINTENANCE PUMP Clutch Lining Replacement For P N EM14320 Clutch Assembly Only The normal lining thickness measures 3 16 of an inch If the clutch starts to slip or make an usual noise it may be necessary to replace the lining Please note that the lining retaining rivets should not be exposed to the rotating weight The following procedure will assist you in replacing the lining 1 Removewornoutlining andrivets Check clutch springs and flyweights for wear 2 Cut 1 8 in off of each end of clutch lining Slide lining into place Insert one rive
18. allthe system is clean If waiting time is excessive it would be wise to wash out the pump and hoses and start over when the new truck arrives This can be avoided by being observant to the pump and system also taking into consideration the above factors affecting the mix C 30HDNI PRECISION PUMP OPERATION AND PARTS MANUAL REV 7 04 03 12 PAGE 31 C 30HDNI PRECISION OPERATING INFORMATION Down Hill Pumping Downhill pumping can be difficult on some jobs Itis suggested that sponge 2 4 6 be placed in the hose before the start of pumping Wetthe sponge before placing itin the hose Reference the Operating Suggestions at the start of this section for slurry procedures The reason for using the wet sponge is to keep the slurry from running too far ahead of the concrete and so reducing the possibility of separation When the pumpis stopped the material can flow slowly down due to gravity and cause the hose to collapse When pumpingis resumed you can expecta blockage atthe point of hosecollapse To preventthis from happening the hose can be kinked off at the discharge end when the pump is stopped to prevent the gravity flow of the material in the hose The use of stiffer mixes when pumping down hill will decrease gravity flow of the material in the hose and will assure a smoother operation between the cam rollerbearing and cam plate As with any job make sure that the hose and
19. lt gt gt Us AIR COMPRESSOR 125 TO 250 CFM De S Vss 7 SN Piro s 2 AD 2 D 2 gt 7 x SES VAS 1 Figure 36 Shotcrete System PAGE 62 C 30HDNI PRECISION PUMP OPERATION AND PARTS MANUAL REV 7 04 03 12 APPENDIX RECOMMENDED SHOTCRETE SYSTEM RECOMMENDED SHOTCRETE SYSTEM NO PARTNO PART NAME QTY REMARKS 1 28904 3 B COUPLING 2 23946 3 90 ELBOW 3 28903 2 1 2 S J COUPLING 4 EM28005DD 3 2 1 2 REDUCER 5 28061 2 1 2 10 6 24849 2 1 2 50FT HOSE 7 EM28001DD 2 1 2 2 REDUCER 8 EM23815D 2 1 2 X 2 REDUCER W AIRVIBRATOR 9 28902 2 5 COUPLING 10 23101 AIR VIBRATOR 11 EM28131 2 2 ELBOW 12 24841 2 X 25 FT HOSE 13 EM23808D NOZZLE ASSEMBLY 14 EM23806 1 3 8 NOZZLE TIP 15 23807 1 1 4 NOZZLE TIP General recommendations Ifthe site will permit use steel pipe from the pump to the pool perimeter It will reduce line pressures which is highly recommended The vibrator on the reducer by the pool improves pumpability Turn both air vibrators off whenever the pump is stopped to prevent separation of mix The air vibrators are low consumption 4 2 s
20. 18 EM14336 PISTON GUIDE 1 19 EM505489 FITTING 1 20 EM14334 COMPENSATOR SPRING 1 21 EM18409 O RING 1 22 EM98032 PLATE OILER 1 23 EM14407 O RING OILER PLATE 1 24 EM14410 RING amp FELT HOLDER 1 25 EM14408 BRONZE RING 1 26 EM14411 PISTON CUP BLACK 1 26 EM98051 PISTON CUP ORANGE 1 27 14412 BUSHING 1 1 4 CRS 1 28 18409 O RING 1 2 29 14413 FACE PLATE 1 30 EM18800HD PUMPING CYLINDER 2 1 2 SLEEVE 31 26525 O RING CYLINDER BOX 1 32 EM968446 NUT HEX 3 4 10 3 33 EM16493 FELT RING 1 34 EM148053 BUSHING 1 35 EM20328TKIT BEARING KIT pm INCLUDES ITEMS W MAYCO C 30HDNI PRECISION PUMP OPERATION AND PARTS MANUAL REV 7 04 03 12 PAGE 71 C 30HDN CONNECTING ROD DRIVE SIDE ASSY CONNECTING ROD DRIVE SIDE ASSY PAGE 72 C 30HDNI PRECISION PUMP OPERATION AND PARTS MANUAL REV 7 04 03 12 C 30HDN PUMP CONNECTING ROD DRIVE SIDE ASSY CONNECTING ROD DRIVE SIDE ASSY NO PARTNO PART NAME QTY REMARKS 7 EM505490 FITTING 1 8x EM903163 BEARING CUP 1 20814 BEARING BUSHING 1 10 20813 SPACER 1 11 903162 BEARING CONE 2 12 20816 O RING 2 21 EM18409 O RING 1 22 EM98032 PLATE OILER 1 23 EM14407 O RING OILER PLATE 1 24 EM14408 BRONZE RING 1 25 EM14410 RING AND FELT HOLDER 1 26 EM14411 PISTON CUP BLACK 1 26 EM98051 PISTON CUP ORANGE 1 27 EM14412 BUSHING 1 1
21. 2 2 27 492628 LOCK WASHER 3 4 2 28 EM968446 NUT HEX 3 4 10 GR5 4 29 EM14324 CUP BEARING 1 30 14323 SPACER BEARING CONE 1 31 EM14325 BEARING 2 32 14326 O RING 2 33 14322 SPACER 1 34 EM98043 CRANKSHAFT FORGED 1 35 14306 KEY CRANKSHAFT 2 38 EM903176 BEARING 1 40 EM402996 SEAL PLATE 1 41 EM923348 WASHER LOCK 5 8 2 424 30139 SET COLLAR 1 43 14302 SPACER CAM BUSHING 1 44 14300 CAM ASSY 1 45 EM14301 BUSHING CAM 1 46 703 SCREW ALLEN HEAD 3 8 16X3 8 6 48 175 BOLT 3 8 16X1 1 4 6 49 14304 BEARING CAM COMPLETE Tae INCLUDES ITEM W 50 916001 ZERK FITTING 1 51 128 BOLT 5 8 11X4 HEX HEAD 2 52 EM620 WASHER SPECIAL 5 8 2 54 EM968013 NUT HEX 5 8 11 4 55 14307 SPROCKET 60 TEETH 1 56 14309 BUSHING 1 57 EM98043K CRANKSHAFT FORGE ASSEMBLY INCLUDES ITEM W MAYCO C 30HDNI PRECISION PUMP OPERATION AND PARTS MANUAL REV 7 04 03 12 PAGE 79 MANIFOLD ASSY 30HDNI PRECISION PUMP C MANIFOLD ASSY ACCESSORIES PART OF FRAME NO PI 0609 A N 96 2 9 NA 9 S 0 G G 3 2 N SN Y lt 0 N P PAGE 80 C 30HDNI PRECISION PUMP OPERATION AND PARTS MANUAL REV 7 04 03 12 C 30HDNI PRECISION PUMP MANIFOLD ASSY MANIFOLD ASSY NO PARTNO PART NAME
22. 4 CRS 1 28 EM18409 O RING 1 2 29 EM14413 FACE PLATE 1 30 EM14807HD CONCRETE CYLINDER 3 3 4 IN SLEEVE 32 EM968446 NUT HEX 3 4 10 3 33 EM14808 PISTON ROD ASSY 1 34 EM16493 FELT RING 1 35 EM20328TKIT BEARING KIT pm INCLUDES ITEMS W MAYCO C 30HDNI PRECISION PUMP OPERATION AND PARTS MANUAL REV 7 04 03 12 PAGE 73 C 30HDNI PRECISION PUMP ROCKER ASSY ROCKER ASSY LUBRICATION INT 6 2 FRAME as g LUBRICATION 5 Y NOTES A LONG STROKE SETTING HIGHER VOLUME LOWER PSI B STANDARD SETTING NORMAL C SHORT STROKE SETTING REDUCED VOLUME HIGHER PSI A SEE CRANKSHAFT ASSEMBLY PAGE 74 MAYCO C 30HDNI PRECISION PUMP OPERATION AND PARTS MANUAL REV 7 04 03 12 C 30HDNI PRECISION PUMP ROCKER ASSY ROCKER ASSY NO PARTNO PART NAME QTY REMARKS 1 EM14329 SHAFT ROCKER ARM 1 2 EM14116 JOURNAL BLOCK 1 3 EM963180 SCREW 3 4 10X5 2 4 EM923350 WASHER LOCK 3 4 SPRING STEEL 2 5 EM14846 CAM ROCKER APM 1 INCLUDES ITEMS W 6 EM133 BOLT 1 14X2 HEX HEAD 1 7 603 WASHER 1 LOCK 1 8 EM916001 ZERK FITTING 1 9 EM903092 BEARING ASSY 1 10 EM20347 BEARING SPACER 2 11 EM402434 BEARING BUSHING 1 12 EM20344 SPECIAL BOLT 1 13 EM916001 ZERK FITTING 1 14 EM417 NUT FLEX LOCK 1 15 EM402456
23. CYLINDER HEAD 8 VALVE COVER ASSY A15 NISSAN ENGINE CYLINDER HEAD amp VALVE COVER ASSY E gt a lt CD lt o lt CC LU gt gt o 5 LLI e 25 39 gt lt A15 NISSAN ENGINE CYLINDER HEAD 8 VALVE COVER ASSY CYLINDER HEAD amp VALVE COVER ASSY PART NAME QTY NO PARTNO 2 11041K4970 3 11044H9822 4 1105173403 5 11056H1000 6 11057H5000 7 1105821002 8 11098H7512 9 11099H8910 10 13212H8500 11 13213H2312 12 1321473400 15 2508089912 17 0822382810 18 0822383510 20 0093130610 21 009331401A 23 0093320670 24 10005M1000 25 1002332200 26 1326461361 27 1327091000 28 1525585030 29 1527083400 31 0831061614 32 14065W1300 1010105H25 HEAD ASSEMBLY CYLINDER 1 GASKET CYLINDER HEAD 1 PLUG BLIND CYLINDER HEAD 4 BOLT CYLINDER HEAD 9 BOLT CYLINDER HEAD 1 WASHER BOLT HEAD 0 INSERT VALVE INT 4 INSERT VALVE EXH 4 GUIDE VALVE INT 4 GUIDE VALVE EXH 4 8 1 7 2 1 1 1 2 1 1 1 RING SNAP VALVE GUIDE TEMP ENG UNIT STUD STUD PLUG TAPER PLUG WELCH TEMP ENG UNIT SLINGER ENG FR DOWEL VALVE COVER PACKING VALVE COVER CAP ASSEMBLY OIL FILL 1 PACKING OIL FILLER CAP 1 SCREW 6 STUD 2 GASKET SET OVERHAUL 1 REMARKS INCLUDES ITEMS W MAYCO C 30HDNI
24. Check all supports attaching the pump to the trailer and make sure they are tight ALWAYS make sure that the pump s trailer is placed on solid level ground so that it cannot slide or shift around endangering workers Place blocks under the trailer s bumper to make it level prevents tipping and use a chocked block underneath the wheels to prevent rolling Also keep the immediate area free of bystanders Before towing check the hitch and secure the safety chain to the towing vehicle Also check for proper tire pressure Tow only with a vehicle and hitch rated to tow a 2 950 105 1 338 Kg load E pump is equipped with ball hitch coupler use only a 2 all steel ball rated for a minimum of 5000 lbs Use a 1 hardened steel pull pin if the pump is equipped with a pin hitch ALWAYS check the machine for loosened threads or bolts before starting A copy of this manual shall accompany the pump at all times DO NOT use worn out hoses or couplings inspect daily iil DO NOT disconnect the hose couplings or nozzle while they are under pressure Relieve the pressure by manually swinging the clamp arm latch handle to the first open position atthe exhaust cone outlet The pump should NEVER be towed in excess of 45 MPH or less depending on road conditions E hose lines are blocked for any reason or if the lines are kinked when starting up or during pumping cycle the pump pressure could straighten out the kink
25. FT LBS FT LBS FT gt 20 25 50 60 90 120 PNEUMATIC AIR GUN TORQUE WRENCH Figure 4 Wheel Lug Nuts Tightening Sequence NEVER use an pneumatic air gun to tighten wheel lug nuts PAGE 18 MAYCO C 30HDNI PRECISION PUMP OPERATION AND PARTS MANUAL REV 7 04 03 12 5 C 30HDNI PRECISION OPERATION AND PARTS MANUAL REV 7 04 03 12 PAGE 19 C 30HDNI PRECISION PUMP OPERATION AND SAFETY DECALS Figure 5 display s the operation and safety decals as they appear on the concrete pump should any of these decals become damaged or unreadable contact the Multiquip Parts Department for a replacement set CAUTION When the pump manifold or delivery system plugs do not disconnect the delivery system clamps or open the manifold A plug has occurred when the pump is running but no concrete is discharging the end of the delivery system immediately switch the engine OFF consult your operating a d instruction manual before proceeding Great care must be taken to clear a plug as a dangerous condition exist due to high CAUTION 1 Before setup and operation of this equipment the designated operator MUST read and completely understand the operating instruction manual Keep unauthorized and untrained people away from the machine during operation Do NOT operate unit with engine cover open rotating or movi
26. MAINTENANCE PUMP PULLEY Z PA 5 7 V BELTS 3 4 MAX DEFLECTION V Belt And Drive Chain Adjustment 1 Loosen the pillow bearing bolts Figure 27 only to the point where the bolts will remain snug Unlock the two pusher bolt lock nuts Turn each pusher bolt clockwise an equal amount until the chain isto proper adjustment of approximately 3 8 to 1 2 in slack inthe chain Itis very important thatthe pulley side and the chain side pillow block bearings are within 1 16 of an equal distance This distance can be checked by using a tape measure or a straight edge ruler measuring from the inside of the pusher bolt bracket to the face of the pillow block bearing The drive chain should be adjusted regularly to remove all slack Once all slack is removed DO NOT over adjust as this will overload the shaft bearings A slack chain on the crank drive creates backlash and shock loads on the shafts and bearings which results in shorter wear life of the drive com ponents Lubricate the chain regularly Note it is advisable to carry a spare chain and master links for replacement in the field if necessary PUSHER BRACKET PILLOW BLOCK BEARING BOLTS LOCK NUTS Figure 27 and Drive Chain Adjustment Drive belts should be regularly adjustedto prevent slippage To adjust the belts loosen the engine mounting bolts and move the engine until there is a maximum 3 4 in deflection i
27. MAYCO C 30HDNI PRECISION PUMP OPERATION AND PARTS MANUAL REV 7 04 03 12 C 30HDNI PRECISION PUMP TRAILER SAFETY GUIDELINES Tires Wheels Lug Nuts Tires and wheels are a very important and critical components ofthe trailer When specifying or replacing the trailer wheels it is important the wheels tires and axle are properly matched CAUTION General Trailer Safety DO NOT attempt to repair or modify wheel DO NOT install an inter tube to correct leak through the rim If the rim is cracked the air pressure in the inter tube may cause pieces of the rim to explode break off with great force and can cause 2 serious eye or bodily injury Tires Wear Inflation Tire inflation pressure is the most important factor in tire life Pressure should be checked cold before operation DO NOT bleed air from tires when they are hot Check inflation pressure weekly during use to insure the maximum tire life and tread wear Table 3 Tire Wear Troubleshooting will help pinpoint the causes and solutions of tire wear problems ALWAYS wear safety glasses when removing or installing force fitted parts Failure to comply may result in serious injury TABLE 4 WEAR TROUBLESHOOTING WEAR PATTERN CAUSE SOLUTION Over Inflation Under Inflation Adjust pressure to particular load per tire manufacturer Center Wear Adjust pressure to particular load per tire manufacturer Make sure l
28. OILER FELT 2 16 EM607 WASHER FLAT 5 8 1 17 EM20349 OILER PLUG PLASTIC 1 19 EM969038 NUT STOP REG 3 4 10 1 20 903163 BEARING CUP 1 21 20814 BEARING BUSHING 1 22 20813 SPACER 1 23 903162 BEARING CONE 2 24 20816 O RING 2 25 EM105 BOLT 1 14X6 HEX HEAD 1 27 203262 BRONZE BUSHING 4 28 EM20364 CONNECTING ROD 1 30 EM702 SCREW ALLEN HEAD 3 8 16 3 4 1 31 EM505490 ZERK FITTING 1 35 EM14328 ROCKER ARM ASSY tidie 1 INCLUDES ITEM W 36 EM402996 SEAL PLATE 1 37 20336 O RING 1 38 EM903176 BEARING 1 40 EM20338 SPACER 1 41 EM923348 WASHER LOCK 5 8 1 42 503982 BOLT 1 2 13X5 1 43 EM98043 FORGED CRANKSHAFT INCLUDES ITEM W 44 405 NUT LOCK 3 4 10 2 45 EM202 BOLT HEX 1 8 X 6 LG 1 46 EM20328TKIT BEARING KIT add INCLUDES ITEMS W MAYCO C 30HDNI PRECISION OPERATION AND PARTS MANUAL REV 47 04 03 12 PAGE 75 SHAFT ASSY 21 LUBRICATION POINT PART OF COUNTER yw LL SY PART OF FRAME AO SAK h 12275 i n 2 Q o O z a I gt Lu a lt lt CD lt a a a o an cp gt lt co a SEE
29. PARTS MANUAL REV 7 04 03 12 PAGE 35 C 30HDNI PRECISION INSPECTION Checking Engine Coolant Level V Belt Deflection 1 Remove the radiator cap and checkthe coolingwaterlevel 1 Visually inspectthe V belt for cracks fraying wear or oiliness inside the radiator Figure 18 2 sure V belt does not the bottom the pulley groove 2 Maintain water coolant level at top of radiator coils 3 ChecktheV belttension Figure 19 by pushing midway through thetwo pulleys The V belt deflection should be between 300 to 472 inches 8 to 12 mm 8 12 MM DEFLECTION Figure 19 V Belt Deflection NEVER remove the radiator cap when the engine is HOT Allow the engine to cool before remove the cap 1 3 Check the radiator and hoses for any signs of leakage If cooling water is dirty flush the cooling system When using antifreeze mix the antifreeze coolant with water Observe the instructions on the antifreeze container Usually a 50 50 mixture is good choice 6 Whenreplacingtheradiatorcap be suretofititsecurely back ontothe radiator If replaced loosely or incorrectly the cooling water will quickly evaporate causingthe engineto overheat PAGE 36 MAYCO C 30HDNI PRECISION PUMP OPERATION AND PARTS MANUAL REV 7 04 03 12 Starting CAUTION General DO NOT attempt to operate this concrete pump until the Safety General Information and In
30. PRECISION PUMP OPERATION AND PARTS MANUAL 7 04 03 12 PAGE 113 15 NISSAN ENGINE CRANKCASE VENTILATION ASSY CRANKCASE VENTILATION ASSY PAGE 114 MAYCO C 30HDNI PRECISION PUMP OPERATION AND PARTS MANUAL REV 7 04 03 12 15 NISSAN ENGINE CRANKCASE VENTILATION ASSY CRANKCASE VENTILATION ASSY NO PARTNO PART NAME QTY REMARKS 3 11823K4901 HOSE BLOWBY 1 4 11828G2561 HOSE PIPE CONNECTION 1 6 1643910B00 CLAMP HOSE 2 8 11810A3501 PCV VALVE 1 C 30HDNI PRECISION PUMP OPERATION AND PARTS MANUAL REV 7 04 03 12 PAGE 115 15 NISSAN ENGINE PISTON CRANKSHAFT AND FLYWHEEL ASSY PISTON CRANKSHAFT AND FLYWHEEL ASSY PAGE 116 C 30HDNI PRECISION PUMP OPERATION AND PARTS MANUAL REV 7 04 03 12 PART 56 Mr DS 12010G3462 12010G3465 12010G3467 12033H9820 12035 9820 12037 9820 12100 7200 12106 1000 12109 1012 1211120910 1211120901 1211120902 1211120903 1211120904 1211120905 1211120906 12112 1000 12207 7201 12208 7200 12209 7201 12210 7201 12211 7201 12212 1000 12310 4970 12315 6200 12200G3400 1230130000 1230218000 12303G2512 12308H1000 1230978200 1231630000 13021H8900 3220218010 P9410 PART NAME QTY PISTON SET W PIN STANDARD PISTON 5 W PIN OS 0 50 PISTON SET W PIN OS 1
31. QTY REMARKS 1 EM23946 ELBOW 3 X90 DEG HD 1 2 EM28004DD REDUCER 3X2X36 HD 1 3 2 BALL 2 SPONGE 2 4 EM28904 COUPLING 3 HD CF 2 5 18409 O RING 1 4 6 EM14843 UPPER DURASEAT 1 7 18801 O RING 6 8 EM18804 BALL 4 1 2 1 9 14801 MANIFOLD ASSY 1 11 EM136 PIN BALL STOP 3 4 16 x 8 3 12 EM18409 O RING 4 13 EM618 WASHER SPECIAL 4 14 EM968266 NUT JAM HEX 3 4 16 4 15 EM104 BOLT 5 8 11X2 HEX HEAD 3 16 923348 WASHER LOCK 5 8 SPRING 3 17 505882 WASHER 5 8 3 18 14842 SEAT DURA LOWER 1 19 EM14818 BALL 4 1 21 EM14819A MANIFOLD ASSY EASY OPEN 1 23 EM18409 O RING 2 24 EM618 WASHER SPECIAL 2 26 EM137 TEE BOLT 3 4 10X14 2 27 EM619 WASHER 3 4 2 28 968446 NUT HEX 3 4 10 GR5 2 30 EM14850 EXHAUST GATE H D 1 31 963180 CAPSCREW 3 4 10 5 HEX G8 1 32 969038 NUT STOP REG 3 4 10 2 33 EM14845 ARM CLAMP 1 34 EM135 BOLT 1 1 4 12X7 HEX HD 1 35 EM14810 SPRING 1 36 EM451 NUT 1 1 4 12 LOCK 1 37 EM160 BOLT 3 8 16X3 4 1 38 509329 SCREW 3 4 10 6 1 C 30HDNI PRECISION OPERATION AND PARTS MANUAL REV 7 04 03 12 PAGE 81 FRAME ASSY PRECISION PUMP C FRAME ASSY INCLUDED WITH ITEM 42 NOTES A RUBBER LIGHT SEAL IS FOR AXLE PARTS SEE AXLE ASSEMBLY 2 N gt lt lt 72 CC amp an lt
32. TPS reading is less than 0 25V or greater than 4 5V Error Code 14 indicates that the Engine Coolant Temperature EC abnormally high readings ECT is used to control fuel mixture timing and idle speed The termistor used has a low resistance when hot rising as the coolant cools This error then indicates a very low resistance in the ECT circuit 14 Conditions for displaying this error code are reading incorrectly TPS moothly to a maximum of Defective TPS Short circuit in the TPS harness to 5 volt reference Open snesor ground circuit Defective ECM NOTE default temperature of 170 77 while the error is present during normal runtime PAGE 50 C 30HDNI PRECISION PUMP OPERATION AND PARTS MANUAL REV 7 04 03 12 C 30HDNI PUMP MALFUNCTION INDICATOR DIAGNOSTIC ERROR CODES TABLE 7 MALFUNCTION INDICATOR DIAGNOSTIC ERROR CODES Continued DESCRIPTION OF ERROR POSSIBLE CAUSES OF ERROR Error Code 22 indicates that the throttle body actuator is not responding to input current Defective actuator Defective ECM Defective actuator to ECM wiring Conditions for displaying this error code are Engine does not change speed per actuator demand function is commanding a solenoid duty scycle of between 5 and 95 No electrical feedback is being recieved from the solenoid The above condition is present for more than 2 seconds Error Code 23 indicates that the Inlet Air Te
33. and an accelerator Red label will be used mainly on commercial jobs Fly Ash is used to help increase the strength of the concrete and decrease the cement content per yard This is one ofthe most common admixtures used All admixtures will be shown on the redi mix concrete ticket Before start ing the pumping job ask the driver of the redi mixtruck to see the concrete ticket and note the admixtures that exist and take the proper action When pumping long distance or pumping stiff mixes you can expecta drop in volume compared to shorter lines and wetter mixes due to the change in valve efficiency or cavitation 4 Leaking manifold seals or hose coupling gaskets which leak water can cause separation and subsequent jamming at that point 5 Damaged hoses with internal restrictions can cause block ages PAGE 30 MAYCO C 30HDNI PRECISION PUMP OPERATION AND PARTS MANUAL REV 7 04 03 12 C 30HDNI PRECISION OPERATING INFORMATION 6 If ablockage occurs in a hose walk the hose until you find the point of trouble The hose will be softimmediately pastthe blockage Ifthis happens atthe start disconnectthe hose at the first coupling pastthe blockage Elevate the hose at that point with the blockage area hanging down CAUTION Hose Pressure Hazard Whendisconnecting hoses use extreme CAUTION The hose is under pressure Using a hammer you can poundthe down stream ed
34. but it will run on ignition mode timing only Conditions for displaying this error code are open or ground in the EST circuit which stalls the engine System in Bypass mode but the ignition module is still controlling timing OR Engine speed is greater than 600 RPM s with no EST pulses ECM controlled timing going to the ignition module for 200 milli seconds Error Code 43 indicates that the gasoline injector is faulty 10 Conditions for displaying this error code are 43 Defective MAP sensor is commanding the fuel injector output to be On or OFF Open sensor ground circuit Electrical feedback to the ECM indicates a short circuit fault or an open circuit fault Error Code 51 indicates that the ECM sensed a fault in the EEPROM When the PROM is initially created a checksum number number representing the total of all the cell values is also stored The ECM used this checksum to determine if the contents of any cell has changed A Code 51 causes the ECM to enter Back Up mode which uses default sensor values Incorrectly installed PROM module Defective PROM module Defective ECM Conditions for displaying this error code are Power has just been applied to the ECM The calculated checksum does not match the stored checksum OR engine was just started Either of two specific EEPROM locations do not contain the expected value
35. chemicals known to cause serious or fatal injury or illness such as respiratory disease cancer birth defects or other reproductive harm you are unfamiliar with the risks associated with the particular process and or material being cut or the composition of the tool being used review the material safety data sheet and or consult your employer the material manufacturer supplier governmental agencies such as OSHA and NIOSH and other sources on hazardous materials California and some other authorities for instance have published lists of substances known to cause cancer reproductive toxicity or other harmful effects Control dust mist and fumes at the source where possible In this regard use good work practices and follow the recommendations of the manufacturers or suppliers OSHA NIOSH and occupational and trade associations Water should be used for dust suppression when wet cutting is feasible When the hazards from inhalation of dust mists and fumes cannot be eliminated the operator and any bystanders should always wear a respirator approved by NIOSH MSHA for the materials being used MAYCO C 30HDNI PRECISION PUMP OPERATION AND PARTS MANUAL REV 7 04 03 12 PAGE 3 TABLE OF CONTENTS MAYCO C 30HDNI PRECISION CONCRETE PUMP Proposition 65 Warning sen 2 Silicosis Warning san 3 Table of Contents es 4 Parts Ordering 5 Pump Specifications
36. concrete DO NOT use itin any othertests BULLET POINTED STEEL ROD 1 2 DIAMETER SS 24 INCHES LONG FOOT Figure 35 A Slump Test 1 3 Full PAGE 58 MAYCO C 30HDNI PRECISION PUMP OPERATION AND PARTS MANUAL REV 7 04 03 12 Figure 35 B Slump Test 2 3 Full 2l Figure 35 C SlumpTest Full Overflow Figure 35 D SlumpTest Removing Excess Concrete Figure 35 E SlumpTest Cone Invert Figure 35 F Slump Test Measurement APPENDIX C 30HDNI CONCRETE MIX INFORMATION The following information has been extracted from actual testing laboratory reports The purpose of this printing is only to help create better understanding of the importance of uniform gradation and proportioning of materials which affect pumpability of concrete mixes These weights and proportions illustrate that when the sieve analysis is ideal the sand rock ratio can be adjusted 65 sand 35 rock and pumpability should be excellent EXAMPLE 1 A California Test Lab Report JOB Building Foundations Water Project Sacks per cu yd 6 5 designed for 2 500 Ibs in 28 days Gallons per sack 7 1 Washed 5 200 wash 13 Organic matter OK Specific gravity SSD Sand 2 58 Pea Gravel 2 60 Sieve analysis percent passing Material Ls 4 34 38 4 8 16 W C Sand 100 997 791 604 Pea Gravel 100 30 95 Comb 100 66 51 39 DESIGN FOR ONE YARD OF CONCRETE SATURATED amp SURFACE DRY Absolute volume
37. following paragraphs is important to the successful operation of your new Direct flow Concrete Placer All concrete pumps require high level of operator skill and more frequent service than most of the other construction equipment The highly abrasive nature of concrete under pressure makes it extremely important that expendable wear components be inspected at regular intervals between jobs to prevent having to replace these items during a pour Experience has proved that inconsistency of batched concrete mixes and frequent moving of the line requires the operator to be readily available at all times during pumping to stop the pump and prevent abuse to the unit which may occur if unexpected blockages develop Pump Mix Guidelines When ordering concrete be certain to advise the concrete supplier that you require a pump mix The Direct flow manifold will pump a wide variety of materials but certain basic principles must be followed to assure successful pumping as follows Generally speaking the washed concrete sand and 4 aggregate pea gravel should conform to A S T M standards in regard to sieve analysis Sands in some areas are washed clean of the 100 and 200 mesh fines which results in separation and jamming in the manifold while pumping under pressure If this condition develops check with your concrete suppliers engineers and get their recommendations for supplementing the lack of the fines The use of locally accept
38. for price increases will not be made for stock on hand at the time of any price change Multiquip reserves the right to quote and sell direct to Government agencies and to Original Equipment Manufacturer accounts who use our products as integral parts of their own products SPECIAL EXPEDITING SERVICE 35 00 surcharge will be added to the invoice for special handling including bus shipments insured parcel post or in cases where Multiquip must personally deliver the parts to the carrier LIMITATIONS OF SELLER S LIABILITY Multiquip shall not be liable hereunder for damages in excess of the purchase price of the item with respect to which damages are claimed and in no event shall Multiquip be liable for loss of profit or good will or for any other special consequential or incidental damages LIMITATION OF WARRANTIES No warranties express or implied are made in connection with the sale of parts or trade accessories nor as to any engine not manufactured by Multiquip Such warranties made in connection with the sale of new complete units are made exclusively by a statement of warranty packaged with such units and Multiquip neither assumes nor authorizes any person to assume for it any other obligation or liability whatever in connection with the sale of its products Apart from such written statement of warranty there are no warranties express implied or statutory which extend beyond the description of
39. hands or any other parts of you body into the hopper Safety Grill The safety grill should be locked at all times when the pump is being towed Under normal working conditions raise and place the safety grill on the support hooks which are located on splash guard Shaft Pulley V Belt ALWAYS inspect the drive shaft V belt for wear and alignment A defective or misaligned V belt can wear prematurely and adversely affect the performance of the pump Replace with only manufactures recommended type V belt Distributor NEVER allow concrete water or any foreign debris to come in contact with the distributor Compartment Hood NEVER operate the pump with the hood removed Installed on the pump frame is a safety inter lock device which prevents the engine from starting if the hood is removed or in the up position open Hood Fastener When the hood is in the down position secure the rubber latch to this fastener Hood Lift Handle Grip this handle pull upward then back to raise the compartment hood Control Box Contains the mechanical and electrical components required to run the pump Below is a list of those components Throttle Control Low Oil Pressure Indicator Battery Charge Indicator Water Temperature Indicator Ignition Switch Remote Connector 12 20 21 22 23 24 25 26 27 Radiator Cap Fill with water anti freeze type solution as recommende
40. heat shields or heat guards removed A 55 PAGE 8 C 30HDNI PRECISION OPERATION AND PARTS MANUAL REV 7 04 03 12 AX WARNING ROTATING PARTS 1 2 AX CAUTION ACCIDENTAL STARTING NEVER operate equipment with covers or guards removed Keep fingers hands hair and clothing away from all moving parts to prevent injury OFF ALWAYS place the Engine ON OFF switch in OFF position and remove the ignition key when the pump is not in use AX CAUTION OVER SPEED CONDITIONS NEVER tamper with the factory settings of the engine governor or settings Personal injury and damage to the engine or equipment can result if operating in speed ranges above maximum allowable This pump other property or the surrounding environment could be damaged if you do not follow instructions C 30HDNI PRECISION PUMP SAFETY MESSAGE ALERT SYMBOLS AX CAUTION RESPIRATORY HAZARDS ziii ALWAYS wear approved respiratory protection AX CAUTION SIGHT AND HEARING HAZARDS zh 7 R ALWAYS wear approved eye and hearing protection AX CAUTION EQUIPMENT DAMAGE MESSAGES Other important messages are provided throughout this manual to help prevent damage to your concrete pump other property or the surrounding environment MAYCO C 30HDNI PRECISION PUMP OPERATION AND PARTS MANUAL REV 7 04 03 12 PAGE 9 C 30HDNI PR
41. is pumped out and the concrete has reached the end of the hose The only time to stop the pump at the start is if a blockage occurs 4 Whenthepumpis stopped forany reason during a pour e g moving hose waiting for redi mix truck the following sugges tions are offered Leavethe hopper full ofconcrete atthe time of shutdown Itisimportantnottoletthe redi mix driver washtoo much water into the hopper as this could cause separation of the concrete in the hopper B Ifthe shutdown period exceeds 2to 3 minutes turn off the engine sothe vibration does not separate the mix in the hopper which can cause a blockage in the manifold when the pump is started C Ifitisnecessary to wait 10 minutes or more for another load of concrete itis wiseto startthe pump and pump 6 018 strokes every 5 minutes to prevent setting of the mix inthe system If waiting time is excessive it would be wise to wash outthe pump and hoses and start over whenthe new truck arrives D When pumping stiff mixes and there is waiting time between redi mix trucks it is advisable to add some water to the last hopper of material and hand mix to ensure an easier start with the following load When the pumping job requires a stiffer mix the follow ing method is suggested for starting Take a water hose with a nozzle on and apply water with a fine spray to the concrete as it comes down the redi mix chute into the pump hopper after the slurry procedure i
42. occurs find where it is and clear it before further pumping DO NOT increase the engine speed to clear the blockage Increasing the engine speed will only compound the problem WARNING Moving The Pump On The Job Site It will be necessary at times to move your pump from one job site location to another Before moving the pump make sure to pump the remaining concrete out of the hopper Moving the pump with a full hopper of concrete can cause severe damage or breakage of the axle and axle springs excess strain and pressure on the hub and bearing assembly New Pumps Allnewpumps are water pressure tested atthe factory before shipment This procedure permits a thorough inspection of the entire drive system and valving under simulated full load condi tions The pump owner can do the same by attaching an adaptor couple to the end of the discharge cone e g the use of a standard 2 in pipe cap with a 3 8in hole drilledin the center screwed onto the end of the hinged cone or reducer at the pump Fillthe hopper with water after making sure that all sand and rock have been removed from the manifold Operate the pump at full throttle andthe 3 8 in diameter hole restriction will create sufficient back pressure to make a thorough inspection of all moving parts Pumping Tips 1 Theeffects of heat and excessive time on concrete Hot concrete commonly referred to as ahotload is concrete that has been in the redi mix truck i
43. of aggregate in one cu yard 17 78 cu ft Specific gravity of aggregates in one cu yard 2 58 Weight of aggregates in one cu yard batch 2850 108 96 W C Sand 65 1800 2 58 PEA GRAVEL 35 1000 2 60 WATER 46 gal 1 CEMENT 6 5 sk 611 TOTAL ADMIXTURE None SLUMP 4 5 This mix designed for pumping NOTE this mix pumped very successfully 30 50 100 36 5 143 4 0 23 9 3 ABS VOL 11 56 6 22 27 00 200 1d 1 0 Due to the availability of well graded sand as shown in the above sieve analysis MAYCO C 30HDNI PRECISION PUMP OPERATION AND PARTS MANUAL REV 7 04 03 12 PAGE 59 APPENDIX C 30HDNI CONCRETE MIX INFORMATION A S T M STANDARD SPECIFICATION FOR GRADING AGGREGATE PERCENTAGE PASSING BY WEIGHT SCREEN TYPE METRIC FINE AGGREGATE Referred to as washed concrete sand 100 3 8 9 50 mm 4 760 microns 4 76 mm 95 to 10076 2 380 microns 2 38 mm 80 to 10096 16 1 190 microns 1 19 mm 50 10 8596 30 590 microns 59 50 to 85 90 50 297 microns 297um 10 to 30 100 149 microns 149um 2 to 1096 3 8 9 51 mm GRAVEL AGGREGATE Referenced to as 4 Rock or Gravel or 1 2 minus 12 7 mm size 100 12 70 mm 3 8 9 51 85 to 100 HA 6 4 760 microns 4 76 10 30 8 2 380 micron 2 38 0 to 10 1
44. or force out the blockage This rapid surge of material could cause the lines to move or whip a manner that could cause injury to personnel Inspect the hose lines at all times DO NOT tow the pump with the hopper full of material E DO NOT tow the pump with the hoses attached disconnect any emergency or safety devices These devices are intended for operator safety Disconnection of these devices can cause severe injury bodily harm or even death Disconnection of any of these devices will void all warranties MAYCO C 30HDNI PRECISION PUMP OPERATION AND PARTS MANUAL REV 7 04 03 12 PAGE 11 C 30HDNI PRECISION PUMP RULES FOR SAFE Maintenance Safety Emergencies NEVER lubricate components or attempt service running ALWAYS know the location of the nearest fire extinguisher machine and first aid kit Know the location of the nearest telephone ALWAYS allow the machine proper amount of timetocool Also know the phone numbers of the nearest ambulance before servicing doctor and fire department This information will be P invaluable in the case of an emergency Keep the machinery in proper running condition Fix damage to the machine immediately and always replace FES broken parts 2 ay M Dispose of hazardous waste properly Examples of potentially hazardous waste are used motor oil fuel and fuel filters DO
45. removed The possibility exists of hands long hair and clothing becoming entangled with the V belt causing injury and bodily harm NEVER place hands or feet inside the hopper ALWAYS make while the engine is running ALWAYS shut down the engine before performing any kind of maintenance service on the pump Before Starting 1 Read safety instructions at the beginning of this manual 2 Removing any dirt and dust that might have accumulated around the engine cooling air inlet fuel injection system 3 Checktheairfilterfor dirt and dust If air filter is dirty replace air filter with a new one as required 4 Checkfuelinjection system for external dirt and dust Clean with dry compressed air Check fastening nuts and bolts for tightness Connect Battery Make sure hopper is free of dirt and foreign debris large objects over 2 inches 8 Make sure radiator is filled with proper amount of anti freeze water solution 50 50 9 Make sure all hose lines are in good condition and are working properly Reference manufacturer engine manual for specific servicing instructions Engine Oil Check 1 To check the engine oil level place the pump on secure level ground with the engine stopped 2 Remove the dipstick from its holder Figure 13 and wipe it clean fr DIPSTICK o LU Figure 13 Engine Oil Dipstick Removal 3 Check the engin
46. sparks from the ignition system Store fuel in approved containers in well ventilated areas and away from sparks and flames NEVER use fuel as a cleaning agent DO NOT smoke while refueling motor fuels are highly flammable and can be dangerous if mishandled Lubrication Box The model C 30HDNI model 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 be added directly into the lubrication box Visually inspect the oil in the lubrication box by making sure the oil is at the correct operating level as indicated by the dip stick Figure 16 Also reference the oil level decal Figure 17 adjacent to the lubrication box Make sure the pump is on a secure level surface when checking the oil level inside the lubrication box AX CAUTION Checking Lubrication Oil Levels The oil level must be checked daily to ensure adequate oil level and oil cleaniness MAX NORMAL OPERATING LEVEL 2 ADD OIL Figure 16 Lubrication Box Dipstick CAUTION NORMAL LOW Before starting engine check that the oil level inside the LUBE BOX is within the indicated operating range Recommended oil type SAE 30 DCL 152 Figure 17 Lubrication Box Oil Caution Decal MAYCO C 30HDNI PRECISION PUMP OPERATION AND
47. spring for a smooth performance PUMPING Figure 10 Pumping Cylinder MAYCO C 30HDNI PRECISION PUMP OPERATION AND PARTS MANUAL REV 7 04 03 12 PAGE 27 C 30HDNI PRECISION PUMP HOW IT WORKS The pumping piston Figure 11 is forcing the material past ball B and out to the nozzle also seating ball A so that the material will not flow back to the hopper This action also fills the compensating piston for the next stroke COMPENSATOR PISTON PW od INTAKE Heg ud eda BALL MUST MOVE FORWARD PUMPING PISTON 1 7 lt a Pp PUMPING ve te tet sss BALL MUST SEAL TO HOPPER Figure 11 Pumping Pistons Figure 12 shows the relationship between the return spring the compensator spring and the rocker arm to maintain a smooth performance DO NOT tighten the bolt Item 1 completely the rod end must be able to move The return spring is installed to eliminate shock and stress between the cam roller and the cam weldment when the pump is in operation If the return spring is removed or replaced for any reason maintain the backing plate dimension 3 inches as shown to produce proper pre loading of the spring for a smooth performance CAM ROLLER ROD END 5 BACKING PLATE RETURN SPRING AAA CO FT COMPENSATOR SPRING Figure 12 Return S
48. the couplings are in good workable shape Vertical Pumping When pumping vertically up the side of a building above 40 feet we would recommend the installation of steel pipe securely fastened at intervals as necessary to support the pipe Ninety degree long radius pipe sweeps shouldbe installed atthe top and bottom of the steel line Use 25 hose or short section offthe pump and forthe balance ofthe horizontal distance to the vertical line use steel pipe This type of installation has been satisfactory on many jobs being pumpedin excess of 100 feet high Line pressures are alwaysless using steel pipe as compared to hose When pumping vertically using all hose it is recommended not to higher than 50 feet with hose The hose should be tied off at intervals of 10 feet if possible Special attention should be given whentieingthe hose off atthe top as the hose will have atendency to stretch when filled with concrete This will increase the possi bility of a blockage at the point where the hose 15 tied off To avoid this a long radius of 90 degree elbow is recommended The suggested place to tie off is on the hose under the clamp Itis strongly recommended that steel pipe be used on ALL vertical pump ing for safety and convenience Valve Seats Ifthe volume at the end of hose starts to decrease gradually and eventually almost stops itis quite likely thatthe valve seats have had excessive wear and need replacement Onc
49. the products on the face hereof Effective February 22 2006 PAGE 134 MAYCO C 30HDNI PRECISION PUMP OPERATION AND PARTS MANUAL REV 7 04 03 12 PUMP WARRANTY MECHANICAL DRIVE MODELS MAYCO PUMB hereinafter referred to as Manufacturer warrants each new Mayco Pump sold by the manufacturer to be free from defects in material and workmanship under normal use and service for a period of one year after the date of delivery to the original retail purchaser Manufacturer will at its option replace or repair at a point designated by the Manufacturer any part or parts which shall appear to the satisfaction of the Manufacturer upon inspection at such point to have been defective in material or workmanship This warranty does not obligate the Manufacturer to bear any transportation charges or labor charges in connection with the replacement or repair the of the defective parts This warranty does not apply to any pump if attempts have been made to pump concrete materials which have separated to any pump which has been repaired with other than Genuine Mayco Parts nor to any pump which has been altered repaired or used in such manner as to adversely affect its performance nor to normal service or maintenance or where blockages have developed within the pump manifold or placing line or which has been operated in any other manner not recommended by the Manufacturer Due to the abrasive nature of concrete Mayco do
50. to install chain on pump sprocket wheel Knowing more about how the chain is constructed may help in assembly and disassembly Further information may be obtained by calling or writing Diamond Chain Company MAYCO C 30HDNI PRECISION PUMP OPERATION AND PARTS MANUAL REV 7 04 03 12 PAGE 47 C 30HDNI PRECISION PUMP ENGINE TROUBLESHOOTING Practically breakdowns can be prevented by proper handling and maintenance inspections but in the event of a breakdown please take a remedial action following the diagnosis based on the Engine Troubleshooting Table 6 information shown below and on the proceeding page If the problem cannot be remedied please leave the unit just as it is and consult our company s business office or service plant TABLE 6 ENGINE TROUBLESHOOTING SYMPTON POSSIBLE PROBLEM SOLUTION Speed control lever is in STOP position Set speed control lever to START position Defective fuel pump Replace fuel pump Fuel filter clogged Replace fuel filter and clean tank Faulty fuel supply line Replace or repair fuel line Engine will not start or start is delayed although engine can Compression too low Check piston cylinder and valves Adjust or be turned over repair per engine repair manual Oil pressure too low Check engine oil pressure Low starting temperature limit exceeded Comply en art proper oil viscosity Defective battery Charge or replace ba
51. you should contact Diamond Chain Company before this is considered A roller chain should never be loaded above 5096 of UTS for even one cycle To do so will damage the chain structure and reduce its capacity The UTS or one time breaking load of multiple strand chain is the UTS of a single strand chain times the number of strands i e two strand chain is twice as strong as single When allowable working loads are considered however the capacity of each strand in a multiple strand chain is only 6596 of the single strand rating thus three strand chain would rate not three times single but only 1 95 times This is because the chain load cannot be exactly distributed across all three strands of the three strand chain Installation and Drive Alignment Chain and sprockets Figure 29 must be installed correctly Sprockets must be properly aligned and sprocket shafts must be parallel so the drive will run in a plane perpendicular to them Axial alignment should be checked with a straight edge which will extend across the finished sides of the sprockets They should be true running with minimum wobble and eccentricity The higher the drive speed the more important these details become Aligning Shafts Aligning Sprockets Figure 29 Shaft and Drive Sprocket Alignment The chain should be installed so the slack span is properly tensioned To check chain tension Figure 30 turn one sprocket to tighten the upper span of the chain while h
52. 00 RING SET PISTON STANDARD RING SET PISTON OS 0 50 RING SET PISTON OS 1 00 ROD ASSEMBLY CONN CAP CONN ROD BOLT CONN ROD BUSH CONN ROD STANDARD BUSH CONN ROD US 0 08 BUSH CONN ROD US 0 12 BUSH CONN ROD US 0 25 BUSH CONN ROD US 0 50 BUSH CONN ROD US 0 75 BUSH CONN ROD US 1 00 NUT HEX CONN ROD BEARING SET STANDARD BEARING SET OS 0 20 BEARING SET OS 0 25 BEARING SET OS 0 50 BEARING SET OS 0 75 BEARING SET OS 1 00 FLYWEEL ASSEMBLY FLYWHEEL BOLT CRANKSHAFT ASSEMBLY WASHER A OIL THROWER CRANK CRANK PULLEY WASH PULLEY BOLT BOLT CRANK PULLEY KEY WDF 5 X 16 SPROCKET CRANK BUSH PILOT SENSOR EFI PROXIMITY 4 4 4 1 1 1 N J CO CO A15 NISSAN ENGINE PISTON CRANKSHAFT AND FLYWHEEL ASSY PISTON CRANKSHAFT AND FLYWHEEL ASSY REMARKS INCLUDES ITEMS W MAYCO C 30HDNI PRECISION PUMP OPERATION AND PARTS MANUAL REV 7 04 03 12 PAGE 117 15 NISSAN ENGINE CAMSHAFT AND VALVE MECHANISM ASSY CAMSHAFT AND VALVE MECHANISM ASSY PAGE 118 MAYCO C 30HDNI PRECISION PUMP OPERATION AND PARTS MANUAL REV 7 04 03 12 A15 NISSAN ENGINE CAMSHAFT AND VALVE MECHANISM ASSY CAMSHAFT AND VALVE MECHANISM ASSY NO PARTNO 1 1102378200 2 1300199800 1301018001 4 13020 9800 5 13024H8660 6
53. 1020 30 13003 1020 30 13004 1020 30 13005H1020 31 1102661000 32 11110K4920 33 1111961000 34 1112869200 35 1113018002 36 1113118002 37 11132 5025 39 11132 5025 40 11140 7200 41 081106161 42 0891110610 43 089151361 44 13035H1000 45 13044H1001 46 081208161B 47 1104673402 48 13510H1010 49 0821666100 50 30411H5001 PART NAME BLOCK ASSY CYL PLUG WELCH 44 425 PLUG TAPER 12 7 NET STEEL CRANK CASE PLATE BAFFLE DOWEL 5 DOWEL BLOCK TO HEAD PIPE ASSY CONN SEAL OIL CRANK RR BOLT MAIN BRG CAP ORIFICE OIL GAL GUIDE OIL GAUGE PLUG TAPER 6 PIPE SUCT WATER DOWEL 9 5 STUD STUD STUD STUD SCREW PLUG WELCH PLUG WELCH LINER CYL 400 LINER CYL 450 BUSH SET CAM STD BUSH SET CAM US 0 25 BUSH SET CAM US 0 50 BUSH SET CAM US 0 75 WASHER SEAT DRAIN PLUG PLUG DRAIN SEAL OIL PAN FR SEAL OIL PAN FR GASKET OIL PAN RH GASKET OIL PAN LH DIPSTICK BOLT NUT WASHER COVER TIMING CHAIN GASKET COVER TIMING BOLT DOWEL OIL SEAL CRANK FR STUD COARSE THD PLATE ENG RR TY REMARKS gt gt 1 1 2 1 1 2 2 1 1 0 1 1 7 1 2 2 3 2 4 2 3 1 R R 1 1 1 1 1 MD Aa A INCLUDES ITEMS INCLUDES ITEMS W MAYCO C 30HDNI PRECISION PUMP OPERATION AND PARTS MANUAL REV 7 04 03 12 PAGE 111
54. 12008 FITTING AFTER JULY 2005 15 C282314 CLAMP FUEL FILTER 34 2 1 8 ID 1 16 282315 CLAMP FUEL 426 1 5 8 ID 2 C 30HDNI PRECISION PUMP OPERATION AND PARTS MANUAL REV 7 04 03 12 PAGE 99 HOPPER ASSY C 30HDNI PRECISION PUMP HOPPER ASSY Q a E gt a lt lt CD an o lt s Lu a gt a gt o an 25 39 lt lt a C 30HDNI PRECISION HOPPER ASSY HOPPER ASSY NO PARTNO PART NAME QTY REMARKS 1 14159 HOPPER SCREEN 1 2 EM14141 HOPPER 1 3 EM925191 PIN HAIR 2 4 104 BOLT 5 8 11 2 HEX HEAD 3 5 EM507599 WASHER 5 8 FLAT 3 MAYCO C 30HDNI PRECISION PUMP OPERATION AND PARTS MANUAL REV 7 04 03 12 PAGE 101 C 30HDNI PRECISION HOOD ASSY HOOD ASSY PAGE 102 MAYCO C 30HDNI PRECISION PUMP OPERATION AND PARTS MANUAL REV 7 04 03 12 C 30HDNI PRECISION PUMP HOOD ASSY HOOD ASSY NO PARTNO PART NAME QTY REMARKS 1 503723 RIVET 4 2 491010 LATCH KIT 2 3 513120 HOOD ASSY 1 4 490937 BUMPER RUBBER 2 5 EM406 NUT 1 2 13 HEAVY HEX 2 6 EM124 BOLT 1 2 DIA NC X4 G5 2 7 EM963003 SCREW HHC 1 4 20 X 3 4 3 8 EM923057 WASHER 3 9 29057 M
55. 1302818001 7 1303018000 8 1303218000 9 1307018001 10 081106161B 11 0812063562 12 081310401A 13 089152402A 14 13201 6200 15 13202H6200 16 13203H1000 17 1320518000 18 13207H7210 19 13209H2302 20 13210U0100 21 1322218001 22 1322418000 23 13231H1001 24 1323418000 25 13238H6201 26 1325218000 27 1325458000 28 1325618000 29 1325718003 30 1325818003 31 13288H5000 32 0891543800 PLUG TAPER CAMSHAFT PLATE LOCAT CAM CAMSHAFT ASSEMBLY SPROCKET CAM CHAIN CAMSHAFT WASHER PLAIN DOWEL CAM TENSIONOR ASSEMBLY BOLT BOLT BOLT WASHER VALVE INTAKE VALVE EXHAUST SPRING VALVE SEAT VALVE SPRING SEAL VALVE OIL RETAINER SPRING COLLECT VALVE BRACKET ROCKER SHAFT BOLT HEX ROCKER SHAFT VALVE LIFTER SCREW ADJUST PUSH ROD SHAFT ASSEMBLY ROCKER PLUG SPRING INSIDE ROCKER ROCKER VALVE 1 ROCKER VALVE 2 NUT ADJUST SCREW WASHER FLAT M8 5 INCLUDES ITEMS MAYCO C 30HDNI PRECISION PUMP OPERATION AND PARTS MANUAL REV 7 04 03 12 PAGE 119 15 NISSAN ENGINE MANIFOLD ASSY MANIFOLD ASSY PAGE 120 C 30HDNI PRECISION PUMP OPERATION AND PARTS MANUAL REV 7 04 03 12 15 NISSAN ENGINE MANIFOLD ASSY MANIFOLD ASSY NO PARTNO PART NAME QTY REMARKS
56. 190 microns 1 19 mm 0 to 5 PAGE 60 C 30HDNI PRECISION PUMP OPERATION AND PARTS MANUAL REV 7 04 03 12 APPENDIX C 30HDNI CONCRETE MIX INFORMATION Consolidated Rock Products Co Division of Tests 3 8 Pea Gravel STANDARD PUMP MIXES one half inch minus NOTE All weights shown are one cubic yard with S S D aggregates CRP Mix Number 6004 anne 6005 ee DDUD 6007 Design Slump in 6 150M oos e 15 0M 6 1300 6 15 Cement SACK T acce ees u as VO anu nas 7 0 Cement Lbs 658 298 kg 058 298 0 658 298 kg 658 298 kg w Con Sand 1 Ib 2031 920 kg 2982 943 kg 1879 851 kg 1943 880 kg Gravel 4 9 51 mm 677 307 kg 693 314 kg 806 1365 Kg os 832 377 kg TOTAL AGGREGATE 2708 1227 k9 2775 1257 2685 1216 kg 2775 1257 kg ADMIXTURE Pozzolight 311 1 Ib 14 63 80 1 4 14 63kg Water Design gals 50 0 189 liters 530 000 liters 50 0 189 liters 53 9 200 liters Mater Max gals 50 0 189 liters 530 200Iiters 53 0 200 liters 53 0 200 liters NOTE Multiply above kilograms and liters by 1 308 to obtain the proportions for one cubic meter of concrete Consolidated Rock Products Co Division of T
57. 2 14001K4970 INTAKE MANIFOLD 1 3 14004G5200 EXHAUST MANIFOLD 1 15 1403505H01 GASKET MANIFOLD 1 16 140373600 MANIFOLD 4 23 1406411 00 STUD EXHAUST 3 29 0164200012 PLUG TAPER 2 30 0164800181 PLUG WELCH 1 32 2707633300 CONN WATER 1 38 0821662210 STUD 4 42 089112081A NUT 9 43 089151381A WASHER 5 46 089313021A PLUG TAPER 2 47 0893130410 PLUG TAPER 1 C 30HDNI PRECISION OPERATION AND PARTS MANUAL REV 7 04 03 12 PAGE 121 15 NISSAN ENGINE OIL PUMP ASSY OIL PUMP ASSY PAGE 122 MAYCO C 30HDNI PRECISION PUMP OPERATION AND PARTS MANUAL REV 7 04 03 12 15 NISSAN ENGINE OIL ASSY OIL PUMP ASSY NO PARTNO PART NAME QTY REMARKS 1 15010M3001 PUMP ASSEMBLY OIL 1 2 1503618000 BOLT OIL PUMP 2 3 1505005H00 STRAINER ASSEMBLY OIL mom INCLUDES ITEM W 4 1505318000 GASKET OIL STRAINER 1 5 15066H1001 GASKET OIL PUMP 1 6 1520855Y00 ELEMENT ASSEMBLY OIL 1 7 2524089910 SWITCH OIL PRESSURE 1 8 081108201B BOLT 2 9 081108551A BOLT 1 10 089151381A WASHER 3 C 30HDNI PRECISION PUMP OPERATION AND PARTS MANUAL REV 7 04 03 12 PAGE 123 A15 NISSAN ENGINE EXHAUST TUBE AND MUFFLER ASSY EXHAUST TUBE AND MUFFLER ASSY NOTE SEE ITEM 23 PAGE 114 PAGE 124 MAYCO C 30HDNI PRECISION PUMP OPERATION AND PARTS MANUAL REV 7 04 03 12 15 NISSAN EN
58. 30 8 x 576 3 mm Dry Net Weight 227 5 103 80 PAGE 6 MAYCO C 30HDNI PRECISION PUMP OPERATION AND PARTS MANUAL REV 47 04 03 12 C 30HDNI PRECISION PUMP PUMP DIMENSIONS 145 IN 3 68 M DISCHARGE CONE IN TRAVEL POSITION 63 5 IN 1 61 M Figure 1 C 30HDNI Concrete Pump Dimensions MAYCO C 30HDNI PRECISION PUMP OPERATION AND PARTS MANUAL REV 7 04 03 12 PAGE 7 C 30HDNI PRECISION PUMP SAFETY MESSAGE ALERT SYMBOLS FOR YOUR SAFETY AND THE SAFETY OF OTHERS Safety precautions should be followed at all times when operating this equipment Failure to read and understand the Safety Messages and Operating Instructions could result in injury to yourself and others This Owner s Manual has been developed to provide complete instructions for the safe and efficient operation of the Mayco 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 the operator and are preceded by one of three words DANGER WARNING or CAUTION You WILL be KIL
59. 6 1 20720 CABLE NEGATIVE BATTERY 1 8 EM505624 COVER NEGATIVE TERMINAL 1 9 EM491344 BATTERY 12 VOLT 1 MAYCO C 30HDNI PRECISION PUMP OPERATION AND PARTS MANUAL REV 7 04 03 12 PAGE 97 C 30HDNI PRECISION PUMP FUEL TANK ASSY FUEL TANK ASSY b FUEL TANK ASSY P N 516550 INCLUDES ITEM 13 PICK UP TUBE ASSY ITEM 13 PICK UP TUBE ASSY REPLACED ITEM 6 PIPE AND ITEM 4 ADAPTER AFTER JULY 2005 PAGE 98 MAYCO C 30HDNI PRECISION PUMP OPERATION AND PARTS MANUAL REV 7 04 03 12 C 30HDNI PRECISION PUMP FUEL TANK ASSY FUEL TANK ASSY NO PARTNO PART NAME QTY REMARKS 1 HOSE FUEL 3 8 IN 1 2 EM506208 CLAMP HOSE 1 3 C282224 FILTER FUEL 1 4 ADAPTER M EE BEFORE JULY 2005 5 EM491210 PLUG 1 4 IN 1 6 EM505594 PIPE 5 16 COPPER BEFORE JULY 2005 514722 FUEL TANK ha uwa qa BEFORE JULY 2005 4 516550 FUEL TANK ASSY aa INCLUDES ITEM 13 AFTER JULY 2005 8 2108 FUEL CAP 9 C282 238 PUMP FUEL 10 19633 BUSHING a uu AFTER JULY 2005 114 60058 HOSE sas zas AFTER JULY 2005 124 12009 SOREEN m Tusen AFTER JULY 2005 13 EM516533 PICK UP TUBE ASSY T nuits INCLUDES ITEMS W AFTER JULY 2005 144
60. 64 65 Explanation of Codes in Remarks Column 66 Suggested Spare Parts 67 COMPONENT DRAWINGS Nameplate and Decals 68 69 Compensator Piston Rod Assembly 70 71 Connecting Rod Drive Side Assembly 72 73 Rocker 74 75 Countershaft 76 77 Crankshaft Assembly 78 79 Manifold Assembly 80 81 Frame Assembly 82 83 Axle Assembly a 84 85 Muffler Air filter And Stop Switch Assembly 86 87 e le ASSY 88 89 Radiator amp Engine Mounting Bracket Assy 90 91 Radiator Mounting And Hoses Assembly 92 93 Control Box Assembly 94 95 Battery 96 97 Fuel Tank Assembly 98 99 Hopper Sedna 100 101 Hood Assembly aner 102 103 Lubrication Panel Assembly 104 105 Remote Control Cable Assembly 106 107 Precision Fuel Injection System 108 109 COMPONENT DRAWINGS NISSAN ENGINE Cylinder Block And Pan Assembly 110 111 Cylinder Head And Valve Cover Ass
61. 8 BARB 1 8 P7625 AIR HORN 1 9 P3004 1 4 20 UNG NUT 2 10 P3005 1 4 LOCK WASHER 2 11 P7619 AIR HORN GASKET 1 12 P5184 DELPHI FUEL RING 1 15 P7618 DELPHI FUEL RING GASKET 1 16 P7623 TOP PLATE FUEL RING ADAPTER 1 17 P2571 FUEL PUMP MOUNTING KIT 1 19 P2562 THROTTLE BODY O RING 1 20 P3206 ENGINE COOLANT TPP SENSOR 1 21 P7600 THROTTLE BODY ASSY 1 23 P3389 3 16 VACUUM HOSE 24 LONG 1 24 P3348 1 4 20 UNC X 6 LONG THREADED ROD 2 25 P3366 3 16 T FITTING FOR VACUUM HOSE 1 26 7635 ENGINE ADAPTER PLATE 1 28 P7668 INTAKE MANIFOLD GASKET 1 29 P2560 MAP SENSOR 1 30 P2561 OXYGEN SENSOR 1 31 4RD93141008 FUEL RELAY Goin Fonsi p NOT ILLUSTRATED MAYCO C 30HDNI PRECISION PUMP OPERATION AND PARTS MANUAL REV 7 04 03 12 PAGE 109 15 NISSAN ENGINE CYLINDER BLOCK 8 OIL ASSY CYLINDER BLOCK amp OIL PAN ASSY PAGE 110 C 30HDNI PRECISION PUMP OPERATION AND PARTS MANUAL REV 87 04 03 12 A15 NISSAN ENGINE CYLINDER BLOCK 8 OIL PAN ASSY CYLINDER BLOCK amp OIL PAN ASSY NO PARTNO 1 11010 4970 2 1101932200 3 11024K0100 4 11037 1000 5 11038 9700 1104673402 7 1105373400 8 11830G3600 9 12279H2301 10 1229301M00 13 1512718000 14 15146H5002 15 0164700011 17 21045K4920 18 30412H1001 19 0821383510 20 0821385510 21 0821661610 22 0822382010 23 0831061214 25 009331355A 27 0093315010 29 11012H7200 29 11013 7200 30 13002
62. ANUAL HOLDER 1 10 969079 NUT LOG NYLON 1 4 3 11 RAL1003S PAINT SPRAY 12 OZ YELLOW AR 12 RAL1003G PAINT GALLON YELLOW AR MAYCO C 30HDNI PRECISION PUMP OPERATION AND PARTS MANUAL REV 7 04 03 12 PAGE 103 C 30HDNI PRECISION PUMP LUBRICATION PANEL ASSY LUBRICATION PANEL ASSY 1 REQUIRED PROTECTIVE SLEEVE TYPICAL 13 PLACES TYPICAL 14 PLACES Grease daily two to three shots of 2 NOTES multi purpose automotive grease PLACE PROTECTIVE SLEEVE Over greasing any bearing will not OVER LUBRICATION LINES damage the machine 1 THROUGH 6 LOCATION LENGTH OF LINES PAGE 104 C 30HDNI PRECISION PUMP OPERATION AND PARTS MANUAL REV 7 04 03 12 C 30HDNI PRECISION PUMP LUBRICATION PANEL ASSY LUBRICATION PANEL ASSY NO PARTNO PART NAME QTY REMARKS 1 916001 FITTING GREASE 1 8 14 2 EM505489 STRAIGHT FITTING 1 8 NPT 13 3 505534 COUPLING W NUT 1 8 NPT 14 4 505516 PLASTIC HOSE LINE 1 4 DIA AR 1FT 1PC 5 EM490531 PROTECTIVE SLEEVE 3 8 HOSE AR 1FT 1PC 6 EM491028 TIE WRAP 2 5 x 95 MM AR 7 505490 ADAPTER 90 ELBOW 1 8 512659 KIL LUBRICATION aaa jme INCLUDES ITEMS W MAYCO C 30HDNI PRECISION PUMP OPERATION AND PARTS MANUAL 7 04 03 12 PAGE 105 C 30HDNI PRECISION REMOTE CONTROL CABLE ASSY
63. AY PIN 87 12 ANG REMOTE PLUG WHTTO 25 AMP FUSE RED 12 AWG REDTO RED TO IGNITION GAUGES RELAY PIN 87 SWITCH 12VDC 12 0 12 VDC SAM STARTER POSITIVE NEGATIVE 12V DC BATTERY m ALTERNATOR CHASSIS GROUND LAMP IGNITION Figure 33 Wiring Diagram PAGE 56 C 30HDNI PRECISION PUMP OPERATION AND PARTS MANUAL REV 7 04 03 12 C 30HDNI PRECISION PUMP WIRING DIAGRAM TAIL LIGHTS TOWING TRAILER SIDE VEHICLE SIDE DOUBLE FILAMENT BULB CONNECT T CHASSIS RIGHT GROUND TAIL LIGHT WHITE COMMON GROUND GREEN BROWN YELLOW BROWN LIGHT KIT HARNESS P N EM51300 GREEN STOP amp TURN LEFT DOUBLE FILAMENT BULB FLAT 4 PIN MOLDED FLAT 4 PIN MOLDED CONNECTOR MATING CONNECTOR LEFT TAIL LIGHT Figure 34 Trailer Tail Lights Wiring Diagram MAYCO C 30HDNI PRECISION PUMP OPERATION AND PARTS MANUAL REV 7 04 03 12 PAGE 57 APPENDIX C 30HDNI C 30HDNI SLUMP TEST PROCEDURE To obtain a representative sample concrete take several samples at three or more regular intervals throughout the discharge ofthe mixerortruck DO NOT take samples atthe beginning or end of the discharge Dampentheinside ofthe cone and place iton a smooth moist nonabsorbent level surface large enough to accommodate both the slumped concrete andthe slump cone S
64. CLUTCH ASSEMBLY CRANKCASE ASSEMBLY NOTES COUNTERSHAFT ASSY C 30HDNI PRECISION 5 ASSY COUNTER SHAFT ASSY NO PARTNO PART NAME QTY REMARKS 1 EM513073 COUNTER SHAFT 1 2 14311 BEARING 2 3 EM124 BOLT HEX 1 2 X 1 3 4 2 4 EM1621 WASHER 5 2 5 EM923346 WASHER LOCK 1 2 2 6 EM968011 NUT HEX 1 2 13 2 7 916001 FITTING 1 8 EM14316 KEY WAY 3 8 X2 5 1 9 14314 BUSHING PULLEY 1 10 EM14313 PULLEY 1 11 EM98089 BELT DOUBLE 83 INCHES 1 12 EM143111 SET COLLAR 1 21 EM14318 SPROCKET 13 TOOTH 1 22 EM14319 BUSHING 1 55 14307 SPROCKET 60 TEETH 1 57 1702 SCREW ALLEN HEAD 3 8 16 3 4 1 58 EM703 SET SCREW 3 8 16X3 8 1 59 14308 CHAIN W MASTER LINK 1 60 EM26314 LINK MASTER 1 61 EM26313 HALF LINK 1 MAYCO C 30HDNI PRECISION PUMP OPERATION AND PARTS MANUAL REV 7 04 03 12 PAGE 77 C 30HDNI PRECISION PUMP CRANKSHAFT ASSY CRANKSHAFT ASSY LUBRICATION SEE ROCKER ARM ASSEMBLY ITEM 43 FOR ASSOCIATED CRANKSHAFT COMPONENTS SEE COUNTER SHAFT ASSEMBLY ITEM 55 PAGE 78 C 30HDNI PRECISION PUMP OPERATION AND PARTS MANUAL REV 7 04 03 12 C 30HDNI PRECISION CRANKSHAFT ASSY CRANKSHAFT ASSY NO PARTNO PART NAME QTY REMARKS 23 14303 BEARING BLOCK 1 24 02 SCREW ALLEN HEAD 3 8 16X3 4 6 25 EM505490 ZERK FITTING 1 26 129 SCREW 3 4 10 8 1
65. DECALS NAME PLATE AND DECALS NO PARTNO PART NAME QTY REMARKS 1 DCL152 DECAL CAUTION OIL LEVEL 1 2 932 DECAL CAUTION MANIFOLD 1 3 EM1028 DECAL MULTIQUIP MAYCO 2 4x 508594 DECAL CAUTION READ MANUAL 2 5 DECAL C 30HDNI 2 6 513165 DECAL MAINTENANCE 1 7 DECAL NAME PLATE CONTACT PARTS 8x 98022 DECAL WARNING 1 9 34536 DECAL OWNER S MANUAL 1 10 DCLC30HDNIKIT DECAL PC 1666 INCLUDES ITEMS W C 30HDNI PRECISION PUMP OPERATION AND PARTS MANUAL REV 7 04 03 12 PAGE 69 C 30HDNI PUMP COMPENSATOR PISTON ROD ASSY COMPENSATOR PISTON ROD ASSY PAGE 70 MAYCO C 30HDNI PRECISION PUMP OPERATION AND PARTS MANUAL REV 7 04 03 12 C 30HDNI PUMP COMPENSATOR PISTON ROD ASSY COMPENSATOR PISTON ROD ASSY NO PARTNO PART NAME QTY REMARKS 1 EM14805 ROD END INCLUDES ITEMS W 1A 148053 BUSHING 1 2 968446 NUT HEX 3 4 10 GR5 2 3 EM14332 ROD SPRING GUIDE 3 4 1 4 EM14331 SPRING BACKING PLATE 1 5 EM14333 SPRING RETURN 1 6 EM14806 PISTON GUIDE ASSY 1 7 505490 FITTING 1 8x EM903163 BEARING CUP 1 20814 BEARING BUSHING 1 10 20813 SPACER 1 11 903162 BEARING CONE 2 12 20816 O RING 2 13 EM916001 FITTING 2 14 EM510266 SCREW HHC 1 2 13X3 1 15 EM621 WASHER 2 16 492584 NUT LOCK 1 2 DIA 1 17 EM14335 PISTON ROD 1
66. E 54 C 30HDNI PRECISION PUMP OPERATION AND PARTS MANUAL REV 7 04 03 12 C 30HDNI WIRING DIAGRAM EFI WIRING HARNESS 18 Or Computer Interface EN 18 Or 10K 1 Potentiometer 18 Gr 5 2 18 BIK YI MALFUNCTION INDICATOR LED LED INDICATOR 18 Or This LED will be mounted near PCB in harness Customer Interface Wires Battery Pos 16 Computer Interface wires are 6 conductor cable 18 BIk YI 18 8 4 LEO 18 RA BIk 18 FUEL PUMP 18 Or BIK Fuse Holder 15 Amp Pins E amp F 7 5 Amp Pins A amp B Oil Pressure Shutdown Switch Switched Battery Pos 16 Org 18 B INLET HL AIR TEMP E 18 BIKNI 18 Bik A 5 mob LH BC FE 18 Rd Bu 9 ml MANIFOLD 9 PRESSURE Ignition Coil Fuel Pump 2 Fuel Injector Relay ETE 1 tt 18 YI C G L 1411 THROTTLE 49 89 20 9 POSITION e 1 x Prom 11 18 18 Dk Bu B E Sensor ACUTATOR Magnete i EN Sensor 5 Pickup Shielded Cable FUELRING Three conductor shielded cable GROMMET Shield connected to power ground Black wire connected to analog ground Signal wire to EFI PCB 18 Rd BIk
67. ECISION PUMP RULES FOR SAFE OPERATION AX DANGER Read This Manual Failure to follow instructions in this manual may lead to serious injury or even death This equipment is to be operated by trained and qualified personnel only This equipment is for industrial use only The following safety guidelines should always be used when operating the Mayco C 30HDNI Concrete Pump General Safety E DO NOT operate or service this equipment before reading this entire manual ALWAYS read understand and follow procedures in Operator s Manual before attempting to operate equipment ALWAYS be sure the operator is familiar with proper safety precautions and operations techniques before using pump This equipment should not be operated by persons under 18 years of age ALWAYS read understand and follow procedures in Operator s Manual before attempting to operate equipment ALWAYS be sure the operator is familiar with proper safety precautions and operations techniques before using pump NEVER operate this equipment without proper protective clothing shatterproof glasses steel toed boots and other protective devices required by the job 00000 NEVER operate this equipment when not feeling p well due to fatigue IIness or taking medicine AN VN NEVER operate this equipment under the influence of drugs or alcohol 212 ALWAYS wear proper respiratory mask 22 hearing and eye protection equipm
68. F ERROR Special case error code that is not logged into the ECM s EEPROM Memory when detected When the power to the ECM is ON and the ECM detects no crankshaft reference pulses coming from the engine it illuminates the malfunction indicator light Code 12 is also used when the ECM is in diagnostic mode engine OFF to signal the beginning or end of the diagnostic sequence when the ECM outputs each stored error code via the LED error indicator light When in this mode the ECM will begin by flashing code 12 via one LED blink followed by a pause and then two quick LED blinks and a pause indicating the beginning of a diagnostic This cycle will continue as long as the ECM is in diagnostic mode NOTE When in this mode error codes are displayed in numerical order rather than the order of occurance sequence It will then flash all error codes stored in EEPROM When all stored error codes have been displayed the ECM will again flash code 12 again followed by a long pause to indicate the end of the diagnostic sequence Error Code 13 indicates an oxygen sensor error Indicates that the exhaust stream oxygen sensor O sensor is not responding correctly When cold the sensor has a defaulted value before it warms up it acts as an open circuit and the ECM will read the bias value The ECM expects the sensor to warm up in a short period of time and begin sending its own voltages Conditions for displaying this error code are Engine
69. GINE EXHAUST TUBE AND MUFFLER ASSY EXHAUST TUBE AND MUFFLER ASSY NO PARTNO PART NAME QTY REMARKS 1 282 355 SENSOR OXYGEN 1 2 20011 4915 TUBE ASSEMBLY EXHAUST 1 3 20601H7210 PLATE FIXING 1 4 2060250600 NUT FIXING TUBE END 3 MAYCO C 30HDNI PRECISION PUMP OPERATION AND PARTS MANUAL REV 7 04 03 12 PAGE 125 15 NISSAN ENGINE WATER PUMP ASSY WATER PUMP ASSY PAGE 126 C 30HDNI PRECISION OPERATION AND PARTS MANUAL REV 7 04 03 12 15 NISSAN ENGINE WATER PUMP ASSY WATER PUMP ASSY NO PARTNO 1 21010K7700 2 093400010P 21014 1001 4 2105120500 5 21054 7700 6 081108501B 8 089111081A 9 2106003W00 10 2106403W00 12 0812064062 16 21200G3100 17 11060H5000 18 1106218001 19 0812083063 20 1172077702 PART NAME WATER PUMP WASHER GASKET WATER PUMP PULLEY FAN amp PUMP HUB PULLEY amp PUMP BOLT NUT FAN COOLING SPACER FAN BOLT THERMOSTAT STD 180 DEGREES OUTLET WATER WASHER JOINT BOLT V BELT FAN QTY PET 1 B C c REMARKS INCLUDES ITEMS MAYCO C 30HDNI PRECISION PUMP OPERATION AND PARTS MANUAL REV 7 04 03 12 PAGE 127 A15 NISSAN ENGINE IGNITION SYSTEM ASSY IGNITION SYSTEM ASSY PAGE 128 MAYCO C 30HDNI PRECISION PUMP OPERATION AND PARTS MANUAL REV 87
70. HDNI PRECISION ENGINE COMPONENTS FRONT VIEW 6 TOP VIEW Figure 9 Nissan Model A15 Basic Engine Components Figure 9 illustrates the location of the basic components for the NISSAN A 15 Engine The function of each component is described below 1 Filter Replace this filter as recommended in the maintenance section of this manual Oil Pressure Switch In the event of low oil level this switch will shutdown the engine Starter Motor Solenoid NEVER allow concrete or any foreign debris to come in contact with the starter motor solenoid Fan V Belt ALWAYS make sure that V belt is properly tensioned A loose or defective V belt can adversely affect the performance of the pump Alternator Provides power to the electrical system Replace with only manufactures recommended type alternator Air Cleaner Prevents dirt and other debris from entering the fuel system Remove wing nut on top of air filter cannister to gain access to filter element Replace with only manufactures recommended type air cleaner Cooling Fan Blades Make sure that the blades of the cooling fan are not bent or broken A damaged fan blade can cause the engine to run hot and overheat Operating the engine without an air filter with a damaged air filter or a filterin need of replacement will allow dirtto enter the engine causing rapid engine wear 13 Crankcase D
71. LED SERIOUSLY injured if you do not follow directions You COULD be KILLED or SERIOUSLY injured if you do not follow directions You CAN be injured if you do not follow directions HAZARD SYMBOLS Potential hazards associated with operation of the pump will be referenced with Hazard Symbols which appear throughout this manual and will be referenced in conjunction with Safety Message Alert Symbols Some examples are listed below WARNING LETHAL EXHAUST GASES Gasoline engine exhaust gases contain poisonous carbon monoxide This gas is colorless and odorless and can cause death if inhaled NEVER operate this equipment in a confined area or enclosed structure that does not provide ample free flow air WARNING EXPLOSIVE FUEL 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 WARNING BURN HAZARDS Engine components can generate extreme heat To prevent burns DO NOT touch these areas while the engine is running or immediately after operations NEVER operate the engine with
72. LUTCH ASSY PAGE 88 C 30HDNI PRECISION PUMP OPERATION AND PARTS MANUAL REV 7 04 03 12 C 30HDNI PRECISION CLUTCH ASSY CLUTCH ASSY NO PARTNO PART NAME QTY REMARKS 1 492395 SCREW 1 2 13 1 3 4 1 2 EM923346 WASHER LOCK 1 2 1 3 EM621 WASHER FLAT 4 2 SPECIAL 1 4x EM26321 ROTOR ASSEMBLY 1 5 EM918050 CLUTCH SPRING 2 26310 CLUTCH LINING 1 8 902204 CLUTCH BEARING 2 9 926066 RETAINING RING 2 10 926053 RETAINING RING 1 11 508342 SCREW M8X25 1 25 6 102 26322 CLUTCH HOUSING W LINING 1 13 0166A WASHER LOCK 3 8 6 14 EM98071 SHAFT STUB FLANGE ENGINE 1 15 EM26348 KEY 1 16 EM14320 CLUTCH COMPLETE ASSEMBLY Lanes INCLUDES ITEMS W MAYCO C 30HDNI PRECISION PUMP OPERATION AND PARTS MANUAL REV 7 04 03 12 PAGE 89 C 30HDNI PUMP RADIATOR AND ENGINE MOUNTING BRACKET ASSY RADIATOR AND ENGINE MOUNTING BRACKET ASSY MOTOR MOUNTING 5 lt E W i gt C 8 15 4905 RER UG 8 E G 40448 6 NOTES A INCLUDED WITH ENGINE A SEE RADIATOR ASSEMBLY PAGE 90 MAYCO C 30HDNI PRECISION PUMP OPERATION AND PARTS MANUAL REV 7 04 03 12 C 30HDNI PUMP RADIATOR AND ENGINE MOUNTING BRACKET ASSY RADIATOR AND ENGINE MOUNTING BRACKET ASSY NO PARTNO 1 64900014 2 64700071 3 EM64700070 4 E
73. M23818 2 X25 GROOVED HOSE EM24841 2 X25 RAISED HOSE EM23845 2 X50 GROOVED HOSE 12 23802 ADAPTER 1 13 23803 GUN BODY 1 14 20816 O RING 1 15 23804 AIR INSERT 1 16 23805 NOZZLE CLAMP 1 17 23806 NOZZLE TIP 1 3 8 1 18 23807 NOZZLE TIP 1 1 4 1 19 911076 STREET ELBOW 1 20 AR MOSE momsen NOT SUPPLIED BY MAYCO 21 EM23808 NOZZLE ASSEMBLY pem INCLUDES ITEMS W MAYCO C 30HDNI PRECISION PUMP OPERATION AND PARTS MANUAL REV 7 04 03 12 PAGE 65 C 30HDNI PUMP EXPLANATION OF CODE IN REMARKS COLUMN The following section explains the different symbols and remarks used in the Parts section of this manual Use the help numbers found on the back page of the manual if there are any questions The contents and numbers listed in the parts section are subject to change without notice Multiquip does not guarantee the availability of the parts listed SAMPLE PARTS LIST NO PARTNO PARTNAME REMARKS 1 12345 BOLT 1 INCLUDES ITEMS W 2 WASHER 1 4 IN NOT SOLD SEPARATELY 2 12347 WASHER 3 8 IN 1 MQ 45T ONLY 3 12348 AR MAKE LOCALLY 4 12349 BEARING 1 S N 23458 AND ABOVE NO Column Unique Symbols All items with same unique symbol 0 95 or gt in the number column belong to the same assembly or kit which is indicated by a note in t
74. M64900156 5 EM65500003 6 EM513094 7 6109160 8 EM513040 10 EM64800145 11 6109160 12 6109180 13 513095 14 492584 15 492600 16 6109160 17 6109160 18 6109180 19 EM64800124 20 EM94700080 21 EM94700079 22 EM20200043 23 EM20100042 24 EM20200042 25 EM20500034 PART NAME QTY REMARKS SCREW HHCS 3 8 16 x 7 8 2 WASHER LOCK 3 8 2 WASHER FLAT 375 x 0734 x 065 6 BOLT HEX 5 16 16 x 1 4 ISOLATOR 38 x 25 3 8 16 2 SCREW SQUARE 1 2 13 x 1 3 4 2 NUT HEX 1 2 13 4 TENSIONER ADJUSTMENT 2 NUT HEX 5 16 18 4 NUT HEX 1 2 13 2 WASHER LOCK 1 2 2 SCREW SQUARE 1 2 13X2 2 4 2 8 2 2 2 2 2 1 1 1 1 NUT NYLOC 1 2 13 WASHER FLAT 1 2 NUT HEX 1 2 13 NUT HEX 1 2 13 WASHER LOCK 1 2 NUT HEX 8 1 25 WASHER LOCK 8 MM WASHER FLAT 8MM NARROW LEFT FRONT SUPPORT LEFT REAR SUPPORT LEFT RIGHT SUPPORT BRACKET CROSS C 30HDNI PRECISION PUMP OPERATION AND PARTS MANUAL REV 7 04 03 12 PAGE 91 gt CD CD lt 42 CD I lt lt LLI x lt cc F lt RADIATOR C 30HDNI PUMP RADIATOR BRACKET AND HOSES ASSY Vae NSN gt INS 4 OM 9 Bi 902 N gt lt lt 72 CC amp an lt lt a a a lt N
75. NCTION INDICATOR DIAGNOSTIC ERROR CODES TABLE 7 MALFUNCTION INDICATOR DIAGNOSTIC ERROR CODES Continued DESCRIPTION OF ERROR POSSIBLE CAUSES OF ERROR Error Code 41 indicates that there may be a malfunction in the Manifold Air Pressure MAP sensor system When the engine speed exceeds 400 5 the MAP sensor should read lower than the returned value before the engine has started The engine can be re started in a default limp mode operation Bad vaccum line to sensor Defective MAP sensor Open sensor ground circuit Dirty or corroded connection s at MAP sensor Open circuit between the ECM and MAP sensor Conditions for displaying this error code are Defective ECM open or ground in the circuit which stalls the engine Error Code 42 indicates that there may be a malfunction in the Electronic Spark Trigger EST system During cranking the timing is controlled by the ignition module while the ECM monitors the engine speed When the engine exceeds 400 RPM s the ECM sends a Bypass signal to the ignition module which switches the Bypass line is open grounded EST line is open or grounded Defective ECM Poor connections between ignition module and ECM Poor routing of EST harness and or poor quality ignition wires EMI induced electrical noise Faulty or incorrect ignition module The ECM calculates what the timing should be then tells the ignition module via this circuit The engine can be re started
76. ONTROL OFF REMOTE PUMP Figure 24 Pumping Control Switch ON System Shut Down 1 Place the pumping control switch in the OFF position Figure 21 Turn the throttle control knob fully counter clockwise Let the engine run at idle speed for 3 5 minutes Turn the ignition key Figure 22 to the OFF position Cleanpump as referenced in the maintenance section of this manual C 30HDNI PRECISION PUMP OPERATION AND PARTS MANUAL REV 7 04 03 12 PAGE 37 C 30HDNI PRECISION MAINTENANCE PUMP Preventive Maintenance General Clean up Procedure It is extremely important to maintain this pump due tothe 1 Ensure that there is no blockage in the hose and line highly abrasive nature of concrete material PumpingTips step 8 orinthe manifold PumpingTips step 7 If a blockage exists clear it to ensure proper operation the nexttime it is used Atthe end of every pour or during long delays during a pour the pump and delivery system mustbe thoroughly cleaned by removing all con 1 Inspectall drive components for loose or worn bolts 2 Drive belt chain should be checkedto remove all slack Refer to adjustment procedure 3 ALWAYS carry extra rings crete material Keep entire pump clean of concrete to prevent build up 2 Proper wash out of all materials or build up within the ALWAYS grease every fitting daily Use only premium grade pump manifold and hoses following the pum
77. RATION AND PARTS MANUAL REV 7 04 03 12 C 30HDNI PRECISION PUMP TOWING GUIDELINES Figure 2 shown below illustrates the typical towing application that should be used when towing the pump HAND WINCH EE ADJUST TRAILER HEIGHT s SAFETY CHAIN MASTER LINK COUPLER LOCK PIN COUPLER LOCK LEVER by zal Z CROSS BOTH SAFETY CHAINS 2 INCH TRAILER COUPLER Figure 2 Towing Applications MAYCO C 30HDNI PRECISION PUMP OPERATION AND PARTS MANUAL REV 47 04 03 12 PAGE 15 C 30HDNI PRECISION PUMP TRAILER SAFETY GUIDELINES The following list defines the major trailer components Trailer Safety Precautions CAUTION General Trailer Safety ALWAYS make sure that the trailer is in good operating condi tion Check the tires for proper inflation and wear Alsocheckthe wheel lug nuts for proper tightness This section is intended to provide the user with trailer service and maintenance information Remember periodic inspection of the trailer will ensure safe towing of the equipment and will prevent damage to the equipment and personal injury Itis the purpose of this section to cover the major maintenance components of the trailer The following trailer components will be discussed in this section Tires Lug Nut Torquing Suspension Electrical 1 10 11 12 Fuel adequate amount of fuel for the equipment in use Fuel ce
78. RDS 55277 0 MULTIGUIP MAYCO C 30HDNI PRECISION PUMP OPERATION AND PARTS MANUAL REV 7 04 03 12 PAGE 5 C 30HDNI PRECISION PUMP SPECIFICATIONS TABLE 1 C 30HDN PUMP SPECIFICATIONS Vertical Pumping Height 2 or 2 1 2 Material Hose 50 8 or 63 5 mm 2 950 bs 1338 Lube oil Box 7 Gallons 26 5 Liters 125 ft cable Standard 7 35 x 14 Volume output will vary depending on mix design slump line size Table 2 Engine Specifications Engine used and job site conditions Model NISSAN A15 INDUSTRIAL ENGINE T 4 stroke overhead valve single cylinder horizontal shaft gasoline ype engine 2 99 x 3 23 in Bore X Stroke 76 x 82 mm Compression Ratio 9 0 1 Displacement 90 784 cu 1 487 cc Continuous Output 51 H P 3600 R PM Fuel Tank Capacity Approx 11 U S Gallons 53 liters Fuel Cell Unleaded Automobile Gasoline Lube Oil Capacity 3 2 liters 3 3 8 qt Engine Speed 2650 rpm 100 No Load 2750 rpm 50 Full Load Load 2750 rpm 100 Engine Speed Full Idle 875 rpm 100 Air Cleaner Air Horn Type Engine Lubrication 10W 30 Grade SG or SF Service Class Starting Method Electric Start Spark Plug B4ES Spark Plug Gap 0 8 0 9 in 0 031 0 035 mm Dimension L x W x H 20 78 x 20 90 x 22 69 in 527 8 x 5
79. TENANCE PUMP Detent Hole 3 Installation 3 Ifthis procedure is not followed closely the heavy loading of the bearing during pumping operation causes the Timken cone bearings to create lateral forces which will move the taper bushing and allow the Timken cone bearings to separate from the race and subsequently fail 1 Afterthebearing assembly hasbeenisinstalled remove the three dog type allen head set screws B to allow detents to be drilled See Figure 26 below The detent holes will prevent the bushing from sliding away from the bearing spacer when the pump is under load Position the O ring on the O D of the bearing spacer during assembly to assure proper bearing adjustment 2 Use a 9 32 drill to detent half minimum 1 8 deep Then 4 Drill detent the shaftundertheallensetscrews B to prevent chase the threads with a 3 8 16 bottom tap and blow out the the bushing from the sliding away from the bearing spacer chips after drilling to be certain that the dog type allen set when the pump is under a load screws bottom inthe detentsto preventthe taper bushing from sliding laterally CAM BUSHING ALLEN HEAD SCREW gt 9 32 DRILL WELDMENT Figure 26 Detent Holes MAYCO C 30HDNI PRECISION PUMP OPERATION AND PARTS MANUAL REV 7 04 03 12 PAGE 43 C 30HDNI PRECISION
80. TROL REMOTE REMOTE PUMP OFF OUTLET PAGE 94 MAYCO C 30HDNI PRECISION PUMP OPERATION AND PARTS MANUAL REV 7 04 03 12 C 30HDNI PRECISION PUMP CONTROL BOX ASSY CONTROL BOX ASSY NO PARTNO PART NAME QTY REMARKS 1 EM513130 FRONT PANEL OVERLAY 1 2 P2554 KNOB THROTTLE CONTROL 1 3 P2204 POTENTIOMETER THROTTLE CONTROL 1 4 P2300 LED MALFUNCTION INDICATOR LED 1 5 7655 LABEL MALFUNCTION INDICATOR 1 6 12305 RED PILOT LENS DIA 5 8 3 7 51908 12 VDC BULB 3 8 10958 IGNITION SWITCH 1 8A 508239 PLASTIC 1 9 11078 IGNITION SWITCH KEY 1 10 EM40711 SWITCH PUMPING CONTROL 1 11 EM513076 CONTROL BOX 1 12 EM26789 RECEPTACLE REMOTE 1 13 506222 HOURMETER 1 C 30HDNI PRECISION PUMP AND PARTS MANUAL REV 7 04 03 12 PAGE 95 C 30HDNI PRECISION ASSY BATTERY ASSY POSITIVE RED CHASSIS GROUND STUD CONNECT TO STARTER NOTES BATTERY HOLD DOWN STRAP IS INCLUDED WITH ITEM 3 P N 34506 PAGE 96 C 30HDNI PRECISION PUMP OPERATION AND PARTS MANUAL REV 7 04 03 12 C 30HDNI PRECISION ASSY BATTERY ASSY NO PARTNO PART NAME QTY REMARKS 1 EM14705 CABLE POSITIVE BATTERY 1 2 EM506266 COVER POSITIVE TERMINAL 1 3 10318 BOX BATTERY 1 4 EM492541 NUT HEX 5 16 18 1 5 EM923023 WASHER FLAT 5 16 1 6 EM923343 WASHER LOCK 5 1
81. UDES ITEMS W unique symbol Serial Number Break Used to list an effective serial number range where a particular part is used Indicated by S N XXXXX AND BELOW S N XXXX AND ABOVE S N TO S N XXX Specific Model Number Use Indicates that the part is used only with the specific model number or model number variant listed It can also be used to show a part is NOT used on a specific model or model number variant Indicated by XXXXX ONLY NOT USED Make Obtain Locally Indicates that the part can be purchased at any hardware shop or made out of available items Examples include battery cables shims and certain washers and nuts Not Sold Separately Indicates that an item cannot be purchased as a separate item and is either part of an assembly kit that can be purchased or is not available for sale through Multiquip PAGE 66 C 30HDNI PRECISION PUMP OPERATION AND PARTS MANUAL REV 7 04 03 12 C 30HDNI SUGGESTED SPARE PARTS C 30HDNI CONCRETE PUMP W PRECISION FUEL INJECTION SYSTEM 1 Units QTY PIN DESCRIPTION 6 EM14904 PISTON CUP KITS 4 EM18804 4 1 2 STEEL BALL 14818 4 STEEL BALL EM14903 BALL STOP PIN KIT 10 18801 0 RING MANIFOLD 14308
82. cfm Leave the air on at the nozzle when the pump is stopped to prevent clogging of air the hoses in the air insert Use item 11 steel elbow the edge of the pool to prevent collapse of the rubber hose which can cause blockage MAYCO C 30HDNI PRECISION PUMP OPERATION AND PARTS MANUAL REV 7 04 03 12 PAGE 63 APPENDIX RECOMMENDED SHOTCRETE ACCESSORIES RECOMMENDED ACCESSORIES NOZZLE FOR SHOTCRETE bx Figure 37 Shotcrete System Accessories Use a 1 3 8 rubber nozzle tip for a wide spray pattern Use a 1 1 4 rubber nozzle tip for a narrow spray pattern DO NOT INSTALLTHE NOZZLE ATTHE END OF THE HOSE UNTILTHE FIRST MATERIAL HAS PASSED THROUGH THE ENTIRE HOSE LENGTH Disassemble and clean the nozzle assembly thoroughly after each job Grease all threads before re assembly DO NOT close the air valve when pumping is stopped as a continued air flow keeps the air passages clean PAGE 64 MAYCO C 30HDNI PRECISION PUMP OPERATION AND PARTS MANUAL REV 7 04 03 12 APPENDIX RECOMMENDED SHOTCRETE ACCESSORIES RECOMMENDED SHOTCRETE ACCESSORIES NO PARTNO PART NAME QTY REMARKS 1 20107 5 1 2 231011 AIR VIBRATOR 1 3 EM132 BOLT 1 2 13X2 2 4 EM23407 AIR HOSE 1 5 EM23408 BUSHING 1 6 EM23411 VALVE 1 7 912073 NIPPLE 2 8 EM23409 COUPLING 1 9 EM923346 WASHER 1 2 LOCK 2 10 EM406 NUT HEX 1 2 13 2 11 E
83. clear the pump Acid will dissolve the chrome finish on the pumping cylinder NEVER use compressed air to clean out the lines When using clean out hook to clean out the rear of the redi mix truck use safety chainto secure the clean out hook to some solid part of the redi mix truck to prevent the hook from jumping off the redi mix truck s hopper Run the pump at half throttle 1 Aftercompletionofthe pour pump the remaining concrete in the hopper through the discharge line Using shovel clean the sides of the hopper The pump engine should be turned OFF as explained in General Clean Up Procedure After the sides of the hopper have been cleaned add a small amount of water to the remaining concrete in the hopper and hand mix Startthe pump engine and pumpthe hopperallthe way down Disconnectthe hose from the pump Fill the hopper with water and pump the remaining concrete out of the pump 4 Openthehingeddischarge cone andthoroughly wash out all remaining concrete sand sediment from the cone and pump manifolds Close the discharge cone and lock in place 5 Takeasponge 2 4 and with water Take the hose that is disconnected from the pump and shake out the concrete so that about 2 feet of itis clear Insertthe sponge into the hose 6 Reconnect the hose to the pump Fill the hopper with water and resume pumping Run the pump approximately half throttle The sponge will be discharged at the en
84. count Parts log in and save on Standard orders for all orders which include complete part numbers L Fr 4 Order via Fax Dealers Only Fax your order and qualify for 2 Discount All customers welcome to order parts Fax on Standard orders for all orders which include Domestic US Customers dial compiea part numbers 1 800 6 PARTS 7 80087278 Note Discounts Are Subject Change Order via Phone Domestic US Dealers Call 1 800 427 1244 tigu pre pe Non Dealer Customers Contact your local Multiquip Dealer for 2 parts or 800 427 1244 for help in PiepresentaliVes locating dealer near you Parts Ordering information 222120 4 When ordering parts please supply Dealer Account Number Specify Preferred Method of Shipment Dealer Name and Address V UPS Fed DHL Shipping Address if different than billing address Priority One v Truck Return Fax Number Ground Next Day Applicable Model Number Second Third Day Quantity Part Number and Description of Each Part All orders are treated as Standard Orders and will ship the same day if received prior to 3PM PST WWW WE ALL MAJOR CREDIT CA
85. d in the maintenance section of this manual ALWAYS make sure that the radiator is filled to the proper operating level before starting the engine Fuel Tank Cap Fill with unleaded fuel Fuel tank cell holds approximately 11 gallons 42 liters DO NOT top off fuel Wipe up any spilled fuel immediately Tow End Jack Stand Use this jack stand to level and support the pump Tow Hitch Coupler Requires 2 inch ball hitch or a 3 inch pintle Capable of towing 5 000 Ibs Safety Chain ALWAYS attach safety chain to the towing vehicle NEVER tow the pump with the safety chain unattached Engine Stop Device This device will prevent the starting of the engine when the compartment hood is in the UP position The compartment hood must be in the DOWN position in order for the engine to start Grease Port Console This console allows for the remote lubrication of components on the pump Access Door There are four access doors on the pump Remove these door to gain access to drive and piston assemblies when maintenance is required Drive Chain Keep this chain properly lubricated and aligned at all times Lubricate this chain as specified in the maintenance section of this maintenance Rubber Latch Secure this rubber latch to the hood fastener whenever the pump is in use or being towed Tires Ply The tire ply layers number is rated in letters This trailer uses 4 ply tires Chock Blocks Place these b
86. d of the line followed by clear water At this point the pump and lines will be completely clean and ready for the next job Repeat steps 1 through 6 a few times to ensure that the hose lines are thoroughly cleaned Lubrication Box The C 30HDNI model features a fully enclosed lubrication box which utilizes the SPLASH method of lubrication Visually inspect the oil in the lubrication box Figure 16 by making sure the oil is at the correct operating level as indicated by the dip stick Also reference the oil level decal Figure 17 adjacent to the lubrication box Make sure the pump is on a secure level surface when checking the oil level inside the lubrication box AX CAUTION Checking Lubrication Oil Levels The oil level must be checked daily to ensure adequate oil level and oil cleaniness Piston Cup Wear The rubber piston cups are a natural wear component and will require periodic replacement The life of the rubber cups depends on many factors proper oil level oil cleanliness abrasiveness of aggregrate being pumped and material slump IMPORTANT ensure maximum cup life the oil level in the lubrication box must be maintained at the proper level In addition the lubrication box must be cleaned periodically As the rubber piston cups wear fine cement particles will accumulate in the bottom of the lubrication box Once this cement paste reaches 1 inch in height it is recommended that th
87. e Tel 0161 339 2223 Momoxpan Cholula Puebla 72760 Mexico Fax 52 222 285 0420 Contact pmastretta cipsa com mx Globe Lane Fax 0161 339 3226 Dukinfield Cheshire SK16 4UJ Contact sales multiquip co uk CANADA Multiquip 4110 Industriel Boul Tel 450 625 2244 Laval Quebec Canada H7L 6 3 Tel 877 963 4411 Contact multiquip com Fax 450 625 8664 COPYRIGHT 2012 MULTIQUIP INC Multiquip Inc the MQ logo and the Mayco logo are registered 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 manual MUST accompany the equipment at all times This manual is considered a permanent part of the equipment and should remain with the unit if resold The information and specifications included in this publication were in effect at the time of approval for printing Illustrations descriptions references and technical data contained in this manual are for guidance only and may not be considered as binding Multiquip Inc reserves the right to discontinue or change specifications design or the information published in this publication at any time without notice and without incurring any obligations Your Local Dealer is VSL MULTIQUIP
88. e lubrication box be drained flushed and cleaned and the oil replaced with new SAE 30 motor oil There are two clean out ports located at the bottom of the lubrication box Any questions regarding the lubrication box clean out procedure contact the MAYCO Service Department C 30HDNI PRECISION PUMP OPERATION AND PARTS MANUAL REV 7 04 03 12 PAGE 39 C 30HDNI PRECISION MAINTENANCE Crankshaft and Cam Assembly Procedure 1 Setbearing block P N EM14303 into hydraulic press Place bearing cup into bearing block and press in evenly Bearing cup should be aligned equally on both sides of bearing block Set crankshaft into hydraulic press with the long end to wards the top Install spacer P N EM14322 O ring P N 14326 and bearing cone P N EM14325 onto crank shaft Place bearing block on crankshaft until the bearing cone is riding in the bearing cup Insertbearing cone spacer P N EM14323 onto crankshaft andinside bearing block Install second bearing cone until it is seated inside bearing cup Place O ring and spacer P N EM14302 on crankshaft Set cam weldmentontop of spacer Install crankshaft key and cam key on cam bushing P N EM14301 Slide cam bushing down crankshaft and align the bushing camand crankshaft Install sleeve over crankshaft and align with hydraulic press Install cam bushing bolts loosely Press bushing down onto bearing assembly Leavi
89. e oil level as shown on the dipstick Figure 14 OIL DIPSTICK SAFE OPERATING OIL LEVEL ADD ENGINE OIL Figure 14 Engine Oil Dipstick 4 ftheengineoillevelislow add oil through the engine oil filler hole Figure 15 with the recommended oil type Table 3 Maximum oil capacity is 3 3 8 quarts 3 2 liters Figure 15 Engine Oil Filler Hole PAGE 34 C 30HDNI PRECISION PUMP OPERATION AND PARTS MANUAL REV 7 04 03 12 C 30HDNI PRECISION INSPECTION TABLE 5 OIL TYPE 25 and greater SAE 10W 30 Spring Fall 10 to 25 10 30 20 Gasoline Check 1 Remove the gasoline cap located on top of fuel tank 2 Handle Fuel safety container If the container does not have spout use funnel 3 Visually inspect to see if fuel level is low If fuel is low replenish with unleaded fuel When refueling be sure to use a strainer for filtration DO NOT top off fuel Wipe up any spilled fuel 4 Payattentionto the fuel tank capacity when replenishing fuel Refer to the fuel tank capacity listed in Table 5 Gasoline is extremely flammable and its vapors can cause an explosion if ignited DO NOT start the engine near spilled fuel WARNING EXPLOSIVE 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
90. e they have reached a certain wear point they may channel out rapidly and material will reciprocate past the ball on each stroke The hollow steel ballshould be replaced when it starts to show dents or appears to be badly worn Sand andaggregate materials insomeareas are extremely sharp and hard and therefore highly abrasive Underthese conditions when pumping stiff mixes orto high elevations which cause line pressures it will be noted that valve components may have short wear life If this condition exists itis advisable to remove the manifold only andinspectthe lower seat the end of each day Ifitappears that the seat is beginning to channel out replace before starting the next day s pour The upper valve seat can be inspected after each washout by running your finger around lower edge of seat where the ball makes contact Youcan reachthis from the inside of the hopper Be sure that the engine is turned off Pulsation A slight pulsation of the hose will always be noticeable near the pump Excessive pulsation ofthe hose nearthe pump is normally dueto higherthan average line pressures caused by stiff harsh mixes or extremely long pumping distances The use of 2 1 2 I D hose in these extreme cases reduces line pressures orthe addition of slight amounts of waterto the mix if permissible will permit easier pumping The use of certain pump ing admixtures may help If excessive pulsation exists in the hose it is ad
91. ed ad mixes may be required For example Pozzolith Bentonite Clay Plastiments etc When properly prescribed additives form the plastic paste sometimes necessary to hold the cement and aggregate together If jamming conditions in the pump or hose occur for any reason at all do not attempt to use more power to correct the condition Determine the cause of jamming correct it and resume pumping Trying to force material through under jammed conditions may result in damage to the drive system thus voiding any warranty services As a general rule the use of approximately six sacks of cement 70 washed concrete sand and 30 4 pea gravel per yard of concrete will result in a pumpable mix The ideal nature of sand and rock in certain areas may permit you to increase the percentage of rock or adjust the mix considerably to meet the job requirements When possible you may experiment with various mixes in your area to determine the degree of versatility of the Direct flow Pump Uniform gradation of the washed concrete sand and the 1 2 minus aggregate along with sufficient cement content and water are important to a successful pump operation A recommended pumpable mix design would be 7096 sand and 30 aggregate cement content to be a minimum of 6 sacks 564 lbs Your local sand and rock engineers will give you the S S D weights of sand and rock required in your local area which will yield one cubic yard per the above recom
92. ed manifest has been obtained from the carrier and any claim for shortage or damage must be settled between the consignee and the carrier MINIMUM ORDER The minimum charge for orders from Multiquip is 15 00 net Customers will be asked for instructions regarding handling of orders not meeting this requirement RETURNED GOODS POLICY Return shipments will be accepted and credit will be allowed subject to the following provisions 1 A Returned Material Authorization must be approved by Multiquip prior to shipment 2 Toobtain a Return Material Authorization a list must be provided to Multiquip Parts Sales that defines item numbers quantities and descriptions of the items to be returned 8 Theparts numbers and descriptions must match the current parts price list b Thelist must be typed or computer generated c The list must state the reason s for the return d The list must reference the sales order s or invoice s under which the items were originally purchased e The list must include the name and phone number of the person requesting the RMA 3 Acopyofthe Return Material Authorization must accompany the return shipment 4 Freight is at the sender s expense All parts must be returned freight prepaid to Multiquip s designated receiving point 5 Parts must be in new and resalable condition in the original Multiquip package if any and with Multiquip part numbers clearly marked 6 The
93. embly 112 113 Crankcase Ventilation Assembly 114 115 Piston Crankshaft And Flywheel Assembly 116 117 Camshaft And Valve Mechanism Assembly 118 119 Manifold Assembly 120 121 Oil Pump Assembly 122 123 Exhaust Tube and Muffler Assembly 124 125 Water Pump Assembly 126 127 Ignition System Assembly 128 129 Distributor Assembly 130 131 Alternator Assembly 132 133 Terms and Conditions Of Sale Parts 134 Pump Warranty tte 135 Specification and part number are subject to change without notice PAGE 4 MAYCO C 30HDNI PRECISION PUMP OPERATION AND PARTS MANUAL REV 47 04 03 12 PARTS ORDERING PROCEDURES Ordering parts has never been easier Choose from three easy options Ela January 15 2006 Order via Internet Dealers Only If you have an MQ Account to obtain a Username Order parts on line using Multiquip s SmartEquip website and Password E mail us at parts multiquip View Parts Diagrams com Order Parts To obtain an MQ Account contact your District Sales Manager for more information Print Specification Information Goto www multiquip com and click Use the internet and qualify for 5 Dis
94. ent when operating the concrete pump Whenever necessary replace nameplate operation and safety decals when they become difficult read Manufacture does not assume responsibility for any accident due to equipment modifications M NEVER use accessories or attachments which are recommended by Multiquip for this equipment Damage to the equipment and or injury to user may result NEVER touch the hot exhaust manifold muffler or cylinder Allow these parts to cool before servicing engine or concrete pump High Temperatures Allow the engine to cool before adding fuel or service and maintenance functions Contact with hot components can cause serious burns The engine section of this concrete pump requires an adequate free flow of cooling air NEVER operate the concrete pump in any enclosed or narrow area where free flow of the air is restricted If the air flow is restricted it will cause serious damage to the concrete pump or engine and may cause injury to people Remember the concrete pump s engine gives off DEADLY carbon monoxide gas ALWAYS refuel in a well ventilated area away from sparks and open flames ALWAYS use extreme caution when working with flammable liquids When refueling stop the engine and allow it to cool DO NOT smoke around or near the machine Fire or explosion could result from fuel vapors or if fuel is spilled on hot engine NEVER ope
95. ering your eyes and have personnel in the immediate area do likewise Chain Link Pin Removal 1 If chainis of cotter pin type construction remove cotters 2 Ifchainis riveted type construction grind pin heads off so pin ends are flush with the linkplate 3 Drive pins out of linkplate using a Diamond pin extractor Model P N 1130r135 Some multiple strand chains orlarge pitch models will require a hammer and punch or a press remove the pins Installation Of Coversides Diamond Chain coversides are manufactured three different ways B Fit Modified Press Fit Full Press Fit Modified and Full Press Fits require some patience and tools to assemble and or disassemble Use vice grips plumbers pliers or a small hammer to drive coversides onto pins Installation of Spring Locks and Cotter Pins After coversides have been installed install spring locks or cotters depending on chain design Avoid using bent or worn cotters or spring locks After spring locks or cotters are installed lightly tap pin ends to position these parts snug against the coverside for additional support Tips To Remember Chian will break if mused or abused Serious injury or property damage can result if chain is installed incorrectly Select install guard and maintain chain in accordance with equipment manufacturer and Diamond Chain Company s recommendations Read chain assembly instructions before attempting
96. es not cover natural component wear THIS WARRANTY AND MANUFACTURER S OBLIGATION HEREUNDER IS IN LIEU OF ALL OTHER WARRANTIES EXPRESS IMPLIED OR STATUTORY AND ALL OTHER OBLIGATIONS OR LIABILITIES INCLUDING SPECIAL OR CONSEQUENTIAL DAMAGES OR CONTINGENT LIABILITIES ARISING OUT OF THE FAILURE OF ANY PUMP OR PART TO OPERATE PROPERLY INCLUDING ANY WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE HYDRAULIC DRIVE MODELS MAYCO PUMP hereinafter referred to as Manufacturer warrants each new Mayco Pump sold by the manufacturer to be free from defects in material and workmanship under normal use and service for a period of one year or 2000 hours after the date of delivery to the original retail purchaser The Manufacturer will at its option replace or repair at a point designated by Manufacturer any part or parts which shall appear to the satisfaction of Manufacturer upon inspection at such point to have been defective in material or workmanship This warranty does not obligate Manufacturer to bear any transportation charges or labor charges in connection with the replacement or repair of the defective parts This warranty does not apply to any pump if attempts have been made to pump concrete materials which have separated to any pump which has been repaired with other than Genuine Mayco Parts nor to any pump which has been altered repaired or used in such manner as to adversely affect it s performance nor to nor
97. ests 3 8 Pea Gravel STANDARD PUMP MIXES one half inch minus NOTE All weights shown are one cubic yard with S S D aggregates CRP Mix Number 11 11 ass 8002 TE 6003 Design Slump in 8 150M 6 111111 6 150M need 6 15cm Cement SACK 0 5 csset e 6 5 6 5 Cement Lbs 6H 276 kg 66 611 276 KO 811 276 kg 611 276 kg w Con Sand 1 1 Ib 2062 934 kg 2112 957 1924 872 kg 1971 893 kg Gravel 4 9 51mm 687 311 kg 704 13919 eesse 825 374 kg 845 383 TOTAL AGGREGATE 2749 1245 kg 2816 1276 kg 2749 1245 kg 2816 1276 kg ADMIXTURE Pozzolight 311 1 3lb 13 59 k9 1 3 59 Water Design gals 50 0 189 liters 530 200Iiters 50 0 189 liters 53 9 200 liters Mater Max gals 50 0 189 liters 530 000 liters 53 0 200 liters 53 0 200 liters NOTE Multiply above kilograms and liters by 1 308 to obtain the proportions for one cubic meter of concrete MAYCO C 30HDNI PRECISION PUMP OPERATION AND PARTS MANUAL REV 7 04 03 12 PAGE 61 APPENDIX RECOMMENDED SYSTEM RECOMMENDED SHOTCRETE SYSTEM X DV 7 MW 1885555855 pan 4 A
98. fold primary manifold Check all parts for wear Remove hopper and hopper seat and inspect Loosen the piston nuts and remove the piston cup assembly andcylinders Inspect all parts for wear and replace parts with excessive wear Check oiler pump for proper operation Cleanall parts thoroughly removing all foreign material and concrete slurry Once parts are clean install concrete cylin ders Place oiler plate O ring in place and coat with oil Install small O ringon piston rod Run oilerlinethroughthe cylinders and connectin the oiler fitting on the oiler plate Push oiler plate into cylinder Install ring and felt holder soak felt ring in oil then install around felt holder in cylinder Make sure the bronze ring is flat then push it up flush with the ring and felt holder Coat piston cup with oil and push it into the cylinder Install bushing into center of piston cup Put small O ring on rod place face plate on rod and tighten down securely Repeat these procedure on the opposite cylinder Thoroughly check T manifold ball stoppings and both steel balls for wear Insert an O ring in the top flange and in the leading edge of the manifold Put the manifold onto the primary side ofthe pump andinstallbolts leaving them loose CheckY manifoldforwear install all O rings ball stop pin ball and seat Align and install Y manifold to T manifold and cylinder assembly Tighten Y manifold bolts first before tight ening T manifold bolts
99. following items are not returnable a Obsolete parts If an item is in the price book and shows as being replaced by another item it is obsolete b Any parts with a limited shelf life such as gaskets seals O rings and other rubber parts that were purchased more than six months prior to the return date c Any line item with an extended dealer net price of less than 5 00 Special order items Electrical components Paint chemicals and lubricants Decals and paper products Items purchased in kits 7 The sender will be notified of any material received that is not acceptable 8 Such material will be held for five working days from notification pending instructions If a reply is not received within five days the material will be returned to the sender at his expense 9 Credit on returned parts will be issued at dealer net price at time of the original purchase less a 15 restocking charge 10 In cases where an item is accepted for which the original purchase document can not be determined the price will be based on the list price that was effective twelve months prior to the RMA date 11 Credit issued will be applied to future purchases only PRICING AND REBATES Prices are subject to change without prior notice Price changes are effective on specific date and all orders received on or after that date will be billed at the revised price Rebates for price declines and added charges
100. ge ofthe packed area until it is free to flow Shake all of the sand and gravel out to the end of the hose Before reconnecting the hose startthe pump and run small amount of concrete out tothe end ofthe hose This will assure that all of the separation is out of the hose Clearing a Plugged Manifold The manifold is plugged if the volume at the discharge end ofthe hose stops andthe hose is soft The drive belts will start to slip and the engine will lugdown Follow steps 7A through 7J to un plug a clogged manifold AX DANGER Clearing A Plugged Manifold Due to pressure build up inside the manifold great care must be taken when clearing a plugged manifold A STOP the pump Switch OFF the engine DONOT open any of the delivery system joint clamps The senior operator must warn all others to stand at least 20 feet away from the pump and turn their heads away from the manifold D The operator must position himself herself away from the hinged side of the manifold E Wearing safety glasses grasp the clamp arm weldment and carefully pull it open to the primary safety position STOP count to 20 Thiswillallowthe pressure to release After the pressure has been released open the clamp arm weldment and swing the hinged discharge cone open G Removeblockage with around 2 footlength of reinforc ing steel rod Flush the manifolds with water sure the 3 x 2 reducer is clear of any blockage befo
101. he Remarks column Duplicate Item Numbers Duplicate numbers indicate multiple part numbers which are in effect for the same general item such as different size saw blade guards in use or a part that has been updated on newer versions of the same machine NOTICE When ordering a part that has more than one item number listed check the remarks column for help in determining the proper part to order PART NO Column Numbers Used Part numbers can be indicated by a number a blank entry or TBD TBD To Be Determined is generally used to show a part that has not been assigned a formal part number at the time of publication A blank entry generally indicates that the item is not sold separately or is not sold by Multiquip Other entries will be clarified in the Remarks Column QTY Column Numbers Used Item quantity can be indicated by a number a blank entry or A R A R As Required is generally used for hoses or other parts that are sold in bulk and cut to length A blank entry generally indicates that the item is not sold separately Other entries will be clarified in the Remarks Column REMARKS Column Some of the most common notes found in the Remarks Column are listed below Other additional notes needed to describe the item can also be shown Assembly Kit All items on the parts list with the same unique symbol will be included when this item is purchased Indicated by INCL
102. igure 6 display s the basic hand signals commonly used in concrete pumping operations CHUTE UP CHUTE UP STOP START PUMP SLOW PUMP SPEED UP DOWN STOP PUMP LITTLE BIT ADD WATER ALL DONE 4 GALLONS CLEAN UP CS DRIVE IN BACK UP PULL FORWARD BACK IN Figure 6 Operation Hand Signals C 30HDNI PRECISION PUMP OPERATION AND PARTS MANUAL REV 7 04 03 12 PAGE 21 30HDNI PRECISION PUMP PUMP COMPONENTS C Figure 7 Major Pump Components E gt lt 7 an lt a a a o cp e lt N a C 30HDNI PRECISION PUMP COMPONENTS Figure 7 illustrates the location of the major components for the C 30HDNI Concrete Pump The function of each component is described below 1 Discharge Connect 3 elbow to this discharge port then connect 3 x 2 reducer to elbow Discharge Cone Safety Latch When towing of the pump is required ALWAYS secure the discharge cone to latch located on the manifold Rear Running Lights ALWAYS check and make sure both the right and left running lights are functioning correctly before towing the pump Hopper Concrete from a Redi Mix truck is poured into this hopper The hopper can hold 6 0 cu ft of concrete NEVER put
103. ilage Avoid sharp turns to prevent rolling Retract wheel stand when transporting DO NOT transport pump with fuel in the fuel tank A CAUTION Never Use Defective Couplers If the trailer coupler is deformed replace entire coupler NEVER tow the pump with a defective trailer coupler There exist the possibility of the trailer separating from the towing vehicle Pump Trailer Vehicle Connection 1 Check the vehicle hitch ball and trailer coupler for signs of wear or damage Replace any parts that are worn or damaged before towing 2 Use only the 2 inch ball diameter with a towing capability of 5 000 Ibs 2 268 kg as indicated on the trailer s coupler Use of any other ball diameter will create an extremely dangerous condition which can result in separation of the coupler and ball or ball failure Be sure the coupler is secured to the hitch ball and the lock lever is down locked 4 Attach safety chains as shown in Figure 2 Remember to crossthe safety chains 5 After towing for about 50 miles recheck the entire towing system for tightness Recommended Maintenance 1 Smear ball socket and clamp face with chassis grease Periodically oil pivot points and were surfaces of coupler with SAE 30 W motor oil 2 Whenparking or storing the concrete pump keep the coupler off the ground so dirt and other debris will not build up in the ball socket PAGE 14 MAYCO C 30HDNI PRECISION PUMP OPE
104. level Low engine power output and Air filter blocked Clean or replace air filter low speed black exhaust smoke Incorrect valve clearances Adjust valves per engine specification Insufficient coolant Replenish Loose fan belt Adjust fan belt Worn or oiled belt Replace belt Inoperative thermostat Replace thermostat Overheating For more detail troubleshooting methods refer to NISSAN Operation and Maintenance manual supplied with your pump C 30HDNI PRECISION OPERATION AND PARTS MANUAL REV 7 04 03 12 PAGE 49 C 30HDNI PUMP MALFUNCTION INDICATOR DIAGNOSTIC ERROR CODES Malfunction Indicator Diagnostic System The Mayco C 30HDNI concrete pump features an engine malfunction indicator LED found on the control panel Figure 5 When a malfunction in the operation of the engine is detected the light will blink in sequence to indicate an error code Use the Diagnostic Error Code Table Table 7 to troubleshoot the malfunction Determining an Error Code The malfunction indicator light blinks in two patterns long and short Count the long blinks to determine the first digit of the error code Count the short blinks to determine the second digit ofthe error code For example four long blinks and three short blinks represent error code 43 indicating a faulty fuel injector TABLE 7 MALFUNCTION INDICATOR DIAGNOSTIC ERROR CODES DESCRIPTION OF ERROR POSSIBLE CAUSES O
105. lls must be empty when transport ing equipment Frame Length This measurement is from the ball hitch to the rear bumper reflector Frame Width This measurement is from fender to fender Jack Stand Trailer support device with maximum pound requirement from the tongue of the trailer Coupler Type ofhitch used on the trailer fortowing This unit employes 2 in ball Tires Size Indicates the diameter of the tire in inches 10 12 13 14 etc and the width in millimeters 175 185 205 etc The tire diameter must match the diameter of the tire rim This unit employes 7 35 x 14 in tires Tires Ply The tire ply layers number is rated in letters 2 ply 4 ply 6 ply 8 ply 10 ply etc This unit employes 4 ply tires Wheel Hub The wheel hubis connectedtothetrailer s axle Tire Rim Tires are mounted on rim The tire rim must match the size of the tire Lug Nuts Used to secure the wheel to the wheel hub Always use atorque wrench to tighten downthe lug nuts See Table 5 and Figure 4 for lug nut tightening and sequence This unit employes 5 lug nuts to secure the wheel to the hub Axle This trailer employes a torsion bar type suspension which can support 3 500 Ibs Electrical Electrical connectors looms are provided with the trailer so that brake lights and turn signal lights can be connectedto the towing vehicle See TrailerWiring Diagram for proper wiring connections PAGE 16
106. locks not included as part of your concrete pump package under each trailer wheel to prevent rolling Pump End Jack Stand Use this jack stand to level and support the pump Discharge Cone Release Lever secures the discharge cone to the Y manifold also relieves manifold pressure Documentation Box Contains engine and pump operation parts and maintenance information 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 MAYCO C 30HDNI PRECISION PUMP OPERATION AND PARTS MANUAL REV 7 04 03 12 PAGE 23 C 30HDNI PRECISION PUMP CONTROL BOX COMPONENTS Su 5 6 9 Figure 8 Pump Control Box Components Figure 8 illustrates the location of the major components for the C 30HDNI Control Box The function of each component is described below 1 Throttle Control Switch This is variable speed type control Holding the control switch to the leftincreases the engine speed To place the engine at IDLE speed hold the control switch to the right and let the engine run for 3 5 minutes Trouble Indicator LED This is a diagnostic feature on the C 30HDNI to assist the operator with identifying problems that occur with the fuel injection system See Table 7 Cil Pressure Indicator Lamp In the event of l
107. mal service or maintenance or where blockages have developed within the pump manifold or placing line or which has been operated in any other manner not recommended by the Manufacturer Due to the abrasive nature of concrete Mayco does not cover natural component wear THIS WARRANTY AND MANUFACTURER S OBLIGATION HEREUNDER IS IN LIEU OF ALL OTHER WARRANTIES EXPRESS IMPLIED OR STATUTORY AND ALL OTHER OBLIGATIONS OR LIABILITIES INCLUDING SPECIAL OR CONSEQUENTIAL DAMAGES OR CONTINGENT LIABILITIES ARISING OUT OF THE FAILURE OF ANY PUMP OR PART TO OPERATE PROPERLY INCLUDING ANY WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE MAYCO C 30HDNI PRECISION PUMP OPERATION AND PARTS MANUAL 7 04 03 12 PAGE 135 OPERATION AND PARTS MANUAL HERE S HOW TO GET HELP PLEASE HAVE THE MODEL AND SERIAL NUMBER ON HAND WHEN CALLING UNITED STATES Multiquip Corporate Office Parts Department 18910 Wilmington Ave Tel 800 421 1244 800 427 1244 Fax 800 672 7877 Carson CA 90746 Fax 800 537 3927 310 537 3700 Fax 310 637 3284 Contact multiquip com Service Department Warranty Department 800 421 1244 Fax 310 537 4259 800 421 1244 Fax 310 943 2249 310 537 3700 310 537 3700 Technical Assistance 800 478 1244 Fax 310 943 2238 MEXICO UNITED KINGDOM MQ Cipsa Multiquip UK Limited Head Office Carr Fed Mexico Puebla KM 126 5 Tel 52 222 225 9900 Unit 2 Northpoint Industrial Estat
108. mendation Sample Design Mix 3000 Psi 3 8 in Slump 4 5 in Type Cement 6 49 sack cu yd 611 Ibs Sand Sat Surf Dry 2000 lbs 4 Gravel Sat Surf Dry 864 Ibs 3 Gravel Sat Surf Dry 0105 Water 48 Gallons 400 Ibs Total Weight 3 906 105 Admixture WRDA 79 26 oz Water 7 40 gal sack Test laboratory data has proven in many areas that the above mix guidelines have produced concrete rated at 3000 psi 28 day test and upwards of 5000 psi with an increase in cement In some areas where the gradation of sand and rock is ideal and sufficient cement is used along with admixtures the Mayco small line concrete pump will handle up to a 50 50 ratio of sand and rock When the mix is designed for wet gunning applications it is normal to increase the cement up to 7 5 or 8 sacks and change the sand to rock ratio to 85 sand and 15 rock The Mayco concrete pump will valve efficiently when using cellular foam concrete mixes upwards of 70 105 per cubic foot wet density Below 70 105 materials roof decks the valving becomes inefficient PAGE 26 MAYCO C 30HDNI PRECISION PUMP OPERATION AND PARTS MANUAL REV 7 04 03 12 C 30HDNI PRECISION PUMP HOW IT WORKS The C 30HDNI 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 compensa
109. mperature IAT sensor is reporting abnormally low readings When the air is cold the thermistor has a high resistance which falls as the air temperature rises Low readings thus indicate a possible bad sensor or open in the IAT circuit Doe sensor Defective ECM Open sensor ground circuit Dirty or corroded connection s at IAT and or ECM Open circuit between ECM and IAT sensor Conditions for displaying this error code are reading is less than 40 F 40 C The above condition is present for more than 2 seconds NOTE A default IAT value indicating 80 F 27 C is used while Code 23 is present Error Code 23 indicates that the Inlet Air Temperature IAT sensor is reporting abnormally high readings When the air is hot the thermistor has a low resistance which rises as the air temperature cools High readings thus indicate a Defective IAT sensor possible bad sensor or short in the IAT circuit Defective ECM IAT signal shorted to ground or to sensor ground Conditions for displaying this error code are reading is greater than 275 F 135 C Error Code 25 indicates that there may be a malfunction in the Electronic Ignition Control Circuit The ECM senses spark knock pinging and retards the timing to eliminate it A knock sensor located at the rear of the engine block sends signals 25 to the ECM that knocking is being detected The ECM will retard the timing by as much as 10 in 1 increment
110. n excess 01210 3 hours Ona hot day this amount of time is even less A brief explanation of why heat and time affect concrete Concrete starts setting by drying up through a chemical reaction The catalyst to this reaction is heat When pumping ahotload itis important to remember that when you have to stop pumpingfor any reason add waterto the concrete in the hopper and hand mix and move concrete in the hose every 5 minutes Ifthe shutdown time becomes too long wash out immediately 2 ADMIXTURES Remixtures that are designed into the concrete mix by the redi mixcompany oran architectural engineering company This section lists common admixtures and a brief explanation oftheirfunctions A Pozzolith 300 or the equivalent acts as a water retarder and a lubricant On a lean mix long pushes stiff mixes and vertical pushes Pozzolith 300R helps pumpability B air entraining acts as a lubricant C Calcium Chloride commonly referred to as C C is used as an accelerator When pumping a load with calcium chloride it is recommended that you wash out ifthe waiting time between delivery trucks becomes too long D Super Plasticizers acts as accelerator The concrete will look very wet after the super plasticizer is added but will begin to set up very fast Wash out immediately if you do not have a truck waiting Super plasticizers are used mainly on commercial jobs E RedLabel acts asa waterretarder
111. n the belts retighten the engine mounting bolts Frequent inspections should be made on all drive compo nents to make certain that all bolts and nuts remain tight Prior to adjusting the chain place the lobe of the cam in the down position The chain should have 83 rivets Including one each half link and full link PAGE 44 MAYCO C 30HDNI PRECISION PUMP OPERATION AND PARTS MANUAL REV 7 04 03 12 C 30HDNI PRECISION MAINTENANCE PUMP Roller Chain Application properly selected installed and maintained drive chain Figure 28 is an extremely versatile means of power transmission It is possible however to greatly reduce a chain s life and even induce failure if the chain is abused through improper installation operating or maintenance procedures In certain applications failure can lead to personal injury or property damage Figure 28 Drive Chain Recommendations and comments on how to get the most from your roller chain drive are given in this section The drive chain used in the MAYCO C 30HDNI pump is manufactured by the DIAMOND CHAIN COMPANY Working Loads UTS Ultimate Tensile Strength is the one time pull required to break the chain For single strand chain the load pull applied to the chain in service should never exceed 1 6th of the UTS for the chain being used except as noted below It is possible to exceed the allowable working loads for a limited number of cycles but
112. ng parts will cause serious injury An automatic shutdown switch has been installed on the hood to prevent this pressure build up inside the pump and delivery system Engine must be shut off before servicing Keep hands out of hopper when engine is running P N EM932 Check hopper for obstructions before operating machine This machine is remotely controlled and may start at any time NORMAL 4 Stop the engine before adding fuel or oil 508594 508594 LOW Before starting engine check that the oil level inside the LUBE is within the indicated operating range Recommended oil type SAE 30 DCL 152 P N TBD P N DCL152 N MAINTENANCE umm GREASE DAILY EVERY ZERK Use No 2 Multipurpose Automotive Grease P N 513165 OWNER S MANUAL A WARNING P N 34536 Refer to the owner s manual for safe operating procedures Welding on the main frame or other components may void warranty Refer to owner s manual for proper use of the piston lubrication sytems Failure to utilize the rear stabilizer leg NAM E PLATE while pumping could damage axle P N 98022 CONTACT MULTIQUIP MAYCO SERVICE DEPT MULTIGUIP 1028 Figure 5 Operation and Safety Decals PAGE 20 MAYCO C 30HDNI PRECISION PUMP OPERATION AND PARTS MANUAL REV 7 04 03 12 C 30HDNI PRECISION PUMP IMPORTANT HAND SIGNALS F
113. ng pressure on the bushing tighten cam bolts evenly to 40 50 foot pounds Release pressure on the bushing reapply pressure to bush ing and tighten bolts evenly to 40 50 foot pounds Repeat procedure 3 to 4 times After bushing has been fitted tightly into cam remove from hydraulic press Remove one bolt at a time using Loctite install bolts and torque to 65 70 foot pounds Counter sink set screw hole and install dog point set screw and second set screw both with Loctite Place cam bearing onto crankshaft keeping bearing loose Make sure the eccentric lock is facing toward the outside of the pumping unit Set crankshaft assembly into the pump box and align both bearing assemblies with the pump box mountings After crankshaft assembly is securely fastened to the pump box place sprocket P N EM14307 onto the cam side of the crankshaft assembly Install bushing P N EM14309 into sprocket Align sprocket with sprocket on countershafts and tighten bolts Install chain P N EM14308 To adjust loosen locknuts on pusher bolts and tighten chain to approximately 1 2 in slack in the chain Once chain is adjusted properly tighten down locknuts Ball and Seat Replacement Procedure 1 10 Remove 3 2 reducer and 3 elbow from the pump outlet Remove exhaust gate and Y manifold secondary manifold Check ball seat and ball stop pin for wear If any wear is detected the part should be replaced Remove T mani
114. oad does Loss of chamber or overloading not exceed axle rating Align wheels Out of balance Check bearing adjust ment and balance tires Avoid sudden stops when possible and adjust brakes Edge Wear Side Wear Toe Wear fee d 1 Torsion Bar Suspension The torsion bar suspension and associated hardware Figure 3 should be visually inspected every 6 000 miles for signs of excessive wear elongation of bolt holes and loosening of fasteners Replace all damaged parts suspension immedi ately CHECK FOR TIGHTNESS Cupping Flat Spots Wheel lockup amp tire skidding TORSION BAR Figure 3 Major Suspension Components C 30HDNI PRECISION OPERATION AND PARTS MANUAL REV 7 04 03 12 PAGE 17 C 30HDNI PRECISION PUMP TRAILER SAFETY GUIDELINES Lug Nut Torque Requirements It is extremely important to apply and maintain proper wheel mounting torque on the trailer Be sure to use only the fasteners matched to the cone angle of the wheel Proper procedure for attachment of the wheels is as follows 1 Start all wheel lug nuts by hand 2 Torquealllug nuts in sequence Figure 4 DO NOTtorque the wheel lug nuts all the way down Tighten each lug nut in 3 separate passes as defined by Table 4 3 Afterfirstroaduse retorque all lug nuts in sequence Check all wheel lug nuts periodically Table 5 Tire Torque ermene
115. olding the other sprocket fixed The lack span should have 4 6 of span length in the mid span movement for horizontal drives and 2 3 for vertical drives Figure 30 Drive Chain Tension A roller chain s capacity can be significantly reduced if it is twisted or bent sideways in the direction of the pin axis Exercise particular care in alignment of hoist or other applications where loads are suspended near personnel MAYCO C 30HDNI PRECISION PUMP OPERATION AND PARTS MANUAL REV 7 04 03 12 PAGE 45 C 30HDNI PRECISION MAINTENANCE PUMP Drive Chain Lubrication s a chain articulates in entering and leaving sprocket there is relative movement between pin and bushing surfaces These surfaces wear causing chain elongation If a lubricant film can be maintained between the pin and bushing the wear rate is very slow and the chain wear life very long Maintaining the oil film is relatively simple at low speeds but becomes increasingly difficult as the speed increases It is recognized that good lubrication is not possible in many applications so shorter wear life must be accepted in these situations In general chain wear leads to rough or unsatisfactory service prior to actual chain breakage Good lubrication can help to prevent chain failure by providing protection against rust or corrosion Rusting can allow pits to form in the surfaces of the chain parts causing stress concentration points Thi
116. ow oil in the engine crankcase or low oil pressure the oil Oil Pressure Lamp indicator will be lit STOP the engine immediately if this lamp is lit NEVER run the engine when this lamp is on 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 the charging system is malfunctioning STOP the engine and remedy the electrical charging problem Water Temperature Lamp In the event of high engine water temperature 220 degrees Fahrenheit this lamp will be lit STOP the engine immediately if this lamp comes on NEVER run the engine when this lamp is on Ignition Switch Insert the ignition key here to start the engine Turn the key clockwise to the ON position then continue turning clockwise to the START position and release To stop the engine turn the key fully counter clockwise to the STOP position Remote Control Input Connector Insert the remote control input cable into this connector Pumping Control Switch This 3 position switch controls the pumping of the pump The left most position is for use with the remote control unit the center position is for off prevents pumping and the right most position is for normal pump operation Hourmeter Display s the number of hours the pump has been in use PAGE 24 C 30HDNI PRECISION OPERATION AND PARTS MANUAL REV 7 04 03 12 C 30
117. ping opera grease tion will prevent problems when starting the next job After completion of the pour pump the remaining concrete in the hopper through the discharge line Over greasing will not damage pump 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 approxi mately 3t04 inches ofconcrete above the inlet ball 3 Turnthe pump engine off before filling the hopper with water Engine vibration at idle may separate material in the hopper causing jamming in manifold when pumping is resumed 4 Fillhopper with water and resume pumping The water will push the concrete through the line When the water runs clear at the endofthe hose disconnect lines and shake outall the sand and sediment so the lines will be clean forthe next pour 5 Itis important that the hinged discharge cone on the pump manifold be opened and all remaining concrete rock and sand be thoroughly washed out This must be done after each job to prevent concrete build up in the discharge manifolds and 3 discharge elbow PAGE 38 MAYCO C 30HDNI PRECISION PUMP OPERATION AND PARTS MANUAL REV 7 04 03 12 C 30HDNI PRECISION MAINTENANCE PUMP Sponge Clean out Procedure This section will explain the recommended procedure for using a sponge to clean out the hose lines CAUTION Clearing The Pump NEVER use muriatic acidto
118. pring Compensator Spring and Rocker Arm Interaction PAGE 28 C 30HDNI PRECISION PUMP OPERATION AND PARTS MANUAL REV 7 04 03 12 C 30HDNI PRECISION OPERATING INFORMATION OPERATING SUGGESTIONS 1 Awell planned location of the pump and routing of hose before starting a pour may save subsequent moves through outthe job 2 Before concrete is dischargedintothe hopper itis suggested that 3 to 4 gallons of water be sprayed into the hopper followedby approximately 5 gallons of a creamy cement and water slurry 1 2 bag of cement to 5 gallons of water This procedure lubricates the hose and prevents separation and blockages in the hose Gettingthe concretetoflowthroughthe hose atthe start of the pumping cycle can be one of the most critical opera tions ofthe pour Manuallyoperatethe throttle when starting NOT remotely WARNING Hose Blockage Hazard If hoses or lines are blocked for any reason or if the lines are kinked when starting up or during the pumping cycle the pump pressure could straighten out the kink or force out the blockage This rapid surge of material could cause the lines to whip or movein a manner that could cause injury to personnel Inspect the lines at all times to prevent the above conditions 3 ltisimportant that once the slurry procedure is completed and you have started concrete flowing through the hose do not stop the pour until all the slurry
119. rain Plug Remove this plug to drain engine oil from the crankcase Replace with recommended engine oil as specified in the maintenance section of this manual Fuel Pump Fuel Filter Replace or clean the fuel pump or fuel filter as specified in the maintenance section of this manual Distributor NEVER allow concrete or any foreign debris to come in contact with the distributor Spark Plug Provides spark to the ignition system Set spark plug gap to 0 6 0 7 mm 0 028 0 031 inch Clean spark plug once a week Dipstick Remove this dipstick to determine if engine oil is low Maintain oil level at the H marking on the dipstick NEVER run engine with low oil Filler Port Cap Remove this cap to add engine oil to the crankcase Fill with recommended type oil as specified in the maintenance section of this manual Fuel Injection System ALWAYS keep dirt dust and any foreign debris from entering the fuel injection system Clean the fuel injection system as recommended in the maintenance section of this manual MAYCO C 30HDNI PRECISION PUMP OPERATION AND PARTS MANUAL REV 7 04 03 12 PAGE 25 C 30HDNI PRECISION PUMP GENERAL INFORMATION The following operating principles and operating suggestions should prove helpful in the successful operation of your concrete pump Your new small line concrete pump has been designed to give you many years of service when operated properly study of the
120. rate the concrete pump in an explosive atmosphere or near combustible materials An explosion or fire could result causing severe bodily harm or even death Topping offto filler port is dangerous as it tends to spill fuel Stop the engine when leaving the concrete pump unattended DO NOT leave the pump unattended Use chock blocks if parking pump grade Maintain this equipment in a safe operating condition at all times PAGE 10 MAYCO C 30HDNI PRECISION PUMP OPERATION AND PARTS MANUAL REV 7 04 03 12 C 30HDNI PRECISION PUMP RULES FOR SAFE CAUTION must always be observed while servicing this pump Rotating parts can cause injury if contacted ALWAYS stored the pump in clean dry location out of the reach of children ALWAYS use extreme care when operating near obstructions on slippery surfaces grades and side slopes Unauthorized equipment modifications will void all warranties Refer to the Engine Owner s Manual for engine technical questions or information Before start up check the hopper and remove all obstructions Keep all hands out of the hopper when the engine is running E 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 before performing maintenance ALWAYS make sure pump is correctly secured to the trailer
121. re closing the discharge cone H After the blockage has been cleared and the pump manifold has been thoroughly flushed with water close the hinged discharged cone and lock into place Before reconnecting hose tothe reducer startthe engine and pump two orthree shovels of concrete through the reducer This will insure that all the blockage has been cleared J Shake outaround 2 feet of concrete before reconnecting hose to pump After this is done connect hose to pump and resume the pumping operation 8 Avoiding Setting of the Mix in the System To avoid setting of the concrete mix in the system when waiting more than 30 minutes between concrete loads flush the system depending on job factors such as presence of accelerators and job site temperature and your particular mix design Clearing a Mix from the System If for any reason the mix should set up in the system the following procedure is suggested A CAUTION Hose Pressure Hazard 1 When disconnecting hoses use EXTREME CAUTION The hose is under pressure Disconnect the hoses from the pump and wash the pump out immediately For example If you had 200 ft of system out you would disconnect each hose Reconnect the first hose and fill the hopper with water DO NOT try to push all the concrete out of all of the hose lines at onetime Clean it out by pushing water through the first hose off the pump then continue progressing through allthe hoses until
122. running at least 5 minutes No Code 21 TPS errors present Engine coolant temperature greater than or equal to 90 F O sensor voltage not fluctuating from 0 3V 0 7V TPS signal indicates above idle Error conditions are present for at least 60 seconds Coolant temperature reported is greater than 284 140 C above condition is present for more than 2 seconds Defective sensor O sensor is corroded with contaminants O sensor connection is bad T sensor is reporting Severe engine overheating Defective ECT Short circuit in ECT ECM harness Defective ECM NOTE A default temperature of 170 F 77 C while the error is present during normal runtime Error Code 15 indicates that the Engine Coolant Temperature EC T sensor is reporting abnormally low readings ECT is used to control fuel mixture timing and idle speed Conditions for displaying this error code are Coolant temperature reported is less than 31 F 35 C and above condition is present for more than 2 seconds Open circuit in ECT ECM harness Defective ECT Open sensor ground circuit Defective ECM NOTE A default temperature of 170 F 77 C while the error is present during normal runtime Error Code 21 indicates that the Throttle Position Sensor TPS is voltage should be approximately 1 0V at closed throttle and rise si approximately 3 6V at WOT Conditions for displaying this error code are Engine is running and
123. s A loss of knock sensor signal or loss of ground at the ECM module will cause the Open or shorted knock sensor signal at the ECM to remain low The ECM will act as if no knock is present and Loose knock sensor may possibly result in engine damage if there is detonation Loss of the knock Excessive mechanical noise within engine sensor signal to the ECM will cause the ECM to constantly retard the timing to its Defective ECM maximum This results in sluggish performance and a Code 25 Conditions for displaying this error code are Engine is running Knock input signal has been high more than 1 seconds Applies only to knock sensor equipped engines Error Code 31 indicates that the Drive by Wire DBW sensor readings may not be incorrect The DBW signal must be between 0 5V and 4 8V durring operation Defective DBW input from sensor or pedal DBW signal shorted to ground or to sensor ground Defective ECM Conditions for displaying this error code are Engine is running DBW reading is less than 0 5V OR DBW reading is greater than 4 8V Faulty battery Power wire from battery Poor ground wiring Defective ECM Bad charging system Error Code 32 indicates that the System Voltage or Battery Level is too low Conditions for displaying this error code are System Voltage is below 9V MAYCO C 30HDNI PRECISION PUMP OPERATION AND PARTS MANUAL REV 7 04 03 12 PAGE 51 C 30HDNI PUMP MALFU
124. s can lead to chain failure at relatively low loads The clearance between pin and bushings is very small Figure 31 on the order of 003 to 005 inches A lubricant must be thin enough to flow into the chain SAE 30 weight oil is about right for room temperature Lighter oil should be used for lower ambients and heavier for higher operating temperatures Grease should not be used as it cannot penetrate chain clearances Roller Link Plates Pin Link Plates Figure 31 Chain Link Cross Section PAGE 46 MAYCO C 30HDNI PRECISION PUMP OPERATION AND PARTS MANUAL REV 7 04 03 12 C 30HDNI PRECISION PUMP MAINTENANCE PUMP Assembling and Disassembling Drive Chain AX CAUTION DRIVE CHAIN SAFETY You may be seriously injured if you attempt to install the drive chain while the pump is running Turn OFF the engine and lock out gears and sprockets before attempting installation Once installed the drive chain must be guarded to prevent personal injury or properly damage in the event the chain separates during operation NEVER run pump with drive chain guard removed AX CAUTION Eyesight Hazard The components of the drive chain are hardened parts Striking these parts may cause metal chips to break off from the chain or the tools used resulting in personal injury During all stages of chain disassembly and assembly wear safety glasses to gt T prevent metal parts chips from ent
125. s completed and you are ready to start pumping Using this procedure will make iteasierto pump through the clean hose Note Once the concrete has reached end of the hose do not apply any more water in this manner as this procedure is used on the start only Hose sizing is very important We strongly recommend onharsh mixes vertical pushes stiff concrete shotcrete long pushes thata 2 1 2 line be used as far as possible The advantages of using the 2 1 2 line are improved pumpability less pumping pressure and less wear onthe pump Following the pump operation proper wash out of all mate rials or build up within the pump manifold and hoses will prevent problems when starting the next job A thorough inspection ofthe drive components and greasing ofall bearings after each job will ensure adequate lubrication and service to the pump whichis normally operating in wet gritty conditions Over greasing any bearing on your Mayco pump will not damage the bearing MAYCO C 30HDNI PRECISION PUMP OPERATION AND PARTS MANUAL REV 7 04 03 12 PAGE 29 C 30HDNI PRECISION PUMP OPERATING INFORMATION WARNING Hose Blockage Hazard If you repeatedly pull the throttle all the way out and try to force your pump to push through blockages due to separation of material in the hose or manifold you will soon have breakdowns and costly repairs which are not covered under warranty If a blockage
126. s of this book C 30HDNI CONCRETE PUMP W PRECISION FUEL INJECTION SYSTEM 3 Units QTY P N DESCRIPTION 10 EM14904 PISTON CUP KITS 10 EM18804 4 1 2 STEEL 10 EM14818 4 STEEL BALL 12 EM14903 BALL STOP PIN KITS 25 18801 MANIFOLD O RINGS gus 14308 CHAINS 10 556 EM26313 HALF LINK 10 EM26314 MASTER LINK PN 14334 COMPENSATOR SPRING Gs EM14408 BRONZE RING 2 nns EM903092 CAM ROLLER BEARING EM14315 V BELT 6 14842 LOWER SEAT EM14843 UPPER SEAT 3 EM26310 CLUTCH LINING 20 EM18409 O RING 20763 FUEL FILTER EM20328TKIT BEARING EM28004DD REDUCER 3 x 2 23946 3 ELBOW a 3 28904 3 CLAMP 10 EM289041 3 GASKET Din 14159 HOPPER SCREEN 1 14300 14801 T MANIFOLD desee 14819 Y MANIFOLD 2 EM14335
127. spection sections have been read and understood 1 Turnthe throttle control knob fully counter clockwise tosetthe engine speed to IDLE Figure 17 DECREASE SPEED INCREASE SPEED Figure 20 Throttle Control Switch During pumping operations the engine speed cannot be reduced below 1300 RPM s This built in feature protects the clutch from disengaging slipping during operation 2 Place the pumping control switch Figure 21 in the OFF position PUMPING CONTROL REMOTE PUMP OFF Figure 21 Pumping Control Switch OFF 3 C 30HDNI PRECISION PUMP STARTUP SHUTDOWN PROCEDURES Insertthe ignition key into the igni IGNITION SWITCH tion switch Figure 22 turn the key to the ON position then to the ON START position release the key when the engine starts START Figure 22 Ignition Switch Verifythatthe oil pressure battery and watertemperature status lamps Figure 23 are all OFF If any ofthese lamps are ON stop the engine and correct the problem OIL WATER PRESSURE BATTERY TEMPERATURE Figure 23 Control Box Status Lamps Let the engine run for 3 5 minutes before putting pump into operational use Push the choke knob in all the way Listen for any abnormal sounds lf any mechanical or electri calproblems exists STOP the engine andcorrectthe problem To begin pumping concrete Place the pumping control switch Figure 24 in the ON position PUMPING C
128. tand onthe foot pieces throughout the test procedure to hold the cone firmly in place Fillthe cone 1 3 full by volume Figure 35 A and 25 times with a 1 2 dia x 24 19 bullet pointed steel rod This is a specific requirement which will produce non standard re sults unless followed exactly Distribute rodding evenly over the entire cross section of the sample Fillcone another 1 3 Figure 35 B which willmake the cone 2 3 full by volume Rod this secondlayer25 times with the rod penetrating into but not through the first layer Distribute rodding evenly over the entire cross section of the layer Fill cone to overflowing Figure 35 C Rod this layer 25 times with rod penetrating into but not through the second layer Distribute rodding evenly over the entire cross section of this layer Remove the excess concrete Figure 35 D from the top ofthe cone using the tamping rod as a screed Liftthe cone vertically Figure 35 E witha slow even motion DO jar the concrete ortiltthe cone during this process Invert the withdrawn cone and place it next to but not touching the slumped concrete Lay a straight edge Figure 35 F across the top of the slumped cone Measure the amount of slump in inches from the bottom of the straight edge to the top of the slumped concrete at a point over the original center of the base The slump operation must be complete in a maximum elapsed time of 1 1 2 minutes Discard
129. tinto clutch lining hole Make sure rivet goes from inside out Wedge a flathead screwdriver between clutch flyweight and rivet head 3 Adjust screwdriver so thatthe rivet sticks outfromthe clutch housing approximately 1 8 of an inch With a flat punch pen the ends on the rivet so that it locks in place with the clutch housing Repeatthis procedureforall remaining clutch rivets The clutch lining is a normal maintenance item and will require periodic replacement MAYCO C 30HDNI PRECISION PUMP OPERATION AND PARTS MANUAL REV 7 04 03 12 PAGE 41 C 30HDNI PRECISION MAINTENANCE PUMP Bearing Installation 1 Installthe bearing components on the crankshaft making full contact with the back side of the crank disc as indicated the symbol See Figure 25 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 allen head bolts A while exerting pressure on the bushing towards the bearing spacer It is important that the Bearing Assembly is installed properly CAM BUSHING ALLEN HEAD SCREW 4 1 X ul 1 1 4 LL esse 2 44 1 Figure 25 Bearing Cam Bushing Installation PAGE 42 MAYCO C 30HDNI PRECISION PUMP OPERATION AND PARTS MANUAL REV 7 04 03 12 C 30HDNI PRECISION MAIN
130. tor Will not start operating until material is pumped into the line and back pressure develops The compensator spring which is installed on the compensator piston rod deflects with each piston stroke This spring cushion in conjunction with the cam profile produces and uninterrupted smooth flow of material under average pumping conditions The pumping cylinder Figure 10 retracts drawing the material past the ball A and filling the cylinder The compensator piston is pumping the material out to the nozzle and causing ball B to seat preventing the material from returning to the pumping cylinder intake HOPPER PUMPING PISTON INTAKE COMPENSATOR PISTON An automatic centrifugal clutch is installed to engage and disengage the pumping action without stopping or starting the engine The centrifugal clutch is set at 1100 R P M The engine idle speed is approximately 875 R P M therefore the clutch is completely disengaged at idle The throttle settings while pumping should always maintain an engine R P M high enough to prevent the clutch from slipping and burning the clutch lining The return spring which is installed on the rocker arm is installed to eliminate shock and stress between the cam roller and the cam weldment when the pump is in operation If the return spring is removed or replaced for any reason maintain the backing plate dimension of 3 as shown on Figure 3 to produce the proper pre loading of the
131. ttery Enaine hick Refill engine crankcase with correct type of oil At low temperatures engine will Engine oil too thick for winter environment not start Defective battery Replace battery Throttle lever in STOP position Reposition throttle lever to RUN position Engine fires but stops soon as Fuel filter blocked Replace fuel filter starter is switched off Fuel supply blocked Check the entire fuel system Electrical problem at fuel solenoid Repair using 7 wire Fuel tank empty Add fuel Fuel filter blocked Replace fuel filter Engine stops by itself during normal operation Defective fuel pump Replace fuel pump Mechanical oil pressure shutdown sensor Add oil Replace low oil shutdown sensor if stops the engine due to low oil necessary For more detail troubleshooting methods refer to NISSAN Operation and Maintenance manual supplied with your pump PAGE 48 MAYCO C 30HDNI PRECISION PUMP OPERATION AND PARTS MANUAL REV 7 04 03 12 C 30HDNI PRECISION PUMP ENGINE TROUBLESHOOTING TABLE 6 ENGINE TROUBLESHOOTING CONTINUED SYMPTON POSSIBLE PROBLEM Fuel tank empty SOLUTION Replace fuel filter Fuel filter clogged Replace fuel filter Low engine power output and Fuel tank venting is inadequate Ensure that tank is adequately vented speed Leaks at pipe unions Check threaded pipe unions tape and tighten unions a required Engine oil level too full Correct engine oil
132. visable to use burlap orsome means of wear protection underthe hose at points where the hose may wear through the outer cover e g overforms steel or sharp curbs PAGE 32 MAYCO C 30HDNI PRECISION PUMP OPERATION AND PARTS MANUAL REV 7 04 03 12 C 30HDNI PRECISION OPERATING INFORMATION Cam Roller Ifthe cam roller does not ride on the cam profile smoothly it may be caused by insufficient line back pressure e g wet mix with only 50 feet of hose Add more hose as necessary It can also be caused by cavitation or the passing of over sized aggregates through the valving causing it to skip Snap Joint When using Snap Joint couplings with gaskets to join hose see thatthey are washedclean after each job Keeping the hose ends clean heavy duty is very important for the best job setup A thin coat of grease on the rubber gasket or dipping both coupling and gasket in water before coupling the hose will make for easier installation MAYCO C 30HDNI PRECISION PUMP OPERATION AND PARTS MANUAL REV 7 04 03 12 PAGE 33 C 30HDNI PRECISION PUMP INSPECTION CAUTION General Saftey Guidelines NEVER operate the pump in confined Ge area or enclosed area structure that does 24 iS not provide ample free flow of air T a ALWAYS wear approved eye and hearing protection before operating the pump NEVER operate the pumps s engine with the 2 engine hood

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