OPERATION AND PARTS MANUAL
SERIES
MODEL C30HDZ
BALL VALVE CONCRETE PUMP
(DEUTZ F2L1011F DIESEL ENGINE)
Revision #12 (04/03/12)
To find the latest revision of this
publication, visit our website at:
www.multiquip.com
THIS MANUAL MUST ACCOMPANYTHE EQUIPMENT AT ALLTIMES.
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PROPOSITION 65WARNING
Diesel engine exhaust and some of
PAGE 2 — MAYCO C30HDZ PUMP — OPERATION AND PARTS MANUAL — REV. #12 (04/03/12)
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SILICOSIS/RESPIRATORYWARNING
WARNING WARNING
SILICOSIS WARNING
RESPIRATORY HAZARDS
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 a
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 a
substance known to cause cancer. When cutting such
materials, always follow the respiratory precautions
mentioned above.
Grinding/cutting/drilling of masonry, concrete, metal and
other materials can generate dust, mists and fumes
containing chemicals known to cause serious or fatal
injury or illness, such as respiratory disease, cancer,
birth defects or other reproductive harm. If you are
unfamiliar with the risks associated with the particular
process and/or material being cut or the composition of
the tool being used, 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 C30HDZ PUMP — OPERATION AND PARTS MANUAL — REV. #12 (04/03/12) — PAGE 3
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TABLE OF CONTENTS
COMPONENT DRAWINGS
MAYCO C30HDZ
CONCRETE PUMP
Nameplate and Decals....................................... 62-63
Compensator Piston Rod Assembly .................. 64-65
Connecting Rod - Drive Side Assembly ............. 66-67
Rocker Assembly ............................................... 68-69
Countershaft Assembly ...................................... 70-71
Crankshaft Assembly ......................................... 72-73
Manifold Assembly ............................................. 74-75
Frame Assembly ................................................ 76-77
Axle Assembly .................................................... 78-79
Muffler, Air Filter and Stop Switch Assembly ..... 80-81
Clutch Assy ........................................................ 82-83
Engine Mounting ................................................ 84-85
Throttle Assembly .............................................. 86-87
Control Box Mounting Bracket Assembly ........... 88-89
Control Box Assembly ........................................ 90-91
Battery Assembly ............................................... 92-93
Fuel Tank Assembly ........................................... 94-95
Hopper Assy....................................................... 96-97
Hood Assembly .................................................. 98-99
Lubrication Panel Assembly ........................... 100-101
Remote Control Cable Assembly................... 102-103
Proposition 65 Warning ..............................................2
SilicosisWarning ........................................................3
Table of Contents .......................................................4
Parts Ordering Procedures ........................................5
Pump Specifications...................................................6
Engine Specifications .................................................6
Pump Dimensions ......................................................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 ............................................ 22-23
Control Box Components .........................................24
Engine Components ................................................25
General Information .................................................26
How it Works....................................................... 27-28
Operating Information ........................................ 29-33
Inspection........................................................... 34-35
Startup/Shutdown Procedures.................................36
Maintenance (Pump) ......................................... 37-46
Engine Troubleshooting...................................... 47-48
Wiring Diagram ........................................................50
Wiring Diagram (Trailer Lights) ................................51
Appendix —
Terms and Conditions Of Sale — Parts .................104
Mayco Pump Warranty ...........................................105
Slump Test Procedure........................................52
Concrete Mix Information............................. 53-55
Recommended Shotcrete System ............... 56-57
Recommended Shotcrete Accessories........ 58-59
Explanation of Codes in Remarks Column ..............60
Suggested Spare Parts ............................................61
Specification and part
NOTE
number are subject to change
without notice.
PAGE 4 — MAYCO C30HDZ PUMP — OPERATION AND PARTS MANUAL — REV. #12 (04/03/12)
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PARTS ORDERING PROCEDURES
Ordering parts has never been easier!
Choose from three easy options:
Effective:
January 1st, 2006
Best Deal!
Order via Internet (Dealers Only):
Order parts on-line using Multiquip’s SmartEquip website!
If you have an MQ Account, to obtain a Username
and Password, E-mail us at: parts@multiquip.
com.
N View Parts Diagrams
N Order Parts
N Print Specification Information
To obtain an MQ Account, contact your
District Sales Manager for more information.
Use the internet and qualify for a 5% Discount
on Standard orders for all orders which include
complete part numbers.*
Goto www.multiquip.com and click on
to log in and save!
Order Parts
Note: Discounts Are Subject To Change
Fax your order in and qualify for a 2% Discount
on Standard orders for all orders which include
complete part numbers.*
Order via Fax (Dealers Only):
All customers are welcome to order parts via Fax.
Domestic (US) Customers dial:
1-800-6-PARTS-7 (800-672-7877)
Note: Discounts Are Subject To Change
Domestic (US) Dealers Call:
Order via Phone:
1-800-427-1244
Non-Dealer Customers:
International Customers should contact
their local Multiquip Representatives for
Parts Ordering information.
Contact your local Multiquip Dealer for
parts or call 800-427-1244 for help in
locating a dealer near you.
When ordering parts, please supply:
R
Dealer Account Number
R
Specify Preferred Method of Shipment:
R
R
R
R
R
Dealer Name and Address
ꢀ UPS/Fed Ex
ꢀ DHL
ꢀ Truck
N
N
Priority One
Ground
Shipping Address (if different than billing address)
Return Fax Number
N Next Day
Second/Third Day
Applicable Model Number
N
Quantity, Part Number and Description of Each Part
NOTICE
All orders are treated as Standard Orders and will
ship the same day if received prior to 3PM PST.
WE ACCEPT ALL MAJOR CREDIT CARDS!
MAYCO C30HDZ PUMP — OPERATION AND PARTS MANUAL — REV. #12 (04/03/12) — PAGE 5
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PUMP SPECIFICATIONS
Table 1. C-30HDZ Pump Specifications
Reciprocating Piston
Pump Type
Pumping Rate
Up to 25 cu. yds. per hour*
Up to 150 ft. (45.73 m)
Vertical Pumping Height
Horizontal Pumping Distance
400 - 500 ft. (122 - 152 m)*
Max. Concrete Piston Face
Pressure
500 PSI
Maximum Aggregate Size
Hopper Capacity
1/2 in. minus (12.7 mm)
6 cu. ft. etc.
2" or 2-1/2"
(50.8 or 63.5 mm)
Material Hose
Weight
2,950 lbs. (1,338 Kg)
7 Gallons (26.5 Liters)
125 ft. cable Standard
Lube oil Box
Remote Control
7.35" x 14"
(187 x 356 mm)
Tire Size
* Volume output will vary depending on mix design, slump, line size
used and job site conditions.
TABLE 2. ENGINE SPECIFICATIONS
Model
Type
DEUTZ F2L1011F ENGINE
Air/Oil-Cooled, Direct Injected, 4 Cycle Diesel
w/ Integrated Cooling System
3.6 x 4.1 in.
(91 x 104 mm)
Bore X Stroke
Compression Ratio
Cylinders
19.0 : 1
2
Displacement
41.7 cu. in. (0.68 L)
27 H.P. @ 2750 R.P.M.
59 lbs. per ft. @ 2550 R.P.M.
Approx. 11 U.S. Gallons (43 L)
No. 2 Diesel
Intermittent Output
Maximum Torque
Fuel Tank Capacity
Fuel Type
1.7 gal. per hour
(6.5 L per hour)
Fuel Consumption at Max. Rating
Fuel Consumption at Max. Torque
1.1 gal. per hour
(4.2 L per hour)
Lube Oil Capacity
Minimum Idle Speed
Air Cleaner
6.34 qt. (6.5 L)
900 RPMs
Dry Type
Starting Method
Electric Start
19.0 x 18.0 x 27.0 in.
(483 x 457 x 686 mm)
Dimensions (LxWxH)
Weight
367.4 lbs. (167 kg)
PAGE 6 — MAYCO C30HDZ PUMP — OPERATION AND PARTS MANUAL — REV. #12 (04/03/12)
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PUMP DIMENSIONS
Figure 1. C30HDZ Concrete Pump Dimensions
MAYCO C30HDZ PUMP — OPERATION AND PARTS MANUAL — REV. #12 (04/03/12) — PAGE 7
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SAFETY MESSAGE ALERT SYMBOLS
HAZARD SYMBOLS
FORYOUR SAFETY ANDTHE SAFETY OF OTHERS!
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:
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
WARNING - LETHAL EXHAUST GASES
instructions for the safe and efficient
operation of the Mayco Model
C30HDZ Concrete Pump.
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.
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.
WARNING - EXPLOSIVE FUEL
SAFETY MESSAGE ALERT SYMBOLS
Gasoline is extremely flammable, and its
vapors can cause an explosion if ignited.
DO NOT start the engine near spilled fuel
or combustible fluids. DO NOT fill the fuel
tank while the engine is running or hot.
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.
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.
DANGER
You WILL be KILLED or SERIOUSLY injured if you do
not follow directions.
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 heat shields or heat guards
removed.
WARNING
You COULD be KILLED or SERIOUSLY injured if you
do not follow directions.
CAUTION
You CAN be injured if you do not follow directions
PAGE 8 — MAYCO C30HDZ PUMP — OPERATION AND PARTS MANUAL — REV. #12 (04/03/12)
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SAFETY MESSAGE ALERT SYMBOLS
WARNING - ROTATING PARTS
NEVER operate equipment with covers,
CAUTION - RESPIRATORY HAZARDS
or guards removed. Keep fingers, hands,
hair and clothing away from all moving
parts to prevent injury.
ALWAYS wear approved respiratory
protection.
CAUTION - ACCIDENTAL STARTING
CAUTION - SIGHT AND HEARING HAZARDS
ALWAYS place the Engine ON/OFF switch
in the OFF position and remove the ignition
key when the pump is not in use.
ALWAYS wear approved eye and
hearing protection.
CAUTION - OVER-SPEED CONDITIONS
CAUTION - EQUIPMENT DAMAGE MESSAGES
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.
Other important messages are provided throughout this manual
to help prevent damage to your concrete pump, other property,
or the surrounding environment.
WARNING
DO NOT operate at pressures exceeding the rating of the
entire material delivery system.
Use snap pins on all snap couplings.
This pump, other property, or the
surrounding environment could
be damaged if you do not follow
instructions.
MAYCO C30HDZ PUMP — OPERATION AND PARTS MANUAL — REV. #12 (04/03/12) — PAGE 9
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RULES FOR SAFE OPERATION
■
■
■
Whenever necessary, replace nameplate, operation and safety
decals when they become difficult read.
DANGER - ReadThis 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.
Manufacture does not assume responsibility for any accident
due to equipment modifications.
NEVER use accessories or attachments, which are not
recommended by Multiquip for this equipment. Damage to the
equipment and/or injury to user may result.
The following safety guidelines should always be used when
operating the Mayco C30HDZ Concrete Pump:
■
■
NEVER touch the hot exhaust manifold, muffler or cylinder.
Allow these parts to cool before servicing engine or
concrete pump.
General Safety
■
DO NOT operate or service this equipment
before reading this entire manual.
HighTemperatures – Allow the engine
to cool before adding fuel or performing
service and maintenance functions.
Contact with hot! components can cause
serious burns.
■
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
■
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
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.
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
a hot engine.
■
■
NEVER operate this equipment when not feeling
well due to fatigue, llness or taking medicine.
NEVER operate this equipment under the
influence of drugs or alcohol.
■
■
NEVER operate 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-off to filler port is dangerous, as it tends to spill fuel.
■
ALWAYS wear proper respiratory (mask),
hearing and eye protection equipment when
operating the concrete pump.
■
■
Stop the engine when leaving the concrete pump unattended.
DO NOT leave the pump unattended. Use chock blocks if
parking pump on a grade.
■
Maintain this equipment in a safe operating condition at all
times.
PAGE 10 — MAYCO C30HDZ PUMP — OPERATION AND PARTS MANUAL — REV. #12 (04/03/12)
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RULES FOR SAFE OPERATION
■
■
■
■
■
CAUTION must always be observed while servicing this
pump.Rotating parts can cause injury if contacted.
■
■
■
A copy of this manual shall accompany the pump at all times.
DO NOT use worn out hoses or couplings;inspect daily.
ALWAYS stored the pump in a clean, dry location out of the
reach of children.
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
at the exhaust cone outlet.
ALWAYS use extreme care when operating near obstructions,
on slippery surfaces, grades and side slopes.
Unauthorized equipment modifications will void all
warranties.
■
■
The pump should NEVER be towed in excess of 45 MPH (or
less depending on road conditions).
Refer to the Engine Owner's Manual for engine technical
questions or information.
If 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 or force out the blockage.
This rapid surge of material could cause the lines to move or
whip in a manner that could cause injury to personnel.
■
■
■
■
Before start-up, check the hopper and remove all obstructions.
Keep all hands out of the hopper when the engine is running.
DO NOT operate the pump with the hood open.
■
■
■
■
Inspect the hose lines at all times
Replace any worn or damaged pump components
immediately.
DO NOT tow the pump with the hopper full of material.
DO NOT tow the pump with the hoses attached.
■
■
ALWAYS turn the engine OFF before performing must be
before performing maintenance.
NEVER 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.
ALWAYS make sure pump is correctly secured to the trailer.
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.
■
ALWAYS make sure the delivery system used, pipe hose,
clamps etc., exceed teh rated pressure of teh pump.In addition,
the pumping system should be checked for worn components
prior to start up. Use snap pins on all snap couplings.
■
■
■
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 lbs.
(1,338 Kg) load.
If 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.
MAYCO C30HDZ PUMP — OPERATION AND PARTS MANUAL — REV. #12 (04/03/12) — PAGE 11
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RULES FOR SAFE OPERATION
Maintenance Safety
Emergencies
■
NEVER lubricate components or attempt service on a running
machine.
■
ALWAYS know the location of the nearest fire extinguisher
and first aid kit. Know the location of the nearest telephone.
Also know the phone numbers of the nearest ambulance,
doctor and fire department. This information will be
invaluable in the case of an emergency.
■
ALWAYS allow the machine a proper amount of time to cool
before servicing.
■
■
Keep the machinery in proper running condition.
Fix damage to the machine immediately and always replace
broken parts.
■
■
■
Dispose of hazardous waste properly.Examples of potentially
hazardous waste are used motor oil, fuel and fuel filters.
DO NOT use food or plastic containers to dispose of
hazardous waste.
DO NOT pour waste, oil or fuel directly onto the ground,
down a drain or into any water source.
Lifting
The pump has an operating weight of approximately 2,950
■
lbs. (1,338 Kg). Use lifting equipment capable of lifting this
weight.
PAGE 12 — MAYCO C30HDZ PUMP — OPERATION AND PARTS MANUAL — REV. #12 (04/03/12)
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NOTES
MAYCO C30HDZ PUMP — OPERATION AND PARTS MANUAL — REV. #12 (04/03/12) — PAGE 13
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TOWING GUIDELINES
Towing Safety Precautions
■
Check wheel mounting lug nuts with a torque wrench.
Torque wheel lug nuts as described in the "Lug NutTorque
Requirements",Table 5.
CAUTION - LocalTowing Regulations
■
■
■
Make sure brakes are synchronized and functioning properly.
Check tightness of suspension hardware (nuts and bolts).
Check with your county or state safety towing regulations
department before towing your concrete pump.
Avoid sudden stops and starts.This can cause skidding, or
jackknifing. Smooth, gradual starts and stops will improve
gas milage.
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.
■
■
■
Avoid sharp turns to prevent rolling.
Retract wheel stand when transporting.
DO NOT transport pump with fuel in the fuel tank.
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).
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.
■
ALWAYS inspect the hitch and coupling for wear. NEVER
tow the light tower's trailer with defective hitches, couplings,
chains etc.
PumpTrailerVehicle Connection
■
■
■
■
CHECK the tire air pressure on both the towing vehicle and
the trailer.Also check the tire tread wear on both vehicles.
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.
ALWAYS make sure the trailer section of the pump is
equipped with a "Safety Chain".
2. Use only the 2-inch ball diameter with a towing capability of
5,000 lbs. (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.
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.
3. Be sure the coupler is secured to the hitch ball and the lock
lever is down (locked).
■
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.
4. Attach safety chains as shown in Figure 2. Remember to
cross the safety chains.
5. After towing for about 50 miles recheck the entire towing
system for tightness.
■
■
Place chocked blocks underneath wheel to prevent rolling,
while parked.
Recommended Maintenance
1. Smear ball socket and clamp face with chassis grease.
Periodically oil pivot points and were surfaces of coupler
with SAE 30W motor oil.
Depending on soil conditions and location it may be
necessary to place support blocks underneath the trailer's
bumper to prevent tipping, while parked.
2. When parking or storing the concrete pump, keep the coupler
off the ground so dirt and other debris will not build up in the
ball socket.
■
Inflate tires to correct pressure, inspect tires for cuts, and
excessive wear. SeeTable 3 (TireWearTroubleshooting).
PAGE 14 — MAYCO C30HDZ PUMP — OPERATION AND PARTS MANUAL — REV. #12 (04/03/12)
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TOWING GUIDELINES
Figure 2 shown below illustrates the typical towing application
that should be used when towing the pump.
Figure 2.Towing Applications
MAYCO C30HDZ PUMP — OPERATION AND PARTS MANUAL — REV. #12 (04/03/12) — PAGE 15
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TRAILER SAFETY GUIDELINES
The following list defines the major trailer components:
Trailer Safety Precautions
1. Fuel Cell – Provides an adequate amount of fuel for the
equipmentinuse.Fuelcellsmustbeemptywhentransport-
ingequipment.
CAUTION - GeneralTrailer Safety
ALWAYS makesurethatthetrailerisingoodoperatingcondi-
tion.Checkthetiresforproperinflationandwear.Alsocheckthe
wheel lug nuts for proper tightness.
2. Frame Length– Thismeasurementisfromtheballhitchto
therearbumper(reflector).
3. FrameWidth – This measurement isfrom fender to fender.
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.
4. Jack Stand – Trailer support device with maximum pound
requirement from the tongue of the trailer.
5. Coupler–Typeofhitchusedonthetrailerfortowing.Thisunit
employes a 2 in. ball.
It is the purpose of this section to cover the major maintenance
components of the trailer.The following trailer components will
be discussed in this section:
6. Tires Size –Indicates the diameter of the tire in inches (10,
12,13,14,etc.),andthewidthinmillimeters(175,185, 205
etc.).The tirediametermustmatchthediameterofthetirerim.
This unit employes 7.35 x 14 in. tires.
■
■
■
■
Tires
Lug NutTorquing
Suspension
Electrical
7. 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-plytires.
8. WheelHub– Thewheelhubisconnectedtothetrailer'saxle.
9. TireRim– Tiresaremountedonatirerim. Thetirerimmust
match the size of the tire.
10. Lug Nuts – Used to secure the wheel to the wheel hub.
Alwaysuseatorquewrenchtotightendownthelugnuts.See
Table5andFigure4forlugnuttightening andsequence.This
unit employes 5 lug nuts to secure the wheel to the hub.
11. Axle – This trailer employs a torsion bar type suspension,
which can support 3,500 lbs.
12. Electrical– Electricalconnectors(looms)areprovidedwith
the trailer so that brake lights and turn signal lights can be
connectedtothetowingvehicle.SeeTrailerWiringDiagram
for proper wiring connections.
PAGE 16 — MAYCO C30HDZ PUMP — OPERATION AND PARTS MANUAL — REV. #12 (04/03/12)
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TRAILER SAFETY GUIDELINES
Tires/Wheels/Lug Nuts
Tires and wheels are a very important and critical components
of the trailer. When specifying or replacing the trailer wheels it is
important the wheels, tires, and axle are properly matched.
CAUTION - GeneralTrailer Safety
DO NOT attempt to repair or modify a wheel. DO NOT install
an inter-tube to correct a 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
serious eye or bodily injury.
TiresWear/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.
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.
Table 3 (TireWearTroubleshooting) 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.
NOTE
Figure 3. Major Suspension Components
MAYCO C30HDZ PUMP — OPERATION AND PARTS MANUAL — REV. #12 (04/03/12) — PAGE 17
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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. Torque all lug nuts in sequence (Figure 4). DO NOT torque
the wheel lug nuts all the way down.Tighten each lug nut in
3 separate passes as defined byTable 4.
3. Afterfirstroaduse,retorquealllugnutsinsequence.Check
all wheel lug nuts periodically.
Table 5. Tire Torque Requirements
Wheel Size
First Pass
FT-LBS
Second Pass
FT-LBS
Third Pass
FT-LBS
12"
13"
14"
15"
16"
20-25
20-25
20-25
20-25
20-25
35-40
35-40
50-60
50-60
50-60
50-65
50-65
90-120
90-120
90-120
Figure 4. Wheel Lug Nuts Tightening Sequence
NEVER! use an pneumatic air gun
to tighten wheel lug nuts.
NOTE
PAGE 18 — MAYCO C30HDZ PUMP — OPERATION AND PARTS MANUAL — REV. #12 (04/03/12)
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NOTES
MAYCO C30HDZ PUMP — OPERATION AND PARTS MANUAL — REV. #12 (04/03/12) — PAGE 19
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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.
C A U T I O N
CAUTION !
When the pump, manifold or delivery system
plugs, do not disconnect the delivery system
1. Before setup and operation of this equipment, the designated operator
MUST read and completely understand the operating instruction manual.
clamps or open the manifold. A plug has
occurred when the pump is running but no
concrete is discharging from the end of the
delivery system: immediately switch the engine
OFF consult your operating a d instruction
manual before proceeding.
2. Keep unauthorized and untrained people away from the machine during
operation.
3. Do NOT operate unit with engine cover open: rotating or moving parts will
cause serious injury. ( An automatic shutdown switch has been
installed on the hood to prevent this.
Great care must be taken to clear a plug
as a dangerous condition exist, due to high
pressure build-up, inside the pump and delivery
system.
4. Engine must be shut off before servicing.
932
5. Keep hands out of hopper when engine is running.
6. Check hopper for obstructions before operating machine.
7. This machine is remotely controlled and may start at any time.
8. Stop the engine before adding fuel or oil.
P/N EM932
508594
CAUTION
NORMAL
LOW
P/N 508594
1”
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
C-30HDZ
P/N 513119
P/N DCL152
MAINTENANCE
GREASE DAILY, EVERY ZERK
Use No. 2 Multipurpose Automotive Grease
P/N EM513165
OWNER’S MANUAL
W A R N I N G
P/N 34536
Refer to the owner’s manual for safe
operating procedures.
OIL
TEMPERATURE
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
while pumping could damage axle.
BATTERY
OIL PRESSURE
PUMPING CONTROL
REMOTE
OUTLET
P/N 98022
PUMP OFF REMOTE
ENGINE HOURS
ON
ON
ON
OFF
START
quartz
P/N EM1028
IGNITION
SWITCH
NAMEPLATE
THROTTLE
310-537-3700
800-421-1244 NATIONWIDE
FAX: 310-537-3927
MAYCO INC 18910
WILMINGTON AVENUE CARSON,
CALIFORNIA 90746
CONTACT PARTS DEPT.
P/N 513163
Figure 5. Operation and Safety Decals
PAGE 20 — MAYCO C30HDZ PUMP — OPERATION AND PARTS MANUAL — REV. #12 (04/03/12)
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IMPORTANT HAND SIGNALS
Figure 6 display's the basic hand signals commonly used in concrete pumping operations.
Figure 6. Operation Hand Signals
MAYCO C30HDZ PUMP — OPERATION AND PARTS MANUAL — REV. #12 (04/03/12) — PAGE 21
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PUMP COMPONENTS
YC0
MA
C-30HDZ
24
7
8
9
10
13
12
6
5
16
4
14
11
3
15
17
19
2
18
1
25
22
20
21
23
Figure 7. Major Pump Components
PAGE 22 — MAYCO C30HDZ PUMP — OPERATION AND PARTS MANUAL — REV. #12 (04/03/12)
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PUMP COMPONENTS
Figure 4 illustrates the location of the major components 11. Fuel Tank/Cap – Fill with unleaded fuel. Fuel tank (cell)
for the C30HDZ Concrete Pump. The function of each
component is described below:
holds approximately 11 gallons (41 liters).DO NOT top off
fuel.Wipe up any spilled fuel immediately
1.
Discharge Cone – Connect 3" elbow to this discharge 12. Tow End Jack Stand – Use this jack stand to level and
port, then connect 3" x 2" reducer to elbow. support the pump.
2.
Discharge Cone Safety Latch – When towing of the pump 13. Tow Hitch Coupler – Requires a 2-inch ball hitch or a
is required, ALWAYS secure the discharge cone to latch
3-inch pintle. Capable of towing 5,000 lbs.
located on the manifold.
14. Safety Chain – ALWAYS attach safety chain to the
towing vehicle. NEVER! tow the pump with the safety
chain unattached.
3.
Rear Running Lights – ALWAYS check and make sure
both the right and left running lights are functioning correctly
before towing the pump.
15. 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.
4.
Hopper – Concrete from a Redi-Mix truck is poured into
this hopper. The hopper can hold 6.0 cu. ft of concrete.
NEVER put hands or any other parts of you body into the
hopper.
16. Grease Port Console – This console allows for the remote
5.
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.
lubrication of components on the pump.
17. 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.
6. 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 typeV-belt.
18. Drive Chain – Keep this chain properly lubricated and
aligned at all times. Lubricate this chain as specified in the
maintenance section of this maintenance.
19. Rubber Latch – Secure this rubber latch to the hood
fastener whenever the pump is in use or being towed.
7.
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).
20. Tires Ply– The tire ply (layers) number is rated in letters;
This trailer uses 4-ply tires.
21. Chock Blocks – Place these blocks (not included as
part of your concrete pump package) under each trailer
wheel to prevent rolling.
8.
9.
Hood Fastener – When the hood is in the down position,
secure the rubber latch to this fastener.
22. Pump End Jack Stand – Use this jack stand to level
Hood Lift Handle – Grip this handle, pull upward then
back to raise the compartment hood.
and support the pump.
23. Discharge Cone Release Lever – secures the
discharge cone to the "Y" manifold; also relieves
manifold pressure.
10. Control Box – Contains the mechanical and electrical
components required to run the pump. Below is a list of
those components:
24. Documentation Box – Contains engine and pump
■
■
■
■
■
■
■
Throttle Control
operation, parts and maintenance information.
Choke Control
25. 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.
Low Oil Pressure Indicator
Battery Charge Indicator
WaterTemperature Indicator
Ignition Switch
Remote Connector
MAYCO C30HDZ PUMP — OPERATION AND PARTS MANUAL — REV. #12 (04/03/12) — PAGE 23
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CONTROL BOX COMPONENTS
Figure 8 illustrates the location of the major
components for the C30HDZ Control Box. The
function of each component is described below:
4
2
3
6
5
quartz
7
8
1
Figure 8. Pump Control Box Components
1.
Throttle Control Knob – This is a variable speed type
3.
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.
control. Turning the throttle lock left (CCW) unlocks the
throttle allowing the throttle control cable to be pulled out to
the desired position. Once the desired engine speed has
been achieved, turning the throttle lock to the right (CW)
locks it in place. Use the fine tune adjustment knob to fine
tune the engine rpm's.
4.
WaterTemperature Lamp – Indicates 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.
To place the engine in idle, press the top button inward all
the way.
ALWAYS unlock the throttle control
5.
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, thecenter position is for normal
pumping operation, and the right most position (OFF)
prevents pumping.
before it is pushed in because if this
NOTE
is not done first, possible damage
could result to the locking
mechanism.
6.
7.
Remote Control Input Connector – Insert the remote
2.
Oil Pressure Indicator Lamp – In the event of low oil in
the engine crankcase or low oil pressure, the indicator lamp
will illuminate.STOP the engine immediately if this occurs.
NEVER run the engine when this lamp is lit.
control input cable into this connector.
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.
8.
Hourmeter– Display's the number of hours the pump has
been in use.
PAGE 24 — MAYCO C30HDZ PUMP — OPERATION AND PARTS MANUAL — REV. #12 (04/03/12)
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ENGINE COMPONENTS
REARVIEW
12
FRONTVIEW
14
10
13
6
1
7
9
3
5
11
8
4
Figure 9. Deutz Model F2L01011F Basic Engine Components
Figure 9 illustrates the location of the basic components
for the Deutz Model F2L01011F Engine. The function of
each component is described below:
7. 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.
8. Crankcase Drain 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.
1.
2.
3.
Oil 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.
9. Fuel Pump/Fuel Filter – Replace or clean the fuel pump
or fuel filter as specified in the maintenance section of this
manual.
Starter Motor/Solenoid – NEVER allow concrete or any
foreign debris to come in contact with the starter motor/
solenoid.
10. Muffler/Guard – DO NOT touch the muffler when engine
is running.The muffler can become extremely hot, causing
severe burns. NEVER run the pump with the muffler guard
removed.
4.
5.
6.
Fan V-Belt – ALWAYS make sure that V-belt is properly
tensioned. A loose or defectiveV-belt can adversely affect
the performance of the pump.
11. 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.
Alternator – (not shown) Provides power to the electrical
system. Replace with only manufactures recommended
type alternator.
12. 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.
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.
Operating the engine without an air
filter, with a damaged air filter, or a
NOTE
filter in need of replacement will allow
dirt to enter the engine, causing rapid
engine wear.
MAYCO C30HDZ PUMP — OPERATION AND PARTS MANUAL — REV. #12 (04/03/12) — PAGE 25
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GENERAL INFORMATION
The following operating principles and operating suggestions As a general rule, the use of approximately six sacks of cement,
should prove helpful in the successful operation of your concrete 70% washed concrete sand and 30% #4 pea gravel per yard of
pump.Your new “small line” concrete pump has been designed concrete will result in a pumpable mix.The ideal nature of sand
to give you many years of service when operated properly. A and rock in certain areas may permit you to increase the
study of the following paragraphs is important to the successful percentage of rock or adjust the mix considerably to meet the job
operation of your new Direct-flow Concrete Placer.
requirements.When possible, you may experiment with various
mixes in your area to determine the degree of versatility of the
Direct-flow Pump.
All concrete pumps require a high level of operator skill and
more frequent service than most of the other construction
equipment.The highly abrasive nature of concrete under pressure Uniform gradation of the washed concrete sand and the 1/2”
makes it extremely important that expendable wear components minus aggregate along with sufficient cement content and water
be inspected at regular intervals between jobs to prevent having are important to a successful pump operation.
to replace these items during a pour.
A recommended pumpable mix design would be 70% sand and
Experience has proved that inconsistency of batched concrete 30% aggregate-cement content to be a minimum of 6 sacks.
mixes and frequent moving of the line requires the operator to be (564 lbs.)
readily available at all times during pumping to stop the pump
and prevent abuse to the unit which may occur if unexpected
blockages develop.
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 recommendation.
NOTE
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:
Sample Design Mix - 3000 Psi 3/8 in. Slump 4- 5 in.
Type II Cement
Sand
6.49 sack/cu. yd
Sat. Surf. Dry
Sat. Surf. Dry
Sat. Surf. Dry
48 Gallons
611 lbs.
2000 lbs.
864 lbs.
0 lbs.
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.
#4 Gravel
#3 Gravel
Water
400 lbs.
3,906 lbs
26 oz.
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 accepted 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.
TotalWeight
AdmixtureWRDA-79
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.
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.
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.
NOTE
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.
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 lbs. per cubic foot
wet density. (Below 70 lbs. materials (roof decks) the valving
becomes inefficient.)
PAGE 26 — MAYCO C30HDZ PUMP — OPERATION AND PARTS MANUAL — REV. #12 (04/03/12)
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HOW ITWORKS
The C30HDZ concrete pump has one main pumping piston which An automatic, centrifugal clutch is installed to engage and
is valved by means of two ball checks. (A inlet, and B outlet.)
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 secondary piston is used as a compensator piston to smooth
out the pulsations of a single piston action.Note:The compensator
will not start operating until material is pumped into the line and
back pressure develops.
The compensator spring, which is installed on the 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 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 spring for a smooth performance.
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.
Figure 10. Pumping Cylinder
MAYCO C30HDZ PUMP — OPERATION AND PARTS MANUAL — REV. #12 (04/03/12) — PAGE 27
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HOW ITWORKS
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.
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.
Figure 12. Return Spring, Compensator Spring and
Rocker Arm Interaction
PAGE 28 — MAYCO C30HDZ PUMP — OPERATION AND PARTS MANUAL — REV. #12 (04/03/12)
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OPERATING INFORMATION
C. If it is necessary to wait 10 minutes or more for another
loadofconcrete,itiswisetostartthepumpandpump6
or8strokesevery5minutestopreventsettingofthemix
inthesystem.Ifwaitingtimeisexcessive,itwouldbewise
towashoutthepumpandhosesandstartoverwhenthe
newtruckarrives.
OPERATING SUGGESTIONS
1. Awell-plannedlocationofthepumpandroutingofthehose
beforestartingapourmaysavesubsequentmovesthrough-
out the job.
2. Beforeconcreteisdischargedintothehopper,itissuggested
that 3 to 4 gallons of water be sprayed into the hopper,
followedbyapproximately5gallonsofacreamycementand
water slurry (1/2 bag of cement to 5 gallons of water).This
procedurelubricatesthehoseandpreventsseparationand
blockages in the hose.
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.
E. Whenthepumpingjobrequiresastiffermix,thefollow-
ingmethodissuggestedforstarting:Takeawaterhose
withanozzleonitandapplywaterwithafinespraytothe
concrete as it comes down the redi-mix chute into the
pumphopperaftertheslurryprocedureiscompletedand
you are ready to start pumping.
Gettingtheconcretetoflowthroughthe
hose at the start of the pumping cycle
can be one of the most critical opera-
tionsofthepour.(Manuallyoperatethe
throttlewhenstarting,NOTremotely)
NOTE
Usingthisprocedurewillmakeiteasiertopumpthrough
thecleanhose.Note:Oncetheconcretehasreachedthe
end of the hose, do not apply any more water in this
manner as this procedure is used on the start only.
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 move in a manner that could cause injury to personnel.
F. Hosesizingisveryimportant:Westronglyrecommend
onharshmixes,verticalpushes,stiffconcrete,shotcrete,
longpushes,thata2-1/2”linebeusedasfaraspossible.
The advantages of using the 2 -1/2” line are improved
pumpability,lesspumpingpressureandlesswearonthe
pump.
Inspect the lines at all times to prevent the above
conditions
5. 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.
3. It is important that once the slurry procedure is completed,
andyouhavestartedconcreteflowingthroughthehose, do
not stop the pour until all the slurry 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.
6. Athoroughinspectionofthedrivecomponentsandgreasing
ofallbearingsaftereachjobwillensureadequatelubrication
and service to the pump which is normally operating in wet,
grittyconditions.
4. Whenthepumpisstoppedforanyreasonduringapour;e.g.,
movinghose,waitingforredi-mixtruck,thefollowingsugges-
tionsareoffered:
Over-greasing any bearing on your
NOTE
A. Leavethehopperfullofconcreteatthetimeofshutdown.
Itisimportantnottolettheredi-mix driverwashtoomuch
waterintothehopper,asthiscouldcauseseparationof
the concrete in the hopper.
Mayco pump will not damage the
bearing.
B. Iftheshutdown periodexceeds2to3minutes,turnoff
theenginesothevibrationdoesnotseparatethemixin
thehopperwhichcancauseablockageinthemanifold
when the pump is started.
MAYCO C30HDZ PUMP — OPERATION AND PARTS MANUAL — REV. #12 (04/03/12) — PAGE 29
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OPERATING INFORMATION
2. ADMIXTURES
WARNING - Hose Blockage Hazard
Remixtures that are designed into the concrete mix by the
redi-mixcompanyoranarchitecturalengineeringcompany.
Thissectionlistscommonadmixturesandabriefexplanation
oftheirfunctions:
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.
A. Pozzolith 300 – or the equivalent acts as a water
retarderandalubricant.Onaleanmix,longpushes,stiff
mixes, and vertical pushes, Pozzolith 300R helps
pumpability.
If a blockage 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.
B. MBVR – 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
ifthewaitingtimebetweendeliverytrucksbecomestoo
long.
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.
D. Super Plasticizers – acts as an 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.
New Pumps
E. RedLabel– actsasawaterretarderandanaccelerator.
Red label will be used mainly on commercial jobs.
Allnewpumpsare“waterpressuretested”atthefactorybefore
shipment.This procedure permits a thorough inspection of the
entire drive system and valving under simulated full load condi-
tions.
F. Fly Ash – is used to help increase the strength of the
concreteanddecreasethecementcontentperyard.This
is one of the most common admixtures used.
Thepumpownercandothesamebyattachinganadaptorcouple
totheendofthedischargecone;e.g., theuseofastandard2in.
pipecapwitha3/8in.holedrilledinthecenter,screwedontothe
end of the hinged cone or reducer at the pump.
All admixtures will be shown on the
redi-mixconcreteticket.Beforestart-
ingthepumpingjob,askthedriverof
theredi-mixtrucktoseetheconcrete
ticket and note the admixtures that
exist and take the proper action.
NOTE
Fillthehopperwithwateraftermakingsurethatallsandandrock
have been removed from the manifold. Operate the pump at full
throttleandthe3/8in.diameterholerestrictionwillcreatesufficient
back-pressuretomakeathoroughinspectionofallmovingparts.
3. Whenpumpinglongdistanceorpumpingstiffmixes,youcan
expectadropinvolumecomparedtoshorterlinesandwetter
mixes due to the change in valve efficiency or cavitation.
Pumping Tips
1. Theeffectsofheatandexcessivetimeonconcrete:Hot
concrete,commonlyreferredtoasahotload,isconcretethat
hasbeenintheredi-mixtruckinexcessof2to3hours.Ona
hotday, thisamountoftimeisevenless. Abriefexplanation
ofwhyheatandtimeaffectconcrete:
4. Leakingmanifoldsealsorhosecouplinggasketswhichleak
watercancauseseparationandsubsequentjammingatthat
point.
5. Damaged hoses with internal restrictions can cause block-
ages.
Concrete starts setting by drying up through a chemical
reaction.Thecatalysttothisreactionisheat. Whenpumping
ahotload,itisimportanttorememberthatwhenyouhaveto
stoppumpingforanyreason,addwatertotheconcreteinthe
hopper and hand mix and move concrete in the hose every
5minutes.Iftheshutdowntimebecomestoolong,washout
immediately.
PAGE 30 — MAYCO C30HDZ PUMP — OPERATION AND PARTS MANUAL — REV. #12 (04/03/12)
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OPERATING INFORMATION
H. After the blockage has been cleared and the pump
manifoldhasbeenthoroughlyflushedwithwater,close
the hinged discharged cone and lock into place.
6. If a blockage occurs in a hose, “walk the hose” until you find
thepointoftrouble.Thehosewillbesoftimmediatelypastthe
blockage.Ifthishappensatthestart,disconnectthehoseat
the first coupling past the blockage.
I. Beforereconnectinghosetothereducer,starttheengine
and pump two or three shovels of concrete through the
reducer.This will insure that all the blockage has been
cleared.
Elevatethehoseatthatpointwiththeblockageareahanging
down.
CAUTION - Hose Pressure Hazard
J. Shakeoutaround2feetofconcretebeforereconnecting
hose to pump.After this is done, connect hose to pump
and resume the pumping operation.
Whendisconnectinghoses,useextremeCAUTION!Thehose
is under pressure!
8. Avoiding Setting of the Mix in the System
Usingahammer,youcanpoundthedown-streamedgeofthe
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,startthepumpandrunasmallamountofconcreteout
totheendofthehose.Thiswillassurethatalloftheseparation
is out of the hose.
To avoid setting of the concrete mix in the system when
waitingmorethan30minutesbetweenconcreteloads,flush
the system depending on job factors (such as presence of
accelerators and job site temperature) and your particular
mixdesign.
Clearing a Mix from the System
7. Clearing a Plugged Manifold
If, for any reason, the mix should set up in the system, the following
procedure is suggested:
The manifold is plugged if the volume at the discharge end
ofthehosestops,andthehoseissoft.Thedrivebeltswillstart
to slip and the engine will lugdown.
CAUTION - Hose Pressure Hazard
Follow steps 7A through 7J to un-plug a clogged manifold.
When disconnecting hoses, use EXTREME CAUTION! The
hose is under pressure!
DANGER - Clearing A Plugged Manifold
Duetopressurebuild-upinsidethemanifold,greatcaremust
be taken when clearing a plugged manifold.
1. Disconnectthehosesfromthepumpandwashthepumpout
immediately.Forexample:Ifyouhad200ft.ofsystemout,you
would disconnect each hose.
A. STOP the pump.Switch OFF the engine.
2. Reconnect the first hose and fill the hopper with water. DO
NOTtrytopushalltheconcreteoutofallofthehoselinesat
onetime.
B. DO NOT open any of the delivery system joint clamps.
C. The senior operator must warn all others to stand at
least20feetawayfromthepumpandturntheirheads
away from the manifold.
3. Clean it out by pushing water through the first hose off the
pump,thencontinueprogressingthroughallthehoses,until
all the system is clean.
D. The operator must position himself/herself away from
the hinged side of the manifold.
4. If waiting time is excessive, it would be wise to wash out the
pump and hoses and startover when the new truck arrives.
This can be avoided by being observant to the pump and
system, also taking into consideration the above factors
affectingthemix.
E. Wearingsafetyglasses,grasptheclamparmweldment
andcarefullypullitopentotheprimary(safety)position.
STOPcount to 20.Thiswillallowthepressuretorelease.
F. After the pressure has been released, open the clamp
arm weldment and swing the hinged discharge cone
open.
G. Removeblockagewitharound 2-footlengthofreinforc-
ingsteelrod. Flushthemanifoldswithwater.Makesure
the (3” x 2”) reducer is clear of any blockage before
closing the discharge cone.
MAYCO C30HDZ PUMP — OPERATION AND PARTS MANUAL — REV. #12 (04/03/12) — PAGE 31
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OPERATING INFORMATION
Down-Hill Pumping
ValveSeats
Downhillpumpingcanbedifficultonsomejobs.Itissuggestedthat
a sponge 2”x 4”x 6” be placed in the hose before the start of
pumping.Wetthespongebeforeplacingitinthehose.Reference
the Operating Suggestions at the start of this section for slurry
procedures.
Ifthevolumeattheendofhosestartstodecreasegraduallyand
eventuallyalmoststops,itisquitelikelythatthevalveseatshave
had excessive wear and need replacement. Once they have
reachedacertainwearpoint,theymay“channelout”rapidlyand
material will reciprocate past the ball on each stroke.
The reason for using the wet sponge is to keep the slurry from
running too far ahead of the concrete and so reducing the
possibilityofseparation.Whenthepumpisstopped,thematerial
can flow slowly down, due to gravity, and cause the hose to
collapse.
The hollow steel ballshould be replaced when it starts to show
dentsorappearstobebadlyworn.Sandandaggregatematerials
insomeareasareextremelysharpandhardandthereforehighly
abrasive.Undertheseconditionswhenpumpingstiffmixes,orto
high elevations which cause line pressures, it will be noted that
valve components may have short wear life.
Whenpumpingisresumed,youcanexpectablockageatthepoint
ofhosecollapse.Topreventthisfromhappening,thehosecanbe
“kinked off” at the discharge end when the pump is stopped to
prevent the gravity flow of the material in the hose.
Ifthisconditionexists,itisadvisabletoremovethemanifoldonly,
andinspectthelowerseatattheendofeachday.Ifitappearsthat
theseatisbeginningto“channelout",replacebeforestartingthe
nextday’spour.
The use of stiffer mixes when pumping down-hill will decrease
gravityflowofthematerialinthehoseandwillassureasmoother
operationbetweenthecamrollerbearingandcamplate.Aswith
any job, make sure that the hose and the couplings are in good
workableshape.
The upper valve seat can be inspected after each washout by
running your finger around lower edge of seat where the ball
makescontact.Youcanreachthisfromtheinsideofthehopper.Be
sure that the engine is turned off.
Pulsation
VerticalPumping
A slight pulsation of the hose will always be noticeable near the
pump.Excessivepulsationofthehosenearthepumpisnormally
duetohigherthanaveragelinepressurescausedbystiff, harsh
mixes,orextremelylongpumpingdistances.
Whenpumpingverticallyupthesideofabuilding,above40feet,
we would recommend the installation of steel pipe securely
fastened at intervals as necessary to support the pipe. Ninety
degree,longradiuspipesweepsshouldbeinstalledatthetopand
bottomofthesteelline.
The use of 2 -1/2”I.D.hose in these extreme cases reduces line
pressures or the addition of slight amounts of water to the mix, if
permissible,willpermiteasierpumping.Theuseofcertainpump-
ing admixtures may help.
Usea25ft.hose,orshortsection,offthepump;andforthebalance
of the horizontal distance to the vertical line, use steel pipe.This
type of installation has been satisfactory on many jobs being
pumpedinexcessof100feethigh.Linepressuresarealwaysless
using steel pipe as compared to hose.
If excessive pulsation exists in the hose, it is advisable to use
burlaporsomemeansofwearprotectionunderthehoseatpoints
wherethehosemaywearthroughtheoutercover;e.g.overforms,
steel or sharp curbs.
When pumping vertically usingall hose, it is recommended not
togohigherthan50feetwithhose.Thehoseshouldbetiedoffat
intervalsof10feet,ifpossible.Specialattentionshouldbegiven
whentieingthehoseoffatthetopasthehosewillhaveatendency
to stretch when filled with concrete.This will increase the possi-
bilityofablockageatthepointwherethehoseistiedoff.Toavoid
this, a long radius of 90 degree elbow is recommended. The
suggested place to tie off is on the hose, under the clamp.
Itisstronglyrecommendedthatsteel
pipe be used on ALL vertical pump-
ing for safety and convenience.
NOTE
PAGE 32 — MAYCO C30HDZ PUMP — OPERATION AND PARTS MANUAL — REV. #12 (04/03/12)
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OPERATING INFORMATION
Cam Roller
Ifthecamrollerdoesnotrideonthecamprofilesmoothly, itmay
becausedbyinsufficientlineback-pressure;e.g.,awetmixwith
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
WhenusingSnap-Jointcouplingswithgasketstojoinhose, see
thattheyarewashedcleanaftereachjob.Keepingthehoseends
clean(heavyduty)isveryimportantforthebestjobsetup.Athin
coatofgreaseontherubbergasketordippingbothcouplingand
gasket in water before coupling the hose will make for easier
installation.
MAYCO C30HDZ PUMP — OPERATION AND PARTS MANUAL — REV. #12 (04/03/12) — PAGE 33
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INSPECTION
Engine Oil Check
CAUTION - General Saftey Guidelines
1. To check the engine oil level, place the pump on secure
level ground with the engine stopped.
NEVER operate the pump in a confined
area or enclosed area structure that does
not provide ample free flow of air.
2. Remove the dipstick from its holder (Figure 13) and wipe it
clean.
OIL FILLER
HOLE
ALWAYS wear approved eye and hearing
protection before operating the pump .
NEVER operate the pumps's engine with the
engine hood removed.The possibility exists
of hands, long hair, and clothing
becoming entangled with theV-belt, causing
injury and bodily harm.
OIL
DIPSTICK
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.
Figure 13. Engine Oil Dipstick (Removal)
3. Check the engine oil level as shown on the dipstick
(Figure 14).
Before Starting
1. Read safety instructions at the beginning of
thismanual.
2. Removing any dirt and dust that might have accumulated
around the engine cooling air inlet, fuel injection system.
3. Check theairfilterfor dirtanddust. Ifairfilterisdirty,replace
air filter with a new one as required.
4. Checkfuelinjectionsystemforexternaldirtanddust.Clean
withdrycompressedair.
Figure 14. Engine Oil Dipstick
4. Iftheengineoillevelislow,addoilthroughtheengineoilfiller
hole (Figure 15) with the recommended oil type (Table 3).
Maximum oil capacity is 3-3/8 quarts (3.2 liters).
5. Checkfasteningnutsandboltsfortightness.
6. ConnectBattery
7. Make sure hopper is free of dirt and foreign debris (large
objectsover2-inches)
8. Makesureradiatorisfilledwithproperamountofanti-freeze
watersolution(50/50).
9. Make sure all hose lines are in good condition and are
workingproperly.
Figure 15. Engine Oil Filler Hole
TABLE 5. OIL TYPE
Reference manufacturer engine
NOTE
manual for specific servicing
instructions.
Season
Summer
Spring/Fall
Winter
Temperature
25oC and greater
10oC to 25oC
Oil Type
SAE 10W-30
SAE 10W-30/20
SAE 10W-10
0oC or Lower
PAGE 34 — MAYCO C30HDZ PUMP — OPERATION AND PARTS MANUAL — REV. #12 (04/03/12)
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INSPECTION
Lubrication Box
Gasoline Check
The C30HDZ model features a fully enclosed lubrication box,
which utilizes the "splash" method of lubrication.
1. Remove the gasoline cap located on top of fuel tank.
2. Handle Fuel in a safety container.If the container does not
have a spout use a funnel.
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).
3. Visually inspect to see if fuel level is low. If fuel is low,
replenishwithunleadedfuel.Whenrefueling,besuretouse
a strainer for filtration. DO NOT top-off fuel. Wipe up any
spilled fuel.
Also reference the oil level decal (Figure 17) adjacent to the
lubrication box.
4. Payattentiontothefueltankcapacitywhenreplenishingfuel.
Refer to the fuel tank capacity listed inTable 5.
Make sure the pump is on a secure
level surface when checking the oil
NOTE
WARNING - Explosive Fuel
level inside the lubrication box.
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.
CAUTION - Checking Lubrication Oil Levels
The oil level must be checked daily to ensure adequate oil
level and oil cleaniness.
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.
DO NOT smoke while refueling, motor fuels are highly
flammable and can be dangerous if mishandled.
V-Belt Deflection
1. Visually inspect theV-belt for cracks, fraying, wear or oiliness.
2. Make sureV-belt does not the bottom the pulleygroove.
3. ChecktheV-belttension(Figure19)bypushingmidwaythrough
thetwopulleys.TheV-beltdeflectionshouldbebetween.300 to
.472 inches (8 to 12 mm).
Figure 16. Lubrication Box Dipstick
CAUTION
NORMAL
1”
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 19.V-Belt Deflection
Figure 17. Lubrication Box Oil Caution Decal
MAYCO C30HDZ PUMP — OPERATION AND PARTS MANUAL — REV. #12 (04/03/12) — PAGE 35
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STARTUP/SHUTDOWN PROCEDURES
3. Inserttheignitionkeyintotheigni-
tion switch(Figure22),turnthekey
to the ON position, then to the
START position, release the key
when the engine starts.
Starting
CAUTION - General Saftey
DO NOT attempt to operate this concrete pump
until the Safety, General Information and
Inspection sections have been read and
understood.
Figure 22. Ignition Switch
6. Verifythattheoilpressure,batteryandwatertemperature
statuslamps(Figure23)areallOFF.Ifanyoftheselampsare
ON, stop the engine and correct the problem.
1. Turnthethrottlecontrolknobfullycounter-clockwisetosetthe
engine speed to IDLE. (Figure 17.)
Figure 23. Control Box Status Lamps
Figure 20.Throttle Control Switch
7. Let the engine run for 3-5 minutes before putting pump into
operational use.Push the choke knob in all the way.
During pumping operations, the
engine speed cannot be reduced
below 1300 RPM's.
NOTE
8. Listenforanyabnormalsounds.Ifanymechanicalorelectri-
calproblemsexists,STOPtheengineandcorrecttheproblem.
9. Tobeginpumpingconcrete.Placethepumpingcontrolswitch
(Figure 24) in the ON position
This built in feature protects the clutch from disengaging
(slipping) during operation.
2. Place the pumping control switch (Figure 21) in the OFF
position.
Figure 24. Pumping Control Switch (ON)
System Shut-Down
Figure 21. Pumping Control Switch (OFF)
1. Place the pumping control switch in the OFF position
(Figure 21).
2. Turn the throttle control knob fully counter-clockwise.
Let the engine run at idle speed for 3-5 minutes.
3. Turn the ignition key (Figure 22) to the OFF position.
4. Cleanpumpasreferencedinthemaintenancesectionofthis
manual.
PAGE 36 — MAYCO C30HDZ PUMP — OPERATION AND PARTS MANUAL — REV. #12 (04/03/12)
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MAINTENANCE (PUMP)
Preventive Maintenance
General Clean-up Procedure
It is extremely important to maintain this pump due to the
highly abrasive nature of concrete material.
1. Ensure that there is no blockage in the hose and line
(PumpingTips, step 8) or in the manifold (PumpingTips,
step 7). If a blockage exists, clear it to ensure proper
operation the next time it is used.At the end of every pour,
orduringlongdelaysduringapour, thepumpanddelivery
system must be thoroughly cleaned by removing all con-
crete material.
1. Inspect all drive components for loose or worn bolts.
2. Drivebelt/chainshouldbecheckedtoremoveallslack.Refer
toadjustmentprocedure.
3. ALWAYS carry extra“O”rings.
4. Keep entire pump clean of concrete to prevent build-up.
2. Proper wash out of all materials or build up within the
pump manifold and hoses following the pumping opera-
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.
5. ALWAYSgreaseeveryfittingdaily.Useonlypremiumgrade
grease.
Over greasing will not damage
pump.
NOTE
Toavoidthepossibilityofseparation
during clean-up, do not pump the
concrete below the inlet ball in the
NOTE
hopper. It is best to leave approxi-
mately3to4inchesofconcreteabove
the inlet ball.
3. Turnthepumpengineoffbeforefillingthehopperwithwater.
Enginevibrationatidlemay“separate”materialinthehopper,
causing jamming in manifold when pumping is resumed.
4. Fill hopper with water and resume pumping.The water will
pushtheconcretethroughtheline.Whenthewaterrunsclear
attheendofthehose,disconnectlinesandshakeoutallthe
sandandsedimentsothelineswillbecleanforthenextpour.
5. It is 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.
MAYCO C30HDZ PUMP — OPERATION AND PARTS MANUAL — REV. #12 (04/03/12) — PAGE 37
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MAINTENANCE (PUMP)
Sponge Clean-out Procedure
Lubrication Box
This section will explain the recommended procedure for using The C30HDZ model features a fully enclosed lubrication box,
a sponge to clean out the hose lines.
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.
CAUTION - ClearingThe Pump
NEVER use muriatic acid to clear the pump. Acid will dissolve
the chrome finish on the pumping cylinder.
NEVER use compressed air to clean out the lines.
Make sure the pump is on a secure
NOTE
When using a clean-out hook to clean out the rear of the redi-
mix truck, use a safety chain to 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.
level surface when checking the oil
level inside the lubrication box.
CAUTION - Checking Lubrication Oil Levels
1. Aftercompletionofthepour,pumptheremainingconcretein
thehopperthroughthedischargeline.Usingashovel,clean
the sides of the hopper.
The oil level must be checked daily to ensure adequate oil
level and oil cleaniness.
The pump engine should be turned
OFF, as explained in General Clean
Up Procedure.
Piston CupWear
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
etc.
NOTE
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.
IMPORTANT! To ensure maximum
2. Startthepumpengineandpumpthehopperallthewaydown.
cup life, the oil level in the lubrication
NOTE
box must be maintained at the
3. Disconnectthehosefromthepump.Fillthehopperwithwater
and pump the remaining concrete out of the pump.
proper level. In addition the
lubrication box must be cleaned
periodically.
4. Openthehingeddischargeconeandthoroughlywashoutall
remaining concrete (sand-sediment) from the cone and
pumpmanifolds.Closethedischargeconeandlockinplace.
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 the
lubrication box be drained (flushed) and cleaned and the oil
replaced with new SAE 30 motor oil.
5. Takeasponge(2”x4”x6”)andsoakitwithwater.Takethehose
that is disconnected from the pump and shake out the
concretesothatabout2feetofitisclear.Insertthespongeinto
thehose.
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 end of the line
followedbyclearwater.Atthispoint, thepumpandlineswill
be completely clean and ready for the next job.
There are two clean-out ports
NOTE
located at the bottom of the
lubrication box.
Any questions regarding the lubrication box clean-out procedure,
contact the MAYCO Service Department.
Repeat steps 1 through 6 a few times
to ensure that the hose lines are
NOTE
thoroughly cleaned.
PAGE 38 — MAYCO C30HDZ PUMP — OPERATION AND PARTS MANUAL — REV. #12 (04/03/12)
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MAINTENANCE (PUMP)
Ball and Seat Replacement Procedure
1. Setbearingblock(P/NEM14303)intohydraulicpress.Place 1. Remove 3”x 2” reducer and 3” elbow from the pump outlet.
Crankshaft and Cam Assembly Procedure
RemoveexhaustgateandY-manifold(secondarymanifold).
Check ball seat and ball stop pin for wear. If any wear is
detected, the part should be replaced.Remove T-manifold
(primarymanifold).Checkallpartsforwear.Removehopper
and hopper seat and inspect.
bearing cup into bearing block and press in evenly.Bearing
cupshouldbealignedequallyonbothsidesofbearingblock.
2. Set crankshaft into hydraulic press with the long end to-
wards the top. Install spacer (P/N EM14322), O-ring (P/N
EM14326) and bearing cone (P/N EM14325) onto crank-
shaft. Place bearing block on crankshaft until the bearing
cone is riding in the bearing cup.
2. Loosenthepistonnutsandremovethepistoncupassembly
andcylinders.Inspectallpartsforwearandreplacepartswith
excessive wear.Check oiler pump for proper operation.
3. Insertbearingconespacer(P/NEM14323)ontocrankshaft
andinsidebearingblock.Installsecondbearingconeuntilit
is seated inside bearing cup.
3. Cleanallpartsthoroughly,removingallforeignmaterialand
concreteslurry.Oncepartsareclean, installconcretecylin-
ders.PlaceoilerplateO-ringinplaceandcoatwithoil.Install
smallO-ringonpistonrod.Runoilerlinethroughthecylinders
and connect in the oiler fitting on the oiler plate.
4. PlaceO-ringandspacer(P/NEM14302)oncrankshaft.Set
camweldmentontopofspacer.Installcrankshaftkeyandcam
key on cam bushing (P/N EM14301).
4. Pushoilerplateintocylinder.Installringandfeltholder,soak
feltringinoil,theninstallaroundfeltholderincylinder.Make
surethebronzeringisflat, thenpushitupflushwiththering
and felt holder.
5. Slide cam bushing down crankshaft and align the bushing,
camandcrankshaft.Installsleeveovercrankshaftandalign
withhydraulicpress.Installcambushingboltsloosely.Press
bushingdownontobearingassembly.Leavingpressureon
thebushing, tightencamboltsevenlyto40-50footpounds.
5. 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.
6. Releasepressureonthebushing,reapplypressuretobush-
ing and tighten bolts evenly to 40-50 foot pounds. Repeat
procedure 3 to 4 times.
6. Thoroughly checkT-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
primarysideofthepumpandinstallboltsleavingthemloose.
7. After bushing has been fitted tightly into cam, remove from
hydraulic press. Remove one bolt at a time, using Loctite,
installboltsandtorqueto65-70footpounds.Countersinkset
screw hole and install dog point set screw and second set
screwbothwithLoctiteTM.
7. CheckY-manifoldforwear,installallO-rings,ballstoppin,ball
and seat. Align and install Y-manifold to T-manifold and
cylinderassembly.TightenY-manifoldboltsfirstbeforetight-
eningT-manifoldbolts.Aftermanifoldsaretight,checkO-rings
forslippage.
8. Place cam bearing onto crankshaft keeping bearing loose.
Make sure the eccentric lock is
facing toward the outside of the
pumping unit.
NOTE
8. InsertseatintoframeholedirectlyabovetheT-manifold.The
seatorificeshouldfitinsidetheframeitself,thentheseatsits
on top of the orifice. On the dura-seat, set the big end of the
seatintheframe.Theseat,orthesmallpartofthedura-seat,
fits into the bottom of the hopper.
9. Set crankshaft assembly into the pump box and align both
bearing assemblies with the pump box mountings.
9. Aftertighteningthemanifoldboltsandinsertingtheseatsin
place, set the hopper over the seat and align the bolt holes.
Tighten bolts, check O-ring and seat for alignment.
10. Aftercrankshaftassemblyissecurelyfastenedtothepump
box,placesprocket(P/NEM14307)ontothecamsideofthe
crankshaft assembly. Install bushing (P/N EM14309) into
sprocket.Alignsprocketwithsprocketoncountershaftsand
tightenbolts.
10. Check exhaust gate for wear, install and align gate onto
Y-manifold.InsertO-ringintoexhaustgateflangeandclose
gate. Lock down lever and adjust clamp arm.
11. Install chain P/N EM14308. To adjust, loosen locknuts on
pusherboltsandtightenchaintoapproximately1/2in.slack
in the chain. Once chain is adjusted properly, tighten down
locknuts.
11. Install3in.elbowand3x2in. reducer.Fillhopperhalffulland
checkforleaks.
MAYCO C30HDZ PUMP — OPERATION AND PARTS MANUAL — REV. #12 (04/03/12) — PAGE 39
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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. Removewornoutliningandrivets.Checkclutchspringsand
flyweightsforwear.
2. Cut 1/8 in. off of each end of clutch lining. Slide lining into
place.Insertonerivetintoclutchlininghole.(Makesurerivet
goesfrominsideout.)Wedgeaflatheadscrewdriverbetween
clutch flyweight and rivet head.
3. Adjustscrewdriversothattherivetsticksoutfromtheclutch
housingapproximately1/8ofaninch.Withaflatpunch, pen
the ends on the rivet so that it locks in place with the clutch
housing.Repeatthisprocedureforallremainingclutchrivets.
The clutch lining is a normal
maintenance item and will require
NOTE
periodic replacement.
PAGE 40 — MAYCO C30HDZ PUMP — OPERATION AND PARTS MANUAL — REV. #12 (04/03/12)
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MAINTENANCE (PUMP)
Bearing Installation
1. Installthebearingcomponentsonthecrankshaftmakingfull
contact with the back side of the crank disc as indicated the
symbol #. See Figure 25 below.
It is important that the Bearing
Assembly is installed properly.
NOTE
2. Installthebushinginthecamweldmentandslideitonto 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.
Figure 25. Bearing/Cam Bushing Installation
MAYCO C30HDZ PUMP — OPERATION AND PARTS MANUAL — REV. #12 (04/03/12) — PAGE 41
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MAINTENANCE (PUMP)
3. If this procedure is not followed closely the heavy loading
of the bearing during pumping operation causes the
Detent Hole (3) Installation
1. Afterthebearingassemblyhasbeenisinstalled,removethe
three“dogtype”allenheadsetscrews(B)toallowdetentsto
be drilled. See Figure 26 below.
Timken
™
conebearingstocreatelateralforceswhichwill
cone
move the taper bushing and allow the Timken
™
bearings to separate from the race and subsequently fail.
The detent holes will prevent the
Position the‘O’ring on the O.D.of the
bushing from sliding away from the
bearing spacer when the pump is
under load.
NOTE
bearing spacer during assembly to
assure proper bearing adjustment.
NOTE
4. Drill(detent)theshaftundertheallensetscrews“B”toprevent
the bushing from the sliding away from the bearing spacer
when the pump is under a load.
2. Use a 9/32”drill to “detent” half (minimum 1/8” deep).Then
“chase”thethreadswitha3/8-16bottomtapandblowoutthe
chips after drilling, to be certain that the“dog type”allen set
screwsbottominthedetentstopreventthetaperbushingfrom
sliding laterally.
Figure 26. Detent Holes
PAGE 42 — MAYCO C30HDZ PUMP — OPERATION AND PARTS MANUAL — REV. #12 (04/03/12)
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MAINTENANCE (PUMP)
Figure 27. V-Belt and Drive Chain Adjustment
V-Belt And Drive Chain Adjustment
7. Drivebeltsshouldberegularlyadjustedtopreventslippage.
To adjust the belts, loosen the engine mounting bolts and
move the engine until there is a maximum 3/4 in. deflection
in the belts, retighten the engine mounting bolts.
1. Loosenthepillowbearingbolts (Figure27)onlytothepoint
where the bolts will remain snug.
2
Unlock the two pusher bolt lock nuts.
3. Turn each pusher bolt clockwise an equal amount until the
chain is to proper adjustment of approximately 3/8 to 1/2 in.
slackinthechain.Itisveryimportantthatthepulleysideand
the chain side (pillow block bearings) are within 1/16” of an
equaldistance.
8. 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.
NOTE
4. Thisdistancecanbecheckedbyusingatapemeasureora
straightedgeruler, measuringfromtheinsideofthepusher
bolt bracket to the face of the pillow block bearing.
The chain should have 83 rivets,
Including one each, half-link and full
link.
5. The drive chain should be adjusted regularly to remove all
slack.Onceallslackisremoved,DONOTover-adjust,asthis
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.
6. Lubricate the chain regularly.Note-it is advisable to carry a
spare chain and master links for replacement in the field if
necessary.
MAYCO C30HDZ PUMP — OPERATION AND PARTS MANUAL — REV. #12 (04/03/12) — PAGE 43
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MAINTENANCE (PUMP)
Roller Chain Application
Installation and Drive Alignment
A 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.
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.
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 C30HDZ pump is manufactured by the
"DIAMOND CHAIN COMPANYTM"
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 holding 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.
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 you should contact Diamond Chain
Company before this is considered. A roller chain should never
be loaded above 50% 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.
Figure 30. Drive ChainTension
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.
When allowable working loads are considered, however, the
capacity of each strand in a multiple strand chain is only 65% of
the single strand rating; thus, three-strand 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.
PAGE 44 — MAYCO C30HDZ PUMP — OPERATION AND PARTS MANUAL — REV. #12 (04/03/12)
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MAINTENANCE (PUMP)
Drive Chain Lubrication
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.
As a chain articulates in entering and leaving a 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.This can lead to
chain failure at relatively low loads.
Figure 31. Chain-Link Cross Section
MAYCO C30HDZ PUMP — OPERATION AND PARTS MANUAL — REV. #12 (04/03/12) — PAGE 45
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MAINTENANCE (PUMP)
Assembling and Disassembling Drive Chain
CAUTION - DRIVE CHAIN SAFETY
Chain-Link Pin Removal
1. Ifchainisofcotterpin-typeconstruction, removecotters.
2. Ifchainisrivetedtypeconstruction,grindpinheadsoffsopin
ends are flush with the linkplate.
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.
3. Drive pins out of linkplate using a Diamond pin extractor
ModelP/N113or135.Somemultiplestrandchainsorlarge
pitch models will require a hammer and punch or a press to
removethepins.
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.
Installation Of Coversides
Diamond Chain coversides are manufactured three different ways:
■
■
■
Slip Fit
CAUTION - Eyesight Hazard
Modified Press Fit
Full Press Fit
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.
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.
During all stages of chain disassembly
and assembly, wear safety glasses to
prevent metal parts or chips from entering
your eyes and have personnel in the
immediate area do likewise.
NOTE
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.
TipsTo 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 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 CompanyTM.
PAGE 46 — MAYCO C30HDZ PUMP — OPERATION AND PARTS MANUAL — REV. #12 (04/03/12)
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ENGINETROUBLESHOOTING
Practically all 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 EngineTroubleshooting (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
Speed control lever is in "STOP" position?
Defective fuel pump?
SOLUTION
Set speed control lever to "START" position.
Replace fuel pump.
Fuel filter clogged?
Replace fuel filter and clean tank.
Replace or repair fuel line.
Faulty fuel supply line?
Engine will not start or start is
delayed, although engine can
be turned over.
Check piston, cylinder and valves. Adjust or
repair per engine repair manual.
Compression too low?
Oil pressure too low?
Check engine oil pressure.
Comply with cold starting instructions and
proper oil viscosity.
Low starting temperature limit exceeded
Defective battery?
Charge or replace battery.
Refill engine crankcase with correct type of oil
for winter environment.
Engine oil too thick?
At low temperatures engine will
not start.
Defective battery?
Replace battery.
Throttle lever in STOP position?
Fuel filter blocked?
Reposition throttle lever to RUN position.
Replace fuel filter.
Engine fires but stops soon as
starter is switched off.
Fuel supply blocked?
Electrical problem at fuel solenoid?
Fuel tank empty?
Check the entire fuel system.
Repair using #7 wire.
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
stops the engine due to low oil?
Add oil. Replace low oil shutdown sensor if
necessary.
For more detail troubleshooting methods, refer
to NISSAN Operation and Maintenance manual
supplied with your pump.
NOTE
MAYCO C30HDZ PUMP — OPERATION AND PARTS MANUAL — REV. #12 (04/03/12) — PAGE 47
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ENGINETROUBLESHOOTING
TABLE 6. ENGINE TROUBLESHOOTING (CONTINUED)
POSSIBLE PROBLEM
Fuel tank empty?
SYMPTON
SOLUTION
Replace fuel filter.
Replace fuel filter.
Fuel filter clogged?
Low engine power, output and
speed.
Fuel tank venting is inadequate?
Leaks at pipe unions?
Ensure that tank is adequately vented.
Check threaded pipe unions tape and tighten
unions a required.
Engine oil level too full?
Air filter blocked?
Correct engine oil level?
Clean or replace air filter.
Low engine power output and
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?
Worn water pump?
Replace thermostat.
Replace water pump.
Flush, repair or replace radiator.
Replace radiator cap.
Retighten each part of cooling system.
Adjust timing.
Overheating
Clogged or leaky radiator?
Faulty radiator filler cap?
Air in cooling system?
Incorrect engine timing?
Improper governor adjustment?
Adjust governor to the specified conditions.
For more detail troubleshooting methods, refer
to NISSANOperation and Maintenance manual
supplied with your pump.
NOTE
PAGE 48 — MAYCO C30HDZ PUMP — OPERATION AND PARTS MANUAL — REV. #12 (04/03/12)
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NOTES
MAYCO C30HDZ PUMP — OPERATION AND PARTS MANUAL — REV. #12 (04/03/12) — PAGE 49
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WIRING DIAGRAM
Figure 32. Wiring Diagram
PAGE 50 — MAYCO C30HDZ PUMP — OPERATION AND PARTS MANUAL — REV. #12 (04/03/12)
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WIRING DIAGRAM (TAIL LIGHTS)
MAYCO C30HDZ PUMP — OPERATION AND PARTS MANUAL — REV. #12 (04/03/12) — PAGE 51
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APPENDIX — SLUMPTEST PROCEDURE
1. To obtain a representative sample (concrete), take several
samples at three or more regular intervals throughout the
dischargeofthemixerortruck.DONOTtakesamplesatthe
beginning or end of the discharge.
Figure 34-B. Slump
Test (2/3 Full)
2. Dampentheinsideoftheconeandplaceitonasmooth,moist,
nonabsorbent,levelsurfacelargeenoughtoaccommodate
boththeslumpedconcreteandtheslumpcone.Standonthe
“footpieces”throughoutthetestproceduretoholdthecone
firmly in place.
2/3 FULL
3. Fillthecone1/3fullbyvolume (Figure34-A)androd25times
with a 1/2” dia x 24” lg. bullet-pointed steel rod. (This is a
specific requirement which will produce non-standard re-
sultsunlessfollowedexactly.)Distributeroddingevenlyover
the entire cross section of the sample.
Figure 34-C. SlumpTest
(Full-Overflow)
4. Fillconeanother1/3 (Figure34-B)whichwillmakethecone
2/3fullbyvolume.Rodthissecondlayer25timeswiththerod
penetrating into, but not through, the first layer. Distribute
rodding evenly over the entire cross section of the layer.
FULL
(OVERFLOW)
5. Fillconetooverflowing(Figure34-C).Rodthislayer25times
with rod penetrating into but not through, the second layer.
Distributeroddingevenlyovertheentirecrosssectionofthis
layer.
6. Removetheexcessconcrete(Figure34-D)fromthetopofthe
cone, using the tamping rod as a screed.
Figure 34-D. SlumpTest
(Removing Excess Concrete)
7. Lifttheconevertically(Figure34-E)withaslowevenmotion.
DONOTjartheconcreteortilttheconeduringthisprocess.
(Invert the withdrawn cone, and place it next to, but not
touchingtheslumpedconcrete.
8. Lay a straight edge (Figure 34-F) across the top of the
slumpedcone.Measuretheamountofslumpininchesfrom
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
timeof1-1/2minutes.Discardtheconcrete.DONOTuseitin
anyothertests.
Figure 34-E. SlumpTest
(Cone Invert)
BULLET POINTED
STEEL ROD
Figure 34-F. SlumpTest
(Measurement)
1/3 FULL
1/2 DIAMETER
24 INCHES LONG
FOOT
PIECE
Figure 34-A. SlumpTest (1/3 Full)
PAGE 52 — MAYCO C30HDZ PUMP — OPERATION AND PARTS MANUAL — REV. #12 (04/03/12)
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APPENDIX — CONCRETE MIX INFORMATION
The following information has been extracted from actual testing laboratory reports. The purpose of this printing is only to help
create a 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 CaliforniaTest Lab. Report)
JOB: Building Foundations (Water Project)
Sacks per cu./yd.
6.5 designed for 2,500 lbs. in 28 days
Gallons per sack
7.1
1.3
Washed Sand-#200 wash
Organic matter-OK
Specific gravity (SSD)
Sand-2.58; Pea Gravel-2.60
Sieve analysis-percent passing
Material
1.5” 1”
3/4”
3/8”
100
100
100
#4
#8
#16
#30
#50
#100
4.0
#200
1.1
W.C. Sand
Pea Gravel
% Comb.
99.7
3.0
66
79.1
60.4
36.5
14.3
51
39
23
9
3
1.0
DESIGN FOR ONEYARD OF CONCRETE (SATURATED & SURFACE DRY):
Absolute volume of aggregate in one cu. yard:
Specific gravity of aggregates in one cu. yard:
Weight of aggregates in one cu. yard batch:
17.78 cu. ft.
2.58
2850 lbs.
%
BATCH
SPEC.GRAVITY
ABS.VOL.
11.56
W.C. Sand
PEA GRAVEL
WATER 46 gal.
CEMENT 6.5 sk.
TOTAL
65
35
1800
1000
1
2.58
2.60
6.22
611
27.00
ADMIXTURE:
SLUMP
None
4”
REMARKS
NOTE:
This mix designed for pumping
Due to the availability of well-graded sand as shown in the above sieve analysis,
this mix pumped very successfully.
MAYCO C30HDZ PUMP — OPERATION AND PARTS MANUAL — REV. #12 (04/03/12) — PAGE 53
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APPENDIX — CONCRETE MIX INFORMATION
A.S.T.M. STANDARD SPECIFICATION FOR GRADING AGGREGATE
PAGE 54 — MAYCO C30HDZ PUMP — OPERATION AND PARTS MANUAL — REV. #12 (04/03/12)
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APPENDIX — 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
Design Slump (in.)
Cement, SACK.
6004 .......................... 6005
6” (15 cm) ............. 6”
7.0 ................................ 7.0 ......................................7.0................................ 7.0
.............................6006 .......................... 6007
(15 cm) .................6” (15 cm) ............. 6”
(15 cm)
Cement, Lbs.
658 (298 kg) ............ 658
2031 (920 kg) ............ 2982
677 (307 kg) ............ 693
2708 (1227 kg) .......... 2775
(298 kg) ................658 (298 kg) ............ 658 (298 kg)
(943 kg) ................1879 (851 kg) ............ 1943 (880 kg)
(314 kg) ................806 (365 kg) ............ 832 (377 kg)
(1257 kg) .............2685 (1216 kg) .......... 2775 (1257 kg)
w/Con Sand (1 lb.)
Gravel #4(9.51 mm)
TOTAL AGGREGATE
ADMIXTURE
Pozzolight 311-1 lb.
Water, Design (gals.)
Mater, Max.(gals.)
1.4
(.63 kg)............. 1.4
(.63 kg) .................1.4
(.63 kg) ............. —
50.0 (189 liters) ......... 53.0
50.0 (189 liters) ......... 53.0
(200 liters) ............50.0 (189 liters) ......... 53.9 (200 liters)
(200 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.
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
Design Slump (in.)
Cement, SACK.
6000 .......................... 6001
6” (15 cm) ............. 6”
6.5 ................................ 6.5 ......................................6.5................................ 6.5
.............................6002 .......................... 6003
(15 cm) .................6” (15 cm) ............. 6”
(15 cm)
Cement. Lbs.
611
2062 (934 kg) ........... 2112
687 (311 kg) ........... 704
2749 (1245 kg) .......... 2816
(276 kg) ........... 611
(276 kg) ................611 (276 kg) ............ 611 (276 kg)
(957 kg) ................1924 (872 kg) ............ 1971 (893 kg)
(319 kg) ................825 (374 kg) ............ 845 (383 kg)
(1276 kg) .............2749 (1245 kg) .......... 2816 (1276 kg)
w/Con Sand (1.1 lb.)
Gravel #4 (9.51mm)
TOTAL AGGREGATE
ADMIXTURE
Pozzolight 311-1.3lb.
Water, Design (gals.)
Mater, Max.(gals.)
1.3
(.59 kg) ............. 1.3
(.59) ......................—
50.0 (189 liters) ......... 53.0
50.0 (189 liters) ......... 53.0
(200 liters) ............50.0 (189 liters) ......... 53.9 (200 liters)
(200 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 C30HDZ PUMP — OPERATION AND PARTS MANUAL — REV. #12 (04/03/12) — PAGE 55
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APPENDIX — RECOMMENDED SHOTCRETE SYSTEM
RECOMMENDED SHOTCRETE SYSTEM
1-800-30-MA
YCO
10
YC0
MA
N
D
H
0
-3
C
1
3
2
3
1/2 STANDARD
AIR HOSE
7
8
11
13
14 15
9
AIR COMPRESSOR
(125 TO 250 CFM)
10
3/4 STANDARD
AIR HOSE
Figure 35. Shotcrete System
PAGE 56 — MAYCO C30HDZ PUMP — OPERATION AND PARTS MANUAL — REV. #12 (04/03/12)
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APPENDIX — RECOMMENDED SHOTCRETE SYSTEM
RECOMMENDED SHOTCRETE SYSTEM
NO.
1
PART NO.
PART NAME
QTY.
REMARKS
EM28904 ........... 3" “B” COUPLING
EM23946 ........... 3"-90° ELBOW
EM28903 ........... 2 1/2" S/J COUPLING
EM28005DD ...... 3"X 2 1/2 REDUCER
EM28061 ........... 2 1/2"X 10FT.PIPE
EM24849 ........... 2 1/2"X 50FT.HOSE
EM28001DD ...... 2 1/2"X 2" REDUCER
EM23815D ........ 2 1/2"X 2" REDUCER
W/AIRVIBRATOR
2
3
4
5
6
7
8
9
EM28902 ........... 2" S/J COUPLING
EM23101 ........... AIRVIBRATOR
EM28131 ........... 2"X 2 ELBOW
10
11
12
13
14
15
EM24841 ........... 2"X 25 FT.HOSE
EM23808D ........ NOZZLE ASSEMBLY
EM23806 ........... 1 3/8" NOZZLETIP
EM23807 ........... 1 1/4" NOZZLETIP
General recommendations
■
If the 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 scfm).
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) at the edge of the pool
to prevent collapse of the rubber hose, which can
cause blockage.
MAYCO C30HDZ PUMP — OPERATION AND PARTS MANUAL — REV. #12 (04/03/12) — PAGE 57
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APPENDIX — RECOMMENDED SHOTCRETE ACCESSORIES
RECOMMENDED SHOTCRETE ACCESSORIES
Figure 36. 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 OFTHE HOSE UNTILTHE FIRST MATERIAL
HAS PASSEDTHROUGHTHE ENTIRE HOSE LENGTH.
NOTE
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 58 — MAYCO C30HDZ PUMP — OPERATION AND PARTS MANUAL — REV. #12 (04/03/12)
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APPENDIX — RECOMMENDED SHOTCRETE ACCESSORIES
RECOMMENDED SHOTCRETE ACCESSORIES
NO.
1
2
3
4
5
6
7
8
PART NO.
EM26107
EM231011
EM132
EM23407
EM23408
EM23411
EM912073
EM23409
EM923346
EM406
EM23818
EM24841
EM23845
EM23802
EM23803
EM20816
EM23804
EM23805
EM23806
EM23807
EM911076
PART NAME
QTY.
REMARKS
HOPPER SCREEN
AIR VIBRATOR
BOLT, 1/2-13X2
AIR HOSE
1
1
2
1
1
1
2
1
2
2
BUSHING
VALVE
NIPPLE
COUPLING
WASHER, 1/2 LOCK
NUT, HEX 1/2-13
2"X25' GROOVED HOSE
2"X25' RAISED HOSE
2"X50' GROOVED HOSE
ADAPTER
9
10
11
12
*
1
1
1
1
1
1
1
1
13
*
GUN BODY
“O” RING
AIR INSERT
14
*
15
*
16
*
NOZZLE CLAMP
NOZZLE TIP, 1-3/8"
NOZZLE TIP, 1-1/4"
STREET ELBOW
AIR HOSE..................................................... NOT SUPPLIED BY MAYCO
NOZZLE ASSEMBLY ...................... 1 .......... INCLUDES. ITEMS W/
17
*
18
*
19
*
20
21
EM23808
*
MAYCO C30HDZ PUMP — OPERATION AND PARTS MANUAL — REV. #12 (04/03/12) — PAGE 59
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EXPLANATION OF CODE IN REMARKS COLUMN
The following section explains the different symbols and
QTY. Column
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.
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.
NOTICE
The contents and part numbers listed in the parts
section are subject to change without notice.Multiquip
does not guarantee the availability of the parts listed.
A blank entry generally indicates that the item is not sold
separately.Other entries will be clarified in the“Remarks”
Column.
SAMPLE PARTS LIST
REMARKS Column
NO. PART NO. PART NAME
QTY. REMARKS
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.
1
2%
12345
BOLT......................1 .....INCLUDES ITEMS W/%
WASHER, 1/4 IN............NOT SOLD SEPARATELY
WASHER, 3/8 IN....1 .....MQ-45T ONLY
2% 12347
3
4
12348
12349
HOSE ..................A/R ...MAKE LOCALLY
BEARING ..............1 .....S/N 2345B AND ABOVE
Assembly/Kit — All items on the parts list with the
same unique symbol will be included when this item is
purchased.
NO. Column
Indicated by:
Unique Symbols — All items with same unique
symbol
“INCLUDES ITEMS W/(unique symbol)”
(@, #, +, %, or >) in the number column belong to the
same assembly or kit, which is indicated by a note in the
“Remarks” column.
Serial Number Break — Used to list an effective serial
number range where a particular part is used.
Indicated by:
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.
“S/N XXXXX AND BELOW”
“S/N XXXX AND ABOVE”
“S/N XXXX 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.
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.
Indicated by:
“XXXXX ONLY”
“NOT USED ON XXXX”
PART NO. Column
Numbers Used — Part numbers can be indicated by a
number, a blank entry, or TBD.
“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.
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.
“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.
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.
PAGE 60 — MAYCO C30HDZ PUMP — OPERATION AND PARTS MANUAL — REV. #12 (04/03/12)
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SUGGESTED SPARE PARTS
C30HDZ CONCRETE PUMP
C30HDZ CONCRETE PUMP
W/ SYSTEM
W/ SYSTEM
1 Units
3 Units
P/N
DESCRIPTION
PISTON CUP KITS
4 1/2" STEEL BALL
4" STEEL BALL
BALL STOP PIN KIT
0-RING MANIFOLD
CHAIN
QTY.
6
4
4
6
10
1
2
2
1
2
2
2
2
2
2
10
2
P/N
DESCRIPTION
PISTON CUP KITS
4 1/2" STEEL
QTY.
10
10
10
12
25
3
10
10
2
4
2
6
6
EM14904
EM18804
EM14818
EM14903
EM18801
EM14308
EM26313
EM26314
EM14334
EM14408
EM903092
EM14315
EM14842
EM14843
EM26310
EM18409
EM20763
EM14904
EM18804
EM14818
EM14903
EM18801
EM14308
EM26313
EM26314
EM14334
EM14408
EM903092
EM14315
EM14842
EM14843
EM26310
EM18409
EM20763
4" STEEL BALL
BALL STOP PIN KITS
MANIFOLD O-RINGS
CHAINS
HALF LINK
HALF LINK
MASTER LINK
COMPENSATOR SPRING
BRONZE RING
CAM ROLLER BEARING
V-BELT
LOWER SEAT
UPPER SEAT
CLUTCH LINING
O-RING
FUEL FILTER
MASTER LINK
COMPENSATOR SPRING
BRONZE RING
CAM ROLLER BEARING
V-BELT
LOWER SEAT
UPPER SEAT
CLUTCH LINING
O-RING
FUEL FILTER
6
3
20
6
EM20328TKIT BEARING KIT
2
1
1
2
4
1
2
2
2
4
10
2
1
1
1
2
1
1
2
2
1
EM28004DD
EM23946
EM28904
EM289041
EM14159
REDUCER 3" X 2"
3" ELBOW
3" CLAMP
3" GASKETS
HOPPER SCREEN
Part number on this Suggested
Spare Parts List may super cede/
replace the P/N shown in the text
pages of this book.
NOTE
MAYCO C30HDZ PUMP — OPERATION AND PARTS MANUAL — REV. #12 (04/03/12) — PAGE 61
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NAMEPLATE AND DECALS
NAME PLATE AND DECALS
4
3
4
YC0
13
MA
11
12
5
C-30HDZ
8
3
DECAL
KIT
10
6
7
1
2
PAGE 62 — MAYCO C30HDZ PUMP — OPERATION AND PARTS MANUAL — REV. #12 (04/03/12)
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NAMEPLATE AND DECALS
NAME PLATE AND DECALS
NO
PART NO
DCL152
EM932
EM1028
508594
EM513119
EM513165
PART NAME
QTY.
REMARKS
1
*
2
*
3
*
4
*
5
6
*
7
DECAL, CAUTION OIL LEVEL
DECAL, CAUTION, MANIFOLD
DECAL, MULTIQUIP MAYCO
DECAL, CAUTION READ MANUAL
DECAL, C30HDZ
1
1
2
2
2
1
DECAL, MAINTENANCE
DECAL, NAME PLATE .............................1........... CONTACT PARTS DEPT.
DECAL, CONTROL PANEL
DECAL, OWNER'S MANUAL
DECAL, DIESEL FUEL ONLY
KIT, DECAL ..............................................1........... INCLUDES ITEMS W/
DECAL, REFER TO MANUAL
DECAL, READ MANUAL
8
513163
34536
TBD
DCLC30HDNIKIT
EM514187
35137
1
1
1
*
9
*
10
*
11
12
13
*
1
1
MAYCO C30HDZ PUMP — OPERATION AND PARTS MANUAL — REV. #12 (04/03/12) — PAGE 63
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COMPENSATOR PISTON ROD ASSY.
COMPENSATOR PISTON ROD ASSY.
PAGE 64 — MAYCO C30HDZ PUMP — OPERATION AND PARTS MANUAL — REV. #12 (04/03/12)
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COMPENSATOR PISTON ROD ASSY.
COMPENSATOR PISTON ROD ASSY.
NO.
1
1A+
2
3
4
5
6
7
PART NO.
EM14805
EM148053
EM968446
EM14332
EM14331
EM14333
EM14806
EM505490
EM903163
EM20814
EM20813
EM903162
EM20816
EM916001
EM510266
EM621
PART NAME
QTY.
REMARKS
ROD END ................................... 1 ........... INCLUDES ITEMS W/+
BUSHING
1
2
1
1
1
1
1
1
1
1
2
2
2
1
2
1
1
1
1
1
1
1
1
1
1
1
1
1
2
1
NUT HEX, 3/4”-10 GR5
ROD SPRING GUIDE 3/4”
SPRING BACKING PLATE
SPRING RETURN
PISTON GUIDE ASSY.
FITTING
BEARING CUP
BEARING BUSHING
SPACER
BEARING CONE
O-RING
FITTING
SCREW, HHC 1/2-13X3
WASHER
NUT LOCK 1/2” DIA.
PISTON ROD
PISTON GUIDE
FITTING
COMPENSATOR SPRING
O-RING
PLATE, OILER
O-RING, OILER PLATE
RING & FELT HOLDER
BRONZE RING
PISTON CUP-BLACK
PISTON CUP-ORANGE
BUSHING 1 1/4 CRS
O-RING 1”
8
*
9
10
11
*
*
*
12
*
13
14
15
16
17
18
19
20
21
22
23
24
25
26
26
27
28
29
30
31
32
33
34
35
492584
EM14335
EM14336
EM505489
EM14334
EM18409
EM98032
EM14407
EM14410
EM14408
EM14411
EM98051
EM14412
EM18409
EM14413
EM18800HD
EM26525
EM968446
EM16493
EM148053
EM20328TKIT
FACE PLATE
PUMPING CYLINDER ................ 1 ............ 2-1/2" LIP SLEEVE
O-RING, CYLINDER BOX
NUT HEX, 3/4-10
FELT RING
1
3
1
1
BUSHING
BEARING KIT ............................ 1 ............ INCLUDES ITEMS W/
*
MAYCO C30HDZ PUMP — OPERATION AND PARTS MANUAL — REV. #12 (04/03/12) — PAGE 65
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C-30HDN PUMP — CONNECTING ROD - DRIVE SIDE ASSY.
CONNECTING ROD - DRIVE SIDE ASSY.
PAGE 66 — MAYCO C30HDZ PUMP — OPERATION AND PARTS MANUAL — REV. #12 (04/03/12)
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C-30HDN PUMP — CONNECTING ROD - DRIVE SIDE ASSY.
CONNECTING ROD - DRIVE SIDE ASSY.
NO.
PART NO.
EM505490
EM903163
EM20814
EM20813
EM903162
EM20816
EM18409
EM98032
EM14407
EM14408
EM14410
EM14411
EM98051
EM14412
EM18409
EM14413
EM14807HD
EM968446
EM14808
EM16493
EM20328TKIT
PART NAME
QTY.
1
1
1
1
2
2
1
1
1
1
1
1
1
1
2
1
REMARKS
7
FITTING
8
BEARING CUP
BEARING BUSHING
SPACER
BEARING CONE
O-RING
*
9
10
11
*
*
*
12
*
21
O-RING
22
23
24
25
26
26
27
28
29
30
32
33
34
35
PLATE, OILER
O-RING, OILER PLATE
BRONZE RING
RING AND FELT HOLDER
PISTON CUP-BLACK
PISTON CUP-ORANGE
BUSHING 1 1/4 CRS
O-RING 1”
FACE PLATE
CONCRETE CYLINDER ............. 1 ............ 3-3/4 IN. LIP SLEEVE
NUT HEX, 3/4-10
PISTON ROD ASSY.
FELT RING
3
1
1
BEARING KIT ............................ 1 ............ INCLUDES ITEMS W/
*
MAYCO C30HDZ PUMP — OPERATION AND PARTS MANUAL — REV. #12 (04/03/12) — PAGE 67
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ROCKER ASSY.
ROCKER ASSY.
7
LUBRICATION
POINT
1
6
31
27
7
25
35
45
7
24
23
1
7
22
LUBRICATION
POINT
21
14
8
20
31
30
23
40
24
41
36
28
46
37
8
KIT
38
37
LUBRICATION
POINT
3
4
2
2
LUBRICATION
POINT
1
PART OF
FRAME
8
LUBRICATION
POINT
5
17
19
13
16
15
43
27
7
6
NOTES:
12
A. LONG STROKE SETTING.
1
HIGHER VOLUME, LOWER PSI.
B. STANDARD SETTING, NORMAL.
C. SHORT STROKE SETTING.
REDUCED VOLUME, HIGHER PSI.
3
SEE CRANKSHAFT ASSEMBLY
44
7
2
7
25
PAGE 68 — MAYCO C30HDZ PUMP — OPERATION AND PARTS MANUAL — REV. #12 (04/03/12)
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ROCKER ASSY.
ROCKER ASSY.
NO.
1
2
3
4
5
6
7
8
PART NO.
EM14329
EM14116
EM963180
EM923350
EM14846
EM133
PART NAME
SHAFT ROCKER ARM
JOURNAL BLOCK
SCREW, HHC 3/4”-10X5
WASHER LOCK 3/4” SPRING STEEL
CAM ROCKER ARM ..................................... 1......... INCLUDES ITEMS W/+
BOLT 1”-14X2” HEX HEAD
WASHER 1”LOCK
ZERK FITTING
BEARING ASSY.
BEARING SPACER
BEARING BUSHING
SPECIAL BOLT
ZERK FITTING
NUT FLEX LOCK
OILER FELT
WASHER, FLAT 5/8”
OILER PLUG, PLASTIC
NUT STOP REG. 3/4”-10
BEARING CUP
BEARING BUSHING
SPACER
BEARING CONE
O-RING
BOLT 1”-14X6” HEX HEAD
BRONZE BUSHING
CONNECTING ROD
SCREW ALLEN HEAD 3/8”-16X3/4”
ZERK FITTING
QTY.
REMARKS
1
1
2
2
1
1
1
1
2
1
1
1
1
2
1
1
1
1
1
1
2
2
1
4
1
1
1
EM603
EM916001
EM903092
EM20347
EM402434
EM20344
EM916001
EM417
EM402456
EM923157
EM20349
EM969038
EM903163
EM20814
EM20813
EM903162
EM20816
EM105
9
10
11
12
13
14
15
16
17
19
20%
21%
22%
23%
24%
25
27
28
30
31
35
36
37
38
40
41
42
43
44
45
46
#+
EM203262
EM20364
EM702
EM505490
EM14328
EM402996
EM20336
EM903176
EM20338
EM923348
EM503982
EM98043
EM417
ROCKER ARM ASSY.................................... 1......... INCLUDES ITEM W/
SEAL PLATE
O-RING
BEARING
SPACER
WASHER LOCK 5/8
BOLT 1/2-13X5
FORGED CRANKSHAFT .............................. 1......... INCLUDES ITEM W/
NUT, LOCK 3/4"-10
BOLT, HEX 1-8 X 6 LG.
BEARING KIT ............................................... 1......... INCLUDES ITEMS W/%
#
1
1
1
1
1
1
*
2
1
EM202
EM20328TKIT
MAYCO C30HDZ PUMP — OPERATION AND PARTS MANUAL — REV. #12 (04/03/12) — PAGE 69
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COUNTER-SHAFT ASSY.
COUNTERSHAFT ASSY.
15
9
7
LUBRICATION
POINT
10
8
13
2
11
3
6
LUBRICATION
POINT
PART OF
FRAME
3
4
4
1
2
7
PART OF
FRAME
1
5
14
21
12
6
13
6
5
22
13
2
6
6
16
NOTES:
55
MASTER
SEE CLUTCH ASSEMBLY
PAGES 84 AND 85.
HALF
LINK
LINK
1
2
SEE CRANKCASE ASSEMBLY,
PAGES 74 AND 75,
60
59
61
PAGE 70 — MAYCO C30HDZ PUMP — OPERATION AND PARTS MANUAL — REV. #12 (04/03/12)
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COUNTER-SHAFT ASSY.
COUNTER-SHAFT ASSY.
NO.
1
2
3
4
5
6
7
8
PART NO.
EM513073
EM14311
EM124
PART NAME
COUNTER SHAFT
CAM BEARING
BOLT HEX 1/2 X 13 X 4"
WASHER WILLIAMS 1/2"
WASHER, LOCK1/2”
NUT HEX, 1/2-13
FITTING, GREASE
KEY 3/8”X2.5”
BUSHING, PULLEY
PULLEY
BELT, DOUBLE 90 INCHES
SET COLLAR
BOLT, SQUARE 1/2" - 13 X 2-1/2"
KEY, 3/8"
BOLT, HEX 3/8"- 16 X 1-1/4"
BOLT, HEX 3/8" - 16 X 1"
SPROCKET, 13TOOTH
BUSHING
QTY.
REMARKS
1
2
4
4
4
7
2
1
1
1
1
1
3
1
3
3
1
1
1
1
1
1
EM621
EM923346
EM968011
EM916001
EM14316
EM14314
EM14313
EM14315
EM143111
EM130
EM14317
EM123
EM161
EM14318
EM14319
EM14307
EM14308
EM26314
EM26313
9
10
11
12
13
14
15
16
21
22
55
59
60
61
SPROCKET 60 TEETH
CHAIN W/MASTER LINK
LINK MASTER
HALF LINK
MAYCO C30HDZ PUMP — OPERATION AND PARTS MANUAL — REV. #12 (04/03/12) — PAGE 71
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CRANKSHAFT ASSY.
CRANKSHAFT ASSY.
57
KIT
LUBRICATION
POINT
25
35
33
32
35
28
31
24
1
27
31
32
34
30
29
23
46
24
45
LUBRICATION
POINT
50
43
26
49
44
55
48
51
54
41
52
56
42
58
2
NOTES:
SEE ROCKER ARM ASSEMBLY
ITEM 43 FOR ASSOCIATED
CRANKSHAFT COMPONENTS.
24
1
2
46
SEE COUNTER-SHAFT ASSEMBLY,
ITEM 55
PAGE 72 — MAYCO C30HDZ PUMP — OPERATION AND PARTS MANUAL — REV. #12 (04/03/12)
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CRANKSHAFT ASSY.
CRANKSHAFT ASSY.
NO.
PART NO.
EM14303
EM702
EM505490
EM129
PART NAME
QTY.
1
6
1
2
2
4
1
1
2
2
1
1
2
1
1
2
REMARKS
23
BEARING BLOCK
SCREW, ALLEN HEAD 3/8-16X3/4
ZERK FITTING
SCREW, HHC 3/4-10X8-1/2
LOCK WASHER 3/4
NUT HEX, 3/4-10 GR5
CUP BEARING
SPACER BEARING CONE
CONE BEARING
O-RING
*
24
*
25
26
27
28
EM492628
EM968446
EM14324
EM14323
EM14325
EM14326
EM14322
EM98043
EM14306
EM903176
EM402996
EM923348
EM30139
EM14302
EM14300
EM14301
EM703
29
*
30
*
31
*
32
*
33
SPACER
*
34
*
CRANKSHAFT, FORGED
KEY CRANKSHAFT
BEARING
SEAL PLATE
WASHER, LOCK 5/8"
SET COLLAR
SPACER, CAM BUSHING
CAM ASSY.
BUSHING, CAM
SCREW ALLEN HEAD 3/8-16X3/8
BOLT 3/8-16X1-1/4
BEARING-CAM COMPLETE ........................ 1......... INCLUDES ITEM W/ #
ZERK FITTING
BOLT 5/8-11X4” HEX HEAD
WASHER, SPECIAL 5/8”
NUT HEX 5/8-11
SPROCKET 60 TEETH
BUSHING
35
*
38
40
41
42#
1
1
1
1
6
6
43
*
44
*
45
*
46
*
48
EM175
*
49
*
EM14304
EM916001
EM128
50
*
1
2
2
4
1
1
51
52
EM620
54
EM968013
EM14307
EM14309
EM98043K
492378
55
*
56
*
57
CRANKSHAFT FORGE ASSEMBLY ............ 1......... INCLUDES ITEM W/
BOLT, HEX 3/8"-16 X 1-3/4"
*
58
3
MAYCO C30HDZ PUMP — OPERATION AND PARTS MANUAL — REV. #12 (04/03/12) — PAGE 73
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MANIFOLD ASSY.
MANIFOLD ASSY.
ACCESSORIES
2
15
16
14
6
13
5
12
7
8
11
3
17
14
23
24
11
PART OF
FRAME
1
4
7
26
9
27
28
12
14
13
31
7
19
21
18
7
38
27
PART OF
FRAME
37
26
30
27
32
7
32
36
33
35
34
PAGE 74 — MAYCO C30HDZ PUMP — OPERATION AND PARTS MANUAL — REV. #12 (04/03/12)
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MANIFOLD ASSY.
MANIFOLD ASSY.
NO.
1
2
3
4
5
6
7
8
PART NO.
EM23946
EM28004DD
EM2C0B
EM28904
EM18409
EM14843
EM18801
EM18804
EM14801
EM136
EM18409
EM618
EM968266
EM104
EM923348
EM505882
EM14842
EM14818
EM14819A
EM18409
EM618
PART NAME
QTY.
1
1
2
2
4
1
6
1
1
3
4
4
4
3
3
3
1
1
1
2
2
2
2
2
1
1
2
1
1
1
1
1
1
REMARKS
ELBOW 3”X90 DEG.HD
REDUCER 3X2X36 HD
BALL 2” SPONGE
COUPLING 3” HD *CF*
O-RING 1”
UPPER DURASEAT
O-RING
BALL 4-1/2”
9
MANIFOLD T ASSY.
PIN BALL STOP 3/4-16 x 8
O-RING
WASHER SPECIAL
NUT JAM HEX 3/4-16
BOLT 5/8-11X2” HEX HEAD
WASHER LOCK 5/8 SPRING
WASHER, 5/8
SEAT DURA LOWER
BALL 4”
MANIFOLD ASSY. EASY OPEN
O-RING
WASHER SPECIAL
TEE-BOLT 3/4-10X14”
WASHER 3/4”
NUT HEX 3/4”-10 GR5
EXHAUST GATE “H/D”
CAPSCREW 3/4-10X5 HEX HD G8
NUT STOP REG.3/4-10
ARM CLAMP
11
12
13
14
15
16
17
18
19
21
23
24
26
27
28
30
31
32
33
34
35
36
37
38
EM137
EM619
EM968446
EM14850
EM963180
EM969038
EM14845
EM135
EM14810
EM451
EM160
BOLT 1-1/4” -12X7” HEX HD.
SPRING
NUT 1-1/4” -12 LOCK
BOLT 3/8-16X3/4”
SCREW HHC 3/4-10X6
EM509329
MAYCO C30HDZ PUMP — OPERATION AND PARTS MANUAL — REV. #12 (04/03/12) — PAGE 75
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FRAME ASSY.
FRAME ASSY.
26
45
44
27
46
20
21
22
21
19
1
20
39
28
17
40
41
29
43
18
1
38
34
42
21
20
35
14
15
16
33
36
12
21
30
32
37
11
10
31
20
23
8
21
2
4
5
7
2
3
13
39
41
40
NOTES:
RUBBER LIGHT SEAL IS
INCLUDED WITH ITEM 42 (ROUND STYLE ONLY)
1
42
1
FOR AXLE PARTS BREAKDOWN
SEE AXLE ASSEMBLY
2
PAGE 76 — MAYCO C30HDZ PUMP — OPERATION AND PARTS MANUAL — REV. #12 (04/03/12)
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FRAME ASSY.
FRAME ASSY.
NO.
1
2
3
4
5
7
8
PART NO.
PART NAME
QTY.
1
1
1
1
1
2
2
4
4
4
1
6
6
1
1
1
REMARKS
EM513085
EM70186
EM744
FRAME ASSEMBLY
JACK STAND, REAR
CLEVIS PIN 1/2” X 4”
HAIR PIN C 5/8- 3/4”
AXLE, ASSEMBLY
WASHER THICK 1”
KEY COTTER 1/8 X 2
SCREW HHC 1/2- 13 X 2
WASHER .5”
EM745
EM14600A
501299
491689
EM492396
EM621
EM406
EM511418
981635
10
11
12
13
14
15
16
17
18
19
20
21
22
23
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
41
42
42
43
44
45
46
NUT LOCK 1/2” DIA.
FENDER RIGHT-SIDE
BOLT, HHC 1/2- 13 X 3/4
WASHER LOCK 1/2”
COVER
COVER
COVER
6109180
EM512251
EM512252
EM512253
EM512250
EM492309
0166 A
EM512263
EM507895
29228
EM969023
EM507658
EM509947
EM14165
EM619
EM968002
EM505121
EM969038
EM513078
10136
EM492264
EM929028
492363
EM923343
EM265361
518570
EM26536
29242
491010
COVER
SCREW, HHC
1
16
24
1
2
1
2
2
2
2
2
2
2
2
1
8
8
2
WASHER, LOCK 3/8”
ROD
PLUG, 2 1/2 NPT
HITCH, TONGUE 2"
NUT, HEX 5/8" NC
SCREW, HHC 5/8" NC 4-1/2 G5
LINK, QUICK
BOLT EYE
WASHER 3/4”WILLIAM
NUT COUPLING 3/4- 10
SCREW 3/4”- 10 X 3 GR.5
NUT STOP REG. 3/4- 10
COVER, CHASSIS BOTTOM
WASHER, FLAT 3/8
HHCS. 3/8" NC X 1"
HOOD REST, STEEL
SCREW HHC 5/16- 18 X 3/4”
WASHER LOCK 5/16”
BRACKET LIGHT, ROUND ............................. 2 .................... BEFORE MARCH 2009
BRACKET LIGHT, SQUARE ........................... 2 .................... FROM MARCH 2009
TAIL LIGHT, ROUND ....................................... 2 .................... BEFORE MARCH 2009
TAIL LIGHT, SQUARE ..................................... 2 .................... FROM MARCH 2009
4
4
HOOD FASTENER, RUBBER
FENDER LEFT-SIDE
JACK STAND, FRONT
2
1
1
1
EM513087
25610
EM513199
BRACKET, CLUTCH SAFETY
MAYCO C30HDZ PUMP — OPERATION AND PARTS MANUAL — REV. #12 (04/03/12) — PAGE 77
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AXLE ASSY.
AXLE ASSY.
PAGE 78 — MAYCO C30HDZ PUMP — OPERATION AND PARTS MANUAL — REV. #12 (04/03/12)
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AXLE ASSY.
AXLE ASSY.
NO.
1
2
PART NO.
PART NAME
QTY.
REMARKS
EM26518
CAP 14” CHROME
2
EM26615A
TIRE ASSY................................. 2 ........... INCLUDES ITEMS W/
*
3
WHEEL....................................... 2 ........... CANNOT BE PURCHASED SEPARATELY
TIRE 14" ..................................... 2 ........... CANNOT BE PURCHASED SEPARATELY
*
4
5#
6#
*
EM26306
EM968481
EM705
DUST COVER
CASTLE NUT
PIN, COTTER 3/16X1 1/2
WASHER
OUTER BEARING
OUTER CUP
NUT
2
2
2
2
2
7
8#
9#
EM26329
EM903113
EM903012
EM26519
EM20612
EM26300
EM903169
EM903168
EM26305
EM20601
EM14600
EM14600A
10#
11#
12#
13#
14#
15#
16#
17%
18%
19
2
12
12
2
STUD
HUB
INNER CUP
INNER BEARING
GREASE SEAL
2
2
2
HUB ASSEMBLY........................ 2 ........... INCLUDES ITEMS W/#
AXLE
AXLEWITH HUBS INSTALLED ..... 1 ........... INCLUDES ITEMS W/%
1
MAYCO C30HDZ PUMP — OPERATION AND PARTS MANUAL — REV. #12 (04/03/12) — PAGE 79
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MUFFLER, AIR FILTER, AND STOP SWITCH ASSY.
MUFFLER, AIR FILTER AND STOP SWITCH ASSY.
PAGE 80 — MAYCO C30HDZ PUMP — OPERATION AND PARTS MANUAL — REV. #12 (04/03/12)
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MUFFLER, AIR FILTER, AND STOP SWITCH ASSY.
MUFFLER, AIR FILTER AND STOP SWITCH ASSY.
NO.
1
1A
2
PART NO.
EM98076
EM98168
513390
PART NAME
QTY.
REMARKS
FILTER, AIR
1
1
1
1
PRECLEANER, AIR FILTER
BRACKET, AIR CLEANER (PIPE)
MUFFLER COVER
3
514772
4
5
6
7
8
9
10
11
513196
MUFFLER PIPE ..........................................1...............INCLUDED W/ ENGINE
EM14217
EM491873
506257
STOP SWITCH, ENGINE COVER
GLAND CONNECTOR
U-BOLT
FUSE HOLDER W/25A FUSE
HOSE CLIP
INTAKE ELBOW
HEX NUT
WASHER, FELT
DUST EJECTOR
HOOD
1
1
1
1
2
1
4
2
1
1
1
1
1
EM98066
01173940
04172501
01112824
03363577
02165357
02240281
02240285
02240283
02339813
02169927
*
12
*
13
14
15
16
17
*
ANGLE PLATE
CLAMPING YOKE
CARTRIDGE
*
18
AIR CLEANER ASSY. .................................1...............INCLUDES ITEMS W/
*
MAYCO C30HDZ PUMP — OPERATION AND PARTS MANUAL — REV. #12 (04/03/12) — PAGE 81
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CLUTCH ASSY.
CLUTCH ASSY.
17
20
18
19
14
11
21
8
22
9
12
13
10
15
9
4
8
3
1
6
16
5
2
PAGE 82 — MAYCO C30HDZ PUMP — OPERATION AND PARTS MANUAL — REV. #12 (04/03/12)
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CLUTCH ASSY.
CLUTCH ASSY.
NO.
PART NO.
492395
EM923346
EM621
PART NAME
QTY.
1
1
1
1
2
1
2
2
1
6
1
6
1
1
REMARKS
1
SCREW, HHC 1/2- 13X1-3/4”
WASHER, LOCK 1/2”
WASHER, FLAT 1/2” SPECIAL
ROTOR ASSEMBLY
CLUTCH SPRING
CLUTCH LINING
CLUTCH BEARING
RETAINING RING
RETAINING RING
SCREW, HHC M8X25 PI.25
CLUTCH HOUSINGW/LINING
WASHER, LOCK 3/8”
SHAFT STUB (FLANGE), ENGINE
KEY
CLUTCH COMPLETE ASSEMBLY ............. 1 .............INCLUDES ITEMS W/
GUARD, CLUTCH
SCREW, M10 X 20 P-1-1.58.8
WASHER, LOCK 7/16"
WASHER, FLAT 3/8
BOLT, 1/4" NC X 1 GR 5
WASHER, LOCK 1/4"
*
2
*
3
*
4
EM26321
EM918050
EM26310
EM902204
EM926066
EM926053
EM508342
EM26322
0166A
EM512707
EM26348
EM14320
513199
*
5
*
6
*
8
*
9
*
10
*
11
*
12
*
13
14
15
16
17
18
19
20
21
22
*
1
2
2
2
2
2
509252
492625
3019092
492357
2101402
MAYCO C30HDZ PUMP — OPERATION AND PARTS MANUAL — REV. #12 (04/03/12) — PAGE 83
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ENGINE MOUNTING ASSY.
ENGINE MOUNTING ASSY.
RADIATOR AND ENGINE MOUNTING
9
8
1
2
1
3
4
4
7
5
7
SECURE TO
FRAME
6
PAGE 84 — MAYCO C30HDZ PUMP — OPERATION AND PARTS MANUAL — REV. #12 (04/03/12)
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ENGINE MOUNTING ASSY.
ENGINE MOUNTING ASSY.
NO.
1
PART NO.
492556
492626
513195
EM130
513204
513095
513194
4280937
EM98190
PART NAME
QTY.
REMARKS
NUT, HEX 1/2 IN.
8
4
2
6
2
2
2
1
1
2
WASHER, LOCK 1/2 IN.
ENGINE SUPPORT BLOCK (SIDE)
SQUARE HEAD BOLT 1/2 NC X 2-1/2 IN.
BOLT 1/2 NC X 5 IN.
3
4
5
6
BOLT, C/T 1/2 NC x 2 IN.
ENGINE SUPPORT BLOCK (REAR)
OIL COOLER
7
8
9
DEUTZ ENGINE
MAYCO C30HDZ PUMP — OPERATION AND PARTS MANUAL — REV. #12 (04/03/12) — PAGE 85
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THROTTLE ASSY.
THROTTLE ASSY.
11
10
6
12
5
4
9
13
19
3
14
16
15
17
8
2
7
20
18
1
24
16
1
31
23
25
26
21
35
29
22
30
34
17
36
1
27
25
33
32
28
37
38
39
NOTES:
CONNECT TO CLUTCH
SIDE OF ENGINE
1
PAGE 86 — MAYCO C30HDZ PUMP — OPERATION AND PARTS MANUAL — REV. #12 (04/03/12)
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THROTTLE ASSY.
THROTTLE ASSY.
NO.
1
PART NO.
492582
505679
492363
512728
492582
492366
492622
506599
492581
EM400
492357
EM50449
492358
492561
CC700
508443
EM25429
492596
492622
492359
EM25511
EM25571
EM98228
EM98232
EM25576
EM25504
EM50449
EM25577
521730
505679
492369
512729
509252
492624
492582
492598
513222
513219
513218
PART NAME
QTY.
1
1
1
1
2
1
1
1
1
1
1
2
1
1
1
2
2
1
1
1
1
1
1
1
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
REMARKS
NYLON LOCK NUT
FLAT WASHER 5/16"
SCREW 5/16" x 3/4"
THROTTLE LEVER
NUT 5/16" NC
2
3
4
5
6
SCREW 5/16" x 1 1/2"
LOCK WASHER 1/4"
SCREW M6 x 15
7
8
9
NYLON LOCK NUT 1/4" INS
NYLON LOCK NUT 1/4" HEX
SCREW 1/4"x 1"
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
FITTING
SCREW 1/4" x 1 1/4"
NYLON LOCK NUT 1/4" HEX
OIL CYLINDER
HOSE .381-4 15" LONG
FITTING
FLAT WASHER 1/4"
LOCK WASHER 1/4"
SCREW 1/4" x 1 1/2"
FITTING
BODY 118206-01
COILWA 704107-12
SPOOL 12 C51SM-10
HOSE 3RLA-4F JX-20
ELBOW 90 DEGREE
FITTING ELBOW
FITTING
SUPPORT, PISTON
FLAT WASHER 5/16"
SCREW 5/16" x 2 1/4"
SUPPORT, OIL FILTER
SCREW M10 x 20
LOCK WASHER 3/8"
NYLON LOCK NUT 5/16" INS
WASHER, LOCK 3/4" ESP
FITTING
HOSE
FITTING
MAYCO C30HDZ PUMP — OPERATION AND PARTS MANUAL — REV. #12 (04/03/12) — PAGE 87
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CONTROL BOX MOUNTING BRACKET ASSY.
CONTROL BOX MOUNTING BRACKET ASSY.
3
4
SECURE TO TOP
OF ENGINE
1
5
2
SECURE TO BELT
COVER ON ENGINE
quartz
1
NOTES:
COMES WITH ENGINE
1
PAGE 88 — MAYCO C30HDZ PUMP — OPERATION AND PARTS MANUAL — REV. #12 (04/03/12)
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CONTROL BOX MOUNTING BRACKET ASSY.
CONTROL BOX MOUNTING BRACKET ASSY.
NO.
1
2
3
4
PART NO.
492363
492582
506559
492596
513380
PART NAME
QTY.
REMARKS
SCREW, HHC 5/16- 18 X 3/4”
NUT, NYLOC 5/16- 18
SCREW, HHC M6 X 20 P-1
WASHER, FLAT 1/4”
1
1
1
1
1
5
SUPPORT, CONTROL PANEL
MAYCO C30HDZ PUMP — OPERATION AND PARTS MANUAL — REV. #12 (04/03/12) — PAGE 89
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CONTROL BOX ASSY.
CONTROL BOX ASSY.
1
10
3
8
4
3
9
5
11
5
2
6
h
4
1
NOTES:
LAMP HOLDER INCLUDED
WITH ITEMS 13, 14, & 15
1
2
3
INCLUDED WITH ITEM 1,
THROTTLE CABLE P/N 510229
INCLUDED WITH ITEM 8,
IGNITION SWITCH P/N 10958
INCLUDED WITH ITEM 5,
REMOTE OUTLET PLUG P/N Em26789
4
5
INCLUDED WITH ITEM 10,
PUMPING CONTROL SWITCH P/N 40711
INCLUDED WITH ITEM 4,
HOUR METER P/N 506222
6
PAGE 90 — MAYCO C30HDZ PUMP — OPERATION AND PARTS MANUAL — REV. #12 (04/03/12)
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CONTROL BOX ASSY.
CONTROL BOX ASSY.
NO.
1
3
PART NO.
510229
01180677
506222
PART NAME
THROTTLE CABLE ASSY.
12 VDC BULB
QTY.
1
3
REMARKS
4
HOURMETER
1
5
6
7
8
EM26789
EM501102
EM491089
0302735
RECEPTACLE (REMOTE)
LOCK, ACCELERATOR COUPLING
SCREW, 1/4“
1
1
1
1
IGNITION SWITCH
9
0302736
IGNITION SWITCH KEY
SWITCH, PUMPING CONTROL
CONTROL BOX
RED PILOT LENS (OIL PRESSURE)
RED PILOT LENS (BATTERY)
RED PILOT LENS (OIL TEMPERATURE)
1
1
1
1
1
1
10
11
13
14
15
EM40711
EM513076
01180383
01180384
01180382
MAYCO C30HDZ PUMP — OPERATION AND PARTS MANUAL — REV. #12 (04/03/12) — PAGE 91
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BATTERY ASSY.
BATTERY ASSY.
PAGE 92 — MAYCO C30HDZ PUMP — OPERATION AND PARTS MANUAL — REV. #12 (04/03/12)
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BATTERY ASSY.
BATTERY ASSY.
NO.
1
2
3
4
5
6
7
8
PART NO.
EM14705
EM506266
34506
EM492541
EM923023
EM923343
EM20720
EM505624
EM491344
PART NAME
QTY.
REMARKS
CABLE, POSITIVE BATTERY
COVER, POSITIVE TERMINAL
BOX, BATTERY
1
1
1
1
1
1
1
1
1
NUT, HEX 5/16- 18
WASHER, FLAT 5/16
WASHER, LOCK 5/16
CABLE, NEGATIVE BATTERY
COVER, NEGATIVE TERMINAL
BATTERY, 12 VOLT
9
MAYCO C30HDZ PUMP — OPERATION AND PARTS MANUAL — REV. #12 (04/03/12) — PAGE 93
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FUELTANK ASSY.
FUEL TANK ASSY.
PAGE 94 — MAYCO C30HDZ PUMP — OPERATION AND PARTS MANUAL — REV. #12 (04/03/12)
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FUELTANK ASSY.
FUEL TANK ASSY.
NO.
1
2
3
4
5
6
7
8
PART NO.
6636A
TBD
TBD
TBD
6109152
EM20763
EM513115
EM20426
EM491210
EM505594
EM514722
EM516551
PART NAME
QTY.
A/R?
REMARKS
HOSE, FUEL LINE 5/16"
CLAMP, HOSE
WASHER, FLAT
BOLT
CLAMP, HOSE
FILTER, FUEL
ADAPTER NLA......................................... 1 .................BEFORE JULY 2005
FITTING 1/4"
PLUG, 1/4"
PIPE, 5/16 COPPER NLA ........................ 1 .................BEFORE JULY 2005
FUELTANK .............................................. 1 .................BEFORE JULY 2005
FUEL TANK ASSY ................................... 1 .................INCLUDES ITEM 18
......................................................................................AFTER JULY 2005
2
2
2
5
1
1
1
9
10
11
11
12
2108
516568
19633
60058
12009
CAP, FUEL
1
14#
15#
16#
17#
18
FITTING 5/16" .......................................... 1 .................AFTER JULY 2005
BUSHING ................................................. 1 .................AFTER JULY 2005
HOSE, 4-1/2"............................................ 1 .................AFTER JULY 2005
SCREEN .................................................. 1 .................AFTER JULY 2005
PICK UP TUBE ASSY ............................. 1 .................INCLUDES ITEMS W/#
......................................................................................AFTER JULY 2005
EM516533
MAYCO C30HDZ PUMP — OPERATION AND PARTS MANUAL — REV. #12 (04/03/12) — PAGE 95
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HOPPER ASSY.
HOPPER ASSY.
3
2
4
5
1
PAGE 96 — MAYCO C30HDZ PUMP — OPERATION AND PARTS MANUAL — REV. #12 (04/03/12)
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HOPPER ASSY.
HOPPER ASSY.
NO.
1
2
3
4
PART NO.
EM14159
EM14141
EM925191
EM104
PART NAME
HOPPER SCREEN
HOPPER
PIN, HAIR
BOLT, 5/8”-11X2” HEX HEAD
QTY.
REMARKS
1
1
2
3
3
5
EM507599
WASHER 5/8”FLAT
MAYCO C30HDZ PUMP — OPERATION AND PARTS MANUAL — REV. #12 (04/03/12) — PAGE 97
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HOOD ASSY.
HOOD ASSY.
PAGE 98 — MAYCO C30HDZ PUMP — OPERATION AND PARTS MANUAL — REV. #12 (04/03/12)
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HOOD ASSY.
HOOD ASSY.
NO.
1
2
PART NO.
PART NAME
QTY.
4
2
REMARKS
503723
RIVET
491010
LATCH KIT
3
4
5
6
7
8
9
10
11
12
12
EM14140
490937
EM406
EM124
EM963003
EM923057
29057
EM969079
RAL1003S
RAL1003G
RAL1003Q
HOOD ASSY.
1
2
2
2
3
3
1
3
BUMPER, RUBBER
NUT 1/2”-13 HEAVY HEX
BOLT 1/2” DIA-NC X4” G5
SCREW, HHC 1/4-20 X 3/4
WASHER
MANUAL HOLDER
NUT LOC NYLON 1/4
PAINT, SPRAY CAN 12 OZ. (YELLOW)
PAINT, GALLON (YELLOW)
PAINT, QUART (YELLOW)
AR
AR
AR
MAYCO C30HDZ PUMP — OPERATION AND PARTS MANUAL — REV. #12 (04/03/12) — PAGE 99
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LUBRICATION PANEL ASSY.
LUBRICATION PANEL ASSY.
Grease daily, two to three shots of #2
multi-purpose automotive grease.
Over-greasing any bearing will not
damage the machine.
NOTE
POSITION
LOCATION
LENGTH OF LINES
1 ....................................................COMPENSATOR ROD ........................................................................ 28"
2 ....................................................COMPENSATOR ROD ........................................................................ 31"
3 ....................................................COMPENSATOR ROD ........................................................................ 28"
4 ....................................................LOWER ROCKER ARM COMPENSATOR ROD ................................. 34"
5 ....................................................LOWER CONNECTING ROD- DRIVE SIDE ........................................ 10"
6 ....................................................LOWER ROCKER ARM - DRIVE SIDE ................................................ 15"
7 ....................................................UPPER ROCKER ARM - COMPENSATOR SIDE ................................ 28"
8 ....................................................UPPER ROCKER ARM - DRIVE SIDE ................................................. 26"
9 ....................................................COUNTER SHAFT BEARING - SPROCKET SIDE .............................. 20"
10 ..................................................COUNTER SHAFT - PULLEY SIDE ..................................................... 20"
11 ..................................................UPPER CONNECTING ROD - DRIVE SIDE ........................................ 40"
12 ..................................................CRANKSHAFT BEARING BLOCK ....................................................... 42"
13 ..................................................CAM BEARING .................................................................................... 42"
14 ..................................................CRANKSHAFT BEARING FLANGE .................................................... 20"
TOTAL LENGTH OF LINES REQUIRED ............................................. 384"
PAGE 100 — MAYCO C30HDZ PUMP — OPERATION AND PARTS MANUAL — REV. #12 (04/03/12)
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LUBRICATION PANEL ASSY.
LUBRICATION PANEL ASSY.
NO.
PART NO.
EM916001
EM505489
505534
EM505516
EM490531
EM491028
EM505490
EM512659
PART NAME
QTY.
14
13
REMARKS
1
*
2
*
3
*
4
*
5
*
6
*
7
*
8
FITTING, GREASE 1/8" NPT
STRAIGHT FITTING 1/8" NPT
COUPLING W/NUT 1/8' NPT
PLASTIC HOSE LINE 1/4" DIA. ................ AR......... 1FT=1PC
PROTECTIVE SLEEVE 3/8" (HOSE)......... AR......... 1FT=1PC
TIE-WRAP 2.5 x 95 MM
ADAPTER, 90 DEGREE ELBOW
KIT, LUBRICATION........................................ 1......... INCLUDES ITEMS W/
14
AR
1
*
MAYCO C30HDZ PUMP — OPERATION AND PARTS MANUAL — REV. #12 (04/03/12) — PAGE 101
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REMOTE CONTROL CABLE ASSY.
REMOTE CONTROL CABLE ASSY.
3
1
4
9
2
2
5
6
1
NOTES:
1
2
INCLUDED WITH ITEM 1.
8
CORD ASSY. ITEM 9
INCLUDES ITEMS WITHIN
DASHED LINES.
7
PAGE 102 — MAYCO C30HDZ PUMP — OPERATION AND PARTS MANUAL — REV. #12 (04/03/12)
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REMOTE CONTROL CABLE ASSY.
REMOTE CONTROL CABLE ASSY.
NO.
PART NO.
EM16753
EM16754
EM16756
EM491897
EM26791
EM26790
EM26793
EM26792
EM26788
PART NAME
JUNCTION BOX
SWITCH, MICRO
GUARD SWITCH - ALUMINUM
CONNECTOR, 3/16 RING
GRIP CORD SEAL
CORD 25' MX P/E
ADAPTER CORD GRIP 1/2"
QTY.
REMARKS
1
*
2
*
3
*
4
*
5
*
6
*
7
1
1
1
2
1
1
1
1
8
9
ADAPTER CORD 100 FT.
REMOTE W/ 25' CORD ONLY ....................... 1......... INCLUDES ITEMS W/
*
MAYCO C30HDZ PUMP — OPERATION AND PARTS MANUAL — REV. #12 (04/03/12) — PAGE 103
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TERMS AND CONDITIONS OF SALE — PARTS
5. Parts must be in new and resalable
condition, in the original Multiquip
package (if any), and with Multiquip part
numbers clearly marked.
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.
PAYMENT TERMS
Terms of payment for parts are net 30 days.
FREIGHT POLICY
6. The following items are not returnable:
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 a
signed manifest has been obtained from the
carrier, and any claim for shortage or damage
must be settled between the consignee and
the carrier.
a. Obsolete parts. (If an item is in the
price book and shows as being
replaced by another item, it is
obsolete.)
SPECIAL EXPEDITING SERVICE
A $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.
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.
LIMITATIONS OF SELLER’S LIABILITY
MINIMUM ORDER
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.
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.
c. Any line item with an extended
dealer net price of less than
$5.00.
d. Special order items.
RETURNED GOODS POLICY
e. Electrical components.
f. Paint, chemicals, and lubricants.
g. Decals and paper products.
h. Items purchased in kits.
Return shipments will be accepted and
credit will be allowed, subject to the following
provisions:
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 the products on the face hereof.
1. A Returned Material Authorization
must be approved by Multiquip prior to
shipment.
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.
2. To obtain 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.
9. Credit on returned parts will be issued
at dealer net price at time of the original
purchase, less a 15% restocking
charge.
a. The parts numbers and descriptions
must match the current parts price
list.
b. The list must be typed or computer
generated.
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.
c. The list must state the reason(s)
for the return.
Effective: February 22, 2006
d. The list must reference the sales
order(s) or invoice(s) under
which the items were originally
purchased.
11. Credit issued will be applied to future
purchases only.
PRICING AND REBATES
e. The list must include the name
and phone number of the person
requesting the RMA.
Prices are subject to change without prior
notice. Price changes are effective on a
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
for price increases will not be made for stock
on hand at the time of any price change.
3. AcopyoftheReturnMaterialAuthorization
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.
PAGE 104 — MAYCO C30HDZ PUMP — OPERATION AND PARTS MANUAL — REV. #12 (04/03/12)
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MAYCO PUMPWARRANTY
MECHANICAL DRIVE MODELS
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 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.
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 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 does not
cover natural component wear.
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 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 does not
cover natural component wear.
THISWARRANTY AND MANUFACTURER’S OBLIGATION
HEREUNDER, IS IN LIEU OF ALL OTHERWARRANTIES,
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
ANYWARRANTIES OF MERCHANTABILITY OR FITNESS
FOR A PARTICULAR PURPOSE.
THISWARRANTY AND MANUFACTURER’S OBLIGATION
HEREUNDER, IS IN LIEU OF ALL OTHERWARRANTIES,
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
ANYWARRANTIES OF MERCHANTABILITY OR FITNESS
FOR A PARTICULAR PURPOSE.
MAYCO C30HDZ PUMP — OPERATION AND PARTS MANUAL — REV. #12 (04/03/12) — PAGE 105
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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
MQ Parts Department
18910 Wilmington Ave.
Carson, CA 90746
Contact: [email protected]
Tel. (800) 421-1244
Fax (800) 537-3927
800-427-1244
310-537-3700
Fax: 800-672-7877
Fax: 310-637-3284
Service Department
Warranty Department
800-421-1244
310-537-3700
Fax: 310-537-4259
Fax: 310-943-2238
800-421-1244
310-537-3700
Fax: 310-943-2249
Technical Assistance
800-478-1244
MEXICO
UNITED KINGDOM
MQ Cipsa
Multiquip (UK) Limited Head Office
Carr. Fed. Mexico-Puebla KM 126.5
Momoxpan, Cholula, Puebla 72760 Mexico
Contact: [email protected]
Tel: (52) 222-225-9900
Unit 2, Northpoint Industrial Estate, Tel: 0161 339 2223
Fax: (52) 222-285-0420 Globe Lane,
Dukinfield, Cheshire SK16 4UJ
Contact: [email protected]
Fax: 0161 339 3226
CANADA
Multiquip
4110 Industriel Boul.
Laval, Quebec, Canada H7L 6V3
Contact: [email protected]
Tel: (450) 625-2244
Tel: (877) 963-4411
Fax: (450) 625-8664
© COPYRIGHT 2011, 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:
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