Zenith C-30HDG manual 30HDG Pump Pump Components

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C-30HDG PUMP — PUMP COMPONENTS

Figure 7 illustrates the location of the major components for the C-30HDG Concrete Pump. The function of each component is described below:

1. Discharge Cone – Connect 3" elbow to this discharge port, then connect 3" x 2" reducer to elbow.

2.Discharge Cone Safety Latch – When towing of the pump is required, ALWAYS secure the discharge cone to latch located on the manifold.

3. Rear Running Lights – ALWAYS check and make sure both the right and left running lights are functioning correctly before towing the pump.

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.

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.

6.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).

7.Hood Fastener – When the hood is in the down position, secure the rubber latch to this fastener.

8.Hood Lift Handle – Grip this handle, pull upward then back to raise the compartment hood.

9.Control Box – Contains the mechanical and electrical components required to run the pump. Below is a list of those components:

Throttle Control Switch

Pumping Control

Check Engine Indicator

Hood Open Indicator

Engine Hour Meter

Ignition Switch

Remote Connector

10. Radiator/Cap – Fill with a water/anti-freeze type solution as recommended in the maintenance section of this manual. ALWAYS make sure that the radiator is filled to the proper operating level before starting the engine.

11. Fuel Tank/Cap – Fill with unleaded fuel. Fuel tank (cell) holds approximately 11 gallons (42 liters). DO NOT top off fuel. Wipe up any spilled fuel immediately

12. Tow End Jack Stand – Use this jack stand to level and support the pump.

13. Tow Hitch Coupler – Requires a 2-inch ball hitch or a 3- inch pintle. Capable of towing 5,000 lbs.

14. Safety Chain – ALWAYS attach safety chain to the towing vehicle. NEVER! tow the pump with the safety chain unattached.

15. Engine Safety Device This device will return the engine speed to idle if the compartment hood is in the UP position. The compartment hood must be in the DOWN position for the pump to operate at high rpm's.

16. Grease Port Console – This console allows for the remote 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.

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.

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.

22. Pump End Jack Stand – Use this jack stand to level and support the pump.

23. Discharge Cone Release Lever – secures the discharge cone to the "Y" manifold; also relieves manifold pressure.

24. Documentation Box – Contains engine and pump operation, parts and maintenance information.

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.

26. Overflow Bottle – Fill with coolant. Maintain coolant at proper level. See fluid level markings on side of bottle.

27. Cam Bearing – Felt ring must be peridically lubricated applying 4 or 5 drops of 30 wt. motor oil until the felt ring is moist.

MAYCO C-30HDG PUMP — OPERATION AND PARTS MANUAL — REV. #6 (04/02/12) — PAGE 23

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Contents Model C-30HDG 30HDG Pump Proposition 65WARNING Silicosis Warning 30HDG Pump SILICOSIS/RESPIRATORYWARNINGSTable of Contents Order via Fax Dealers Only Parts Ordering ProceduresBest Deal! Order via Internet Dealers Only 30HDG Pump Specifications 30HDG Pump Pump Specifications30HDG Concrete Pump Dimensions 30HDG Pump Pump DimensionsYou can be injured if you do not follow directions 30HDG Pump Safety Message Alert SymbolsStructure that does not provide ample free flow air Always wear approved eye and hearing protection 30HDG Pump Safety Message Alert SymbolsAlways wear approved respiratory protection 30HDG Pump Rules for Safe Operation General SafetyHigh Temperatures Allow the engine Do not use worn out hoses or couplings inspect daily 30HDG Pump Rules for Safe OperationEmergencies Maintenance SafetyLifting Page PumpTrailer Vehicle Connection Recommended Maintenance30HDG Pump -TOWING Guidelines Towing Applications 30HDG Pump -TOWING GuidelinesTrailer Safety Precautions 30HDG Pump -TRAILER Safety GuidelinesTorsion Bar Suspension 30HDG Pump -TRAILER Safety GuidelinesTires/Wheels/Lug Nuts TiresWear/InflationNEVER! use an pneumatic air gun to tighten wheel lug nuts 30HDG Pump -TRAILER Safety GuidelinesLug Nut Torque Requirements Start all wheel lug nuts by handPage Operation and Safety Decals 30HDG Pump Operation and Safety DecalsOperation Hand Signals 30HDG Pump Important Hand SignalsMajor Pump Components 30HDG Pump Pump Components30HDG Pump Pump Components Pump Control Box Components 30HDG Pump Control BOX ComponentsZenith 416 Basic Engine Components 30HDG Pump Engine ComponentsSample Design Mix 3000 Psi 3/8 in. Slump 4- 5 30HDG Pump General InformationPump Mix Guidelines Pumping Cylinder 30HDG Pump HOW IT WorksPumping Pistons 30HDG Pump HOW IT WorksOperating Suggestions 30HDG Pump Operating InformationMbvr air entraining, acts as a lubricant 30HDG Pump Operating InformationNew Pumps Pumping TipsClearing a Mix from the System Stop the pump. Switch OFF the engineAvoiding Setting of the Mix in the System Clearing a Plugged ManifoldPulsation Down-Hill PumpingVerticalPumping ValveSeatsSnap-Joint 30HDG Pump Operating InformationCam Roller Engine Oil Check Read safety instructions at the beginning of this manual30HDG Pump Inspection Before StartingLubrication Box 30HDG Pump InspectionGasoline Check Belt Deflection 30HDG Pump INSPECTION/STARTUPChecking Engine Coolant Level If cooling water is dirty, flush the cooling systemRadio Remote Control Operation 30HDG Pump STARTUP/SHUTDOWN ProceduresRemote Control Operation Always carry extra Orings 30HDG Pump Maintenance PumpPreventive Maintenance General Clean-up ProcedurePiston Cup Wear 30HDG Pump Maintenance PumpSponge Clean-out Procedure Never use compressed air to clean out the linesCrankshaft and Cam Assembly Procedure 30HDG Pump Maintenance PumpFollowing procedure will assist you in replacing the lining Bearing/Cam Bushing Installation Bearing InstallationDetent Holes Detent Hole 3 Installation30HDG Pump Maintenance Pump Working Loads Installation and Drive AlignmentRoller Chain Application Chain-Link Cross Section Drive Chain LubricationChain-Link Pin Removal Installation Of CoversidesInstallation of Spring Locks and Cotter-Pins Assembling and Disassembling Drive ChainEngine Troubleshooting 30HDG Pump EnginetroubleshootingEngine oil level too full? Correct engine oil level? 30HDG Pump EnginetroubleshootingFuel tank empty? Replace fuel filter Fuel filter clogged? Unions a requiredExample 30HDG Pump Engine Fault CodesMalfunction Indicator Diagnostic System GCP ECU Fault Code List for ZZP 416 Engine 30HDG Pump Engine Fault CodesFuel LPG or NG run-out longer than expected AUX 5V Analog Input 3 low Zenith Fuel Injection System Wiring Diagram 30HDG Pump -WIRING Diagram Zenith Wiring Harness30HDNI Pump -WIRING Diagram Zenith Wiring Harness Wiring Diagram 30HDG Pump -WIRING DiagramZPP 416, 420 & 640 Customer 16-PIN Connections 30HDG Pump PIN ConnectionsTrailerTail Lights Wiring Diagram 30HDG Pump -WIRING Diagram Tail LightsPage Slump Test 2/3 Full Appendix C-30HDNI C-30HDNI Slumptest ProcedureAppendix C-30HDG Concrete MIX Information Appendix C-30HDG Concrete MIX Information 2749 27082775 2685Recommended Shotcrete System Appendix Recommended Shotcrete SystemGeneral recommendations Recommended Shotcrete Accessories Appendix Recommended Shotcrete AccessoriesAppendix Recommended Shotcrete Accessories Xxxxx only Not Used on Explanation of Code in Remarks ColumnUnits 30HDG Pump Suggested Spare Parts30HDG Pump Nameplate and Decals 30HDG Pump Nameplate and Decals Compensator Piston ROD Assy 30HDG Pump Compensator Piston ROD AssyBearing CUP Spring ReturnPiston Guide Assy FittingConnecting ROD Drive Side Assy 30HDG Pump Connecting ROD Drive Side AssyPiston ROD Assy Rocker Assy 30HDG Pump Rocker AssyBolt 1-14X2 HEX Head Connecting RODShaft Rocker ARM Journal BlockCountershaft Assy 30HDG Pump COUNTER-SHAFT Assy30HDG Pump COUNTER-SHAFT Assy Crankshaft Assy 30HDG Pump Crankshaft AssyLock Washer 3/4 30HDG Pump Crankshaft AssyBearing Block Manifold Assy 30HDG Pump Manifold Assy30HDG Pump Manifold Assy Frame Assy 30HDG Pump Frame AssyWasher Thick Frame AssemblyAXLE, Assembly Jack STAND, RearAxle Assy 30HDG Pump Axle AssyOuter Bearing CAP 14 Chrome Includes Items WDust Cover Castle NUTMUFFLER, AIR Filter and Stop Switch Assy 30HDG Pump MUFFLER, AIR FILTER, and Stop Switch AssyFILTER, AIR PRECLEANER, AIR Filter ZE1 ELEMENT, AIR FilterGland Connector Stop SWITCH, Engine CoverClutch Assy 30HDG Pump Clutch AssyWASHER, Flat 1/2 Special Rotor AssemblyClutch Housing W/LINING WASHER, Lock 1/2Engine Mounting Brackets Assy 30HDG Pump Engine Mounting Brackets AssyBRACKET, ECU Mount Support BRACKET, RightSupport BRACKET, Left SPACER, 20 OD X 11 ID X 32 LongRADIATOR, Bracket and Hoses Assy 30HDG Pump RADIATOR, Mounting Bracket and Hoses AssyPart Name Control BOX Assy 30HDG Pump Control BOX AssyIgnition Switch KEY SWITCH, Throttle ControlIgnition Switch CONNECTOR, PlasticBattery Assy 30HDG Pump Battery AssyBATTERY, 12 Volt CABLE, Positive BatteryBOX, Battery CABLE, Negative BatteryFuel Tank Assy 30HDG Pump Fueltank AssyIncludes Item HOSE, Fuel 5/16CLAMP, Hose FILTER, FuelHopper Assy 30HDG Pump Hopper AssyWasher 5/8 Flat HopperPIN, Hair Hood Assy 30HDG Pump Hood AssyNUT 1/2-13 Heavy HEX RivetLatch KIT BUMPER, RubberLubrication Panel Assy 30HDG Pump Lubrication Panel Assy1FT=1PC FITTING, Grease 1/8 NPTStraight Fitting 1/8 NPT Coupling W/NUT 1/8 NPTRemote Control Cable Assy 30HDG Pump Remote Control Cable AssyJunction BOX SWITCH, MicroGuard Switch Aluminum CONNECTOR, 3/16 RingFreight Policy Terms and Conditions of Sale PartsMechanical Drive Models Mayco PumpwarrantyHERE’S HOW to GET Help