Zenith C-30HDG manual 30HDG Pump Engine Components, Zenith 416 Basic Engine Components

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C-30HDG PUMP — ENGINE COMPONENTS

Figure 9. Zenith 416 Basic Engine Components

Figure 9 illustrates the location of the basic components for the Zenith 416, 1.6 liter gasoline engine..The function of each component is described below:

1. Air Filter – 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 filter.

2. Fuse Connector – Contains fuses for electrical system. replace with only recommended type fuses.

3. 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

4. Spark Plug – Provides spark to the ignition system. Set spark plug gap to 0.6 - 0.7 mm (0.028 - 0.031 inch). Clean spark plug once a week

5. 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.

6. Alternator – Provides power to the electrical system. Replace with only manufactures recommended type alternator.

7. Oil Filter – Replace this oil filter as recommended in the maintenance section of this manual.

8. Fan V-Belt – ALWAYS make sure that V-belt is properly tensioned. A loose or defective V-belt can adversely affect the performance of the pump.

9. 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.

10. 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.

11. Control Relays – Includes a main relay, fuel pump relay and starter relay. Replace with only recommended type relays.

12. Starter Motor/Solenoid – NEVER allow concrete or any foreign debris to come in contact with the starter motor/ solenoid.

13. Fuel Filter/Fuel Pump/Fuel Regulator – Replace or clean the fuel filter, fuel pump or fuel regulator as specified in the maintenance section of this manual.

Operating the engine without an air filter, with a damaged air filter, or a filter in need of replacement will allow dirt to enter the engine, causing rapid engine wear.

MAYCO C-30HDG PUMP — OPERATION AND PARTS MANUAL — REV. #6 (04/02/12) — PAGE 25

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Contents Model C-30HDG 30HDG Pump Proposition 65WARNING Silicosis Warning 30HDG Pump SILICOSIS/RESPIRATORYWARNINGSTable of Contents Best Deal! Order via Internet Dealers Only Parts Ordering ProceduresOrder via Fax Dealers Only 30HDG Pump Specifications 30HDG Pump Pump Specifications30HDG Concrete Pump Dimensions 30HDG Pump Pump DimensionsStructure that does not provide ample free flow air 30HDG Pump Safety Message Alert SymbolsYou can be injured if you do not follow directions Always wear approved respiratory protection 30HDG Pump Safety Message Alert SymbolsAlways wear approved eye and hearing protection High Temperatures Allow the engine General Safety30HDG Pump Rules for Safe Operation Do not use worn out hoses or couplings inspect daily 30HDG Pump Rules for Safe OperationLifting Maintenance SafetyEmergencies Page 30HDG Pump -TOWING Guidelines Recommended MaintenancePumpTrailer Vehicle Connection Towing Applications 30HDG Pump -TOWING GuidelinesTrailer Safety Precautions 30HDG Pump -TRAILER Safety GuidelinesTires/Wheels/Lug Nuts 30HDG Pump -TRAILER Safety GuidelinesTiresWear/Inflation Torsion Bar SuspensionLug Nut Torque Requirements 30HDG Pump -TRAILER Safety GuidelinesStart all wheel lug nuts by hand NEVER! use an pneumatic air gun to tighten wheel lug nutsPage 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 ComponentsPump Mix Guidelines 30HDG Pump General InformationSample Design Mix 3000 Psi 3/8 in. Slump 4- 5 Pumping Cylinder 30HDG Pump HOW IT WorksPumping Pistons 30HDG Pump HOW IT WorksOperating Suggestions 30HDG Pump Operating InformationNew Pumps 30HDG Pump Operating InformationPumping Tips Mbvr air entraining, acts as a lubricantAvoiding Setting of the Mix in the System Stop the pump. Switch OFF the engineClearing a Plugged Manifold Clearing a Mix from the SystemVerticalPumping Down-Hill PumpingValveSeats PulsationCam Roller 30HDG Pump Operating InformationSnap-Joint 30HDG Pump Inspection Read safety instructions at the beginning of this manualBefore Starting Engine Oil CheckGasoline Check 30HDG Pump InspectionLubrication Box Checking Engine Coolant Level 30HDG Pump INSPECTION/STARTUPIf cooling water is dirty, flush the cooling system Belt DeflectionRemote Control Operation 30HDG Pump STARTUP/SHUTDOWN ProceduresRadio Remote Control Operation Preventive Maintenance 30HDG Pump Maintenance PumpGeneral Clean-up Procedure Always carry extra OringsSponge Clean-out Procedure 30HDG Pump Maintenance PumpNever use compressed air to clean out the lines Piston Cup WearCrankshaft 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 Roller Chain Application Installation and Drive AlignmentWorking Loads Chain-Link Cross Section Drive Chain LubricationInstallation of Spring Locks and Cotter-Pins Installation Of CoversidesAssembling and Disassembling Drive Chain Chain-Link Pin RemovalEngine Troubleshooting 30HDG Pump EnginetroubleshootingFuel tank empty? Replace fuel filter Fuel filter clogged? 30HDG Pump EnginetroubleshootingUnions a required Engine oil level too full? Correct engine oil level?Malfunction Indicator Diagnostic System 30HDG Pump Engine Fault CodesExample 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 2775 27082685 2749Recommended 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 AssyPiston Guide Assy Spring ReturnFitting Bearing CUPConnecting ROD Drive Side Assy 30HDG Pump Connecting ROD Drive Side AssyPiston ROD Assy Rocker Assy 30HDG Pump Rocker AssyShaft Rocker ARM Connecting RODJournal Block Bolt 1-14X2 HEX HeadCountershaft Assy 30HDG Pump COUNTER-SHAFT Assy30HDG Pump COUNTER-SHAFT Assy Crankshaft Assy 30HDG Pump Crankshaft AssyBearing Block 30HDG Pump Crankshaft AssyLock Washer 3/4 Manifold Assy 30HDG Pump Manifold Assy30HDG Pump Manifold Assy Frame Assy 30HDG Pump Frame AssyAXLE, Assembly Frame AssemblyJack STAND, Rear Washer ThickAxle Assy 30HDG Pump Axle AssyDust Cover CAP 14 Chrome Includes Items WCastle NUT Outer BearingMUFFLER, AIR Filter and Stop Switch Assy 30HDG Pump MUFFLER, AIR FILTER, and Stop Switch AssyGland Connector PRECLEANER, AIR Filter ZE1 ELEMENT, AIR FilterStop SWITCH, Engine Cover FILTER, AIRClutch Assy 30HDG Pump Clutch AssyClutch Housing W/LINING Rotor AssemblyWASHER, Lock 1/2 WASHER, Flat 1/2 SpecialEngine Mounting Brackets Assy 30HDG Pump Engine Mounting Brackets AssySupport BRACKET, Left Support BRACKET, RightSPACER, 20 OD X 11 ID X 32 Long BRACKET, ECU MountRADIATOR, Bracket and Hoses Assy 30HDG Pump RADIATOR, Mounting Bracket and Hoses AssyPart Name Control BOX Assy 30HDG Pump Control BOX AssyIgnition Switch SWITCH, Throttle ControlCONNECTOR, Plastic Ignition Switch KEYBattery Assy 30HDG Pump Battery AssyBOX, Battery CABLE, Positive BatteryCABLE, Negative Battery BATTERY, 12 VoltFuel Tank Assy 30HDG Pump Fueltank AssyCLAMP, Hose HOSE, Fuel 5/16FILTER, Fuel Includes ItemHopper Assy 30HDG Pump Hopper AssyPIN, Hair HopperWasher 5/8 Flat Hood Assy 30HDG Pump Hood AssyLatch KIT RivetBUMPER, Rubber NUT 1/2-13 Heavy HEXLubrication Panel Assy 30HDG Pump Lubrication Panel AssyStraight Fitting 1/8 NPT FITTING, Grease 1/8 NPTCoupling W/NUT 1/8 NPT 1FT=1PCRemote Control Cable Assy 30HDG Pump Remote Control Cable AssyGuard Switch Aluminum SWITCH, MicroCONNECTOR, 3/16 Ring Junction BOXFreight Policy Terms and Conditions of Sale PartsMechanical Drive Models Mayco PumpwarrantyHERE’S HOW to GET Help

C-30HDG specifications

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